Ouis Abousoufiane, Habba Mohamed I A, Ahmed Mohamed M Z, Barakat Waheed S
Mechanical Engineering Department, College of Engineering at Al-Kharj, Prince Sattam Bin Abdulaziz University, Al-Kharj, 11942, Saudi Arabia.
Mechanical Department, Faculty of Technology and Education, Suez University, Suez, 43221, Egypt.
Sci Rep. 2025 Jul 1;15(1):22437. doi: 10.1038/s41598-025-03977-7.
Friction stir welding (FSW) of thick extruded AA6082-T6 aluminum alloy plates presents challenges in maintaining optimal mechanical and corrosion properties. This study investigated the effects of incorporating Al₂O₃ interlayer reinforcements on the microstructural, tribological, and corrosion behaviors of FSW joints. AA6082-T6 plates were friction stir welded with Al₂O₃ interlayer strips at various levels of 0, 4, 8, and 12 vol%. The resulting joints were characterized using optical microscopy, electron microscopy, X-ray diffraction, hardness testing, potentiodynamic polarization, and pin-on-disk wear tests. The Al₂O₃ reinforcement led to grain refinement, increased dislocation density, and enhanced microstrain in the weld zone. The relative density decreased with an increase in the Al₂O₃ content. The Vickers hardness improved systematically across all thicknesses of the reinforced joints, with the highest values observed in the 12 vol% Al₂O₃ specimen. The corrosion resistance of the reinforced joints improved significantly, approaching that of the base material. The wear resistance was enhanced in the reinforced joints with 8 vol% Al₂O₃ specimen consistently showing the highest enhancement ratios under various load conditions. The incorporation of Al₂O₃ interlayer reinforcements effectively mitigated the negative effects of FSW on AA6082-T6 joints, enhancing their microstructural, mechanical, tribological, and corrosion properties. Optimal performance was achieved with 8 vol% Al₂O₃ reinforcement, balancing improvements in hardness, wear resistance, and corrosion behavior.
对厚挤压AA6082-T6铝合金板材进行搅拌摩擦焊（FSW）时，在保持最佳力学性能和耐腐蚀性方面存在挑战。本研究调查了加入Al₂O₃中间层增强材料对FSW接头微观结构、摩擦学和腐蚀行为的影响。将AA6082-T6板材与不同体积分数（0%、4%、8%和12%）的Al₂O₃中间层条带进行搅拌摩擦焊。使用光学显微镜、电子显微镜、X射线衍射、硬度测试、动电位极化和销盘磨损试验对所得接头进行表征。Al₂O₃增强材料导致焊缝区晶粒细化、位错密度增加和微观应变增强。相对密度随Al₂O₃含量的增加而降低。在所有增强接头厚度上，维氏硬度均有系统提高，在Al₂O₃体积分数为12%的试样中观察到最高值。增强接头的耐腐蚀性显著提高，接近母材。在含8%Al₂O₃的增强接头中耐磨性增强，在各种载荷条件下，该试样始终显示出最高的增强率。加入Al₂O₃中间层增强材料有效减轻了FSW对AA6082-T6接头的负面影响，提高了其微观结构、力学、摩擦学和腐蚀性能。在Al₂O₃增强体积分数为8%时实现了最佳性能，平衡了硬度、耐磨性和腐蚀行为方面的改善。
