MICROSTRUCTURE AND MECHANICAL PROPERTIES OF AZ31B-H24/AL2O3

NANO COMPOSITE JOINTS FABRICATED BY FRICTION STIR WELDING

PROCESS AND ITS EFFECT OF STIR ZONE VOLUME FRACTIONS

Mr.J.BALAJIa, Dr.S.VIJAYAKUMARb

a
Assistant Professor, Jayalakshmi Institute of Technology, Thoppur, Dharmapuri(Dt), India
b
Assistant Professor, University College of Engineering, Kancheepuram (Dt),India

ABSTRACT
In the present study, Al2O3 nano particles (20nm) were synthesized to AZ31B-H24
magnesium alloy using Friction Stir Welding (FSW) technique at five different Stir Zone (SZ)
volume fractions such as 4Vol%(V4), 8Vol%(V8), 12Vol%(V12), 16Vol%(V16) and 20Vol%
(V20). Al2O3 reinforced magnesium matrix nano composite welded joints were produced at a
tool rotational speed of 1260rpm and a tool traverse speed of 20mm/min. Initially,
microstructure analysis of V4, V8 and V12 welded joints were observed as good accordance
with homogeneous dispersion of Al2O3 particles within the SZ. Moreover, the particle’s
agglomeration and large size of clusters were observed in the SZ, due to lack of heat generation
of specimens V16 and V20 during FSW. Mechanical test of composite joints was conducted and
the results indicated that the volume fractions increased as the Ultimate Tensile Strength (UTS)
and average micro hardness also increased upto V12.With this effect, fracture morphology was
examined in the joints which reveals, brittle fracture mode which was observed in specimens
V16 and V20 and the remaining was produced in the ductile fracture mode compared to base
metal weld joint. From this experimental work, SZ volume fraction with Al2O3 particles
significantly influenced the area of composite, particles distribution, grain size, tensile strength,
and average hardness of the composite welded joints.

KEYWORDS
Friction Stir Welding, AZ31B-H24 Magnesium Alloy, Al2O3 nano particles, Microstructure,
Mechanical properties.
1. INTRODUCTION

In recent decades, Friction Stir Welding (FSW) process offered many potential benefits
to join magnesium alloys in automobile and aerospace industries for weight reduction
applications. In the year 1991, The Welding Institute (TWI), UK invented FSW process
especially for development of aluminum alloys. Basically, it is a solid state welding technique
which is used to recast the adjoining base plates along the weld joint line without the melting of
base material [1]. Among the magnesium alloys, AZ31B-H24 wrought magnesium alloy has
attracted significant attention, because it is the lightest structural metallic material with high
specific strength and stiffness, good heat conductivity, good machinability and cast ability [2].
Recently, more attention has paid by the authors to develop a Magnesium Matrix Composite
(MMCs) welded joints which is employed through an FSW process by adding ceramic
reinforcements to the abutting edges of the plates. Ceramic particles are a proper driving force
for producing high strength MMCs joints because of its integration ability of molten matrix,
hard nature and grain refining effect [3]. In order to achieve high strength MMC joints, have to
eliminate conventional welding technique problems such as porosity, hot cracking and
formation of surface oxide layers [4,5]. On the other hand, the important issue of interfacial
chemical reactions between particles and matrix alloy has considered, which leads to produce
the intermetallic components and alloy segregations which is the dominant effect on mechanical
properties [6,7].
Friction Stir Processing (FSP) is an emerging technique which is used to synthesis nano
and micro sized reinforcements into matrix alloy and fabricated surface composites [8]. By
adopting these techniques Azizieh et al. [9] fabricate AZ31B/Al 2O3 nano composite layer and
reported that the tool pin profile and number of FSP passes significantly influence the
distribution of Al2O3 particles. Also they addressed the effect of high tool rotational speed and
low travelling speed which lead to improve the average microhardness value and cluster size.
Thangarasu et al. [10] synthesized TiC particles into AA6082 aluminium alloy with five
different stir zone volume fractions and analyze the effect of volume fractions on the
microstructure and mechanical properties. As a result, volume fraction of TiC particles
significantly influences the Area of Surface Composite (ASC), Ultimate Tensile Strength (UTS)
and average microhardness values. Satishkumar et al. [11] fabricate Cu/B 4C surface composite
with five different volume fractions and the results indicate when the volume fraction of B 4C
particles increase the microhardness value from lower to higher volumes also increase.
Increased volume fraction influence the area of surface composite. Moreover, a few researchers
have given the attention to study the effect of stir zone of various volume fractions on
microstructure and mechanical properties of FS processed plates.
Initially, Sun and Fujii et al. [12] to fabricate Cu/SiC composite welded joint which is
employed through FSW process and have reported SiC reinforced welded joint is completed in
copper surface without any defect and considerable amount of nugget zone strength was
improved. Accordingly, Mahmoud Abbasi et al. [13] successfully produced AZ31B/SiC
reinforced composite welded joints and they reveal the effect of SiC particles on the
microstructure, mechanical and corrosion properties. Taking the above survey, no author has so
far been reported that the FSW of AZ31B-H24 magnesium alloy with Al2O3 nano sized ceramic
reinforcement incorporated along the weld joint line with five different stir zone volume
fractions. In the present analysis, deliberate effect of Al2O3 particles and stir zone volume
fraction on microstructure and mechanical properties of MMC joints.

2. EXPERIMENTAL WORK
In this research experimentation, FSW process was done by using commercially
available AZ31B-H24 magnesium alloy with 6mm thickness of plates. The chemical
compositions of received matrix alloy are presented in Table 1 and Transmission Electron
Microscopy (TEM) image of as received Al2O3 nano particles (~20 nm) are shown in Fig. 1. The
dimensions of the weld plates are 75 mm width and 100 mm length which were extracted from
the base plate through Wire-Cut EDM process. A groove of width varying from (0.3, 0.6, 0.9,
1.2 and 1.5 mm) and depth of 4.5mm was made in the weld joint line through EDM process. A
five level of volume fraction samples (V4, V8, V12, V16 and V20) are clearly showed in Fig. 2.
Before welding process Al2O3 nano particles are compacted into the slot which is located in the
weld centre line of adjoining plates. In this work, CNC controlled vertical milling center as
FSW machine. Fig 3 represents the FSW process assembly with purposefully developed fixture
base. Initially several trail experiments were conducted to produced AZ31B-H24/Al 2O3 MMC
joints. From the result of several trail experiments, FSW parameters were finalized at constant
tool rotational speed of 1260 rpm and tool travelling rate 20 mm/min. The prepared MMC joints
were taken to conduct a cross sectional examinations and as a result was found to produce good
defect free weld joints such as pin hole, tunnel defect and kissing bonds irrespective of volume
fractions. Fig. 4 is a pictorial representation of H13 hot working tool steel having 56 HRC with
cylindrical threaded tool pin profile of 18 mm shoulder diameter, 6 mm pin diameter and 5.7
mm pin height are used in this experimentation. According to the process parameters five levels
of volume fractioned AZ31B-H24/Al2O3 composite welded joints from V4 to V20 are
developed. The theoretical and actual volume fractions of Al2O3 particles were calculated using
the following expressions [10].

Theoretical volume fraction (Vt) = (Area of groove/Projected area of tool pin) ×100
Actual volume fraction (Va) = (Area of groove/Area of surface composite) ×100
Area of groove = Groove width × Groove depth
Projected area of tool pin = Pin diameter × Pin length

Metallographic examination of the welded joints is studied as per ASTM/E3-95 standard

and the specimens were prepared accordingly. Wire cut machined out samples, which are
initially polished and etched with the solutions of 5g picric acid, 10 mL acetic acid, 10 mL
water, and 100 mL ethanol. After etching Optical Microscopy (OM) and Scanning Electron
Microscopy (SEM) test was performed to find the particle’s distributions, agglomerations and
particle rich and free fields on the cross section of the weld nugget zone. As per ASTM-E8
standard, sub sized tensile test specimen was extracted from the AZ31B-H24/Al 2O3 composite
welded joints normal to the FSW direction by using wire cut EDM process. Electronically
controlled Universal Testing Machine was utilized to evaluate Ultimate Tensile Strength (UTS)
and Percentage of Elongation (POE). The microhardness value was measured using Vicker’s
microhardness tester to evaluate average microhardness of the stir zone under the load of 25g
applied at 15 s. microhardness surveys which was taken at 2 mm constant distance at every ball
indentation.

3. RESULTS AND DISCUSSION

3.1 Macrostructural observation

Five different volume fractions of AZ31B-H24/Al2O3 MMC FSWed joint macrostructure

are presented along with base material welded joint are shown in Fig. 5(a-f). Because of a tool
rotation speed, travelling speed, tool material, tool pin profile and thermal conductivity of
material basin shaped nugget zone was formed in all the specimens [14]. The absence of
identified defects like tunnel defect, pinhole, kissing bond and piping defect in specimen
numbers V4-V20 [15].But in the case of samples V16 and V20 with sever Al2O3 particles
accumulations were observed in weld nugget zones. This attributes to important phenomenon,
one because of non-deformable Al2O3 particles which act as a barrier of free flow of plasticized
AZ31B-H24 magnesium with an increase in the volume fraction of stir zone. Second relates to
non homogeneous distribution of Al2O3 particles in the stir zone due to lack of amount of
plasticization of matrix material, which decreases during FSW while increasing the amount of
reinforcement particles achieved through increasing slot size that will not produce satisfactory
martial flow around the pin tool. From the specimens of V16 and V20, it could be inferred that
the nominal width of slots was achieved in the case of V4, V8 and V12 samples. It is clearly
evident from Fig. 5(a-c), that satisfactory particle’s distributions are around the pin tool and
enough amount of plasticization of matrix material which got produce defect free FSWed
composite joints in the given welding condition.

Variable stir zone volume fractions directly influence the area of friction stir welded
zone that involves Al2O3 surface composite. The Area of Surface Composite (ASC) was
measured using an image analyzing software. The ASC depends on the amount of plasticization
of matrix material within the weld nugget zone. On the other hand, the responsible factors of
plasticization of matrix material are tool rotation speed and area of groove width. Sathishkumar
et al.[16], addressed a tool rotation speed which increases with a constant volume fraction
condition; the frictional heat generation increases in the nugget zone due to increasing
rotational speed that leads to improve the amount of plasticization of molten matrix. Thangarasu
et al.[10] and Sathishkumar et al.[11], reported that there is an increase in the stir zone volume
fraction with constant welding speed and feed condition which will decreases in the amount of
plasticization of molten matrix within the SZ due to lack of heat generation. As a result, ASC is
absolutely irreversible factor in the groove width of weld plate. According to Fig.5 (a-e), the stir
zone volume fraction of Al2O3 particles increased from V4 to V20, achieved by varying groove
width 0.3 to 1.5mm, which was found to decrease the ASC from 67.41mm 2 to 46.85mm2
respectively. Hence, the reduction of ASC while increasing the SZ volume fraction may be in
the following reasons (a) the lack of amount of plasticization of matrix in SZ (b) generation of
flow stress within the SZ around the pin tool profile which is offered by a non- deformable
Al2O3 particles (c) more addition of Al2O3 particles leads to reduction of heat generation in the
SZ. During FSW, same tool was utilized irrespective of the groove size to accommodate various
volume fractions of Al2O3 particles. Hence, the theoretical area of the surface composite is equal
to the projected area of the tool pin in all cases. The decreases in the ASC leads to reduction in
the actual volume fraction of Al2O3 particles in the surface composite as shown in Table
1.Comparison between theoretical and actual volume fraction of Al2O3 particles in the MMC is
represented in Fig. 6. It indicates the actual volume fraction is observed to be lower than the
theoretical volume fraction under all experimental conditions. It could be inferred that, more
amount of molten matrix is produced during FSW process compared to theoretically calculate
molten matrix.
3.2 Microstructural observations

3.2.1 Transition zones containing Al2O3 nano particles

The successful combination of tool rotational speed and tool travelling speed are
important parameters for up gradation of fine equiaxed grain structure and enhancing the
particles distributions in the stir zone during the FSW process. Generally, FSW joints have Stir
Zone (SZ), Thermo-mechanically affected zone (TMAZ), Heat Affected Zone (HAZ) and Base
Material Zone (BMZ). Fig. 7(a-e) show that these regions clearly indicate the dark lines in the
specimens of V4 to V20 of AZ31B-H24/Al 2O3 particles reinforced MMCs. However, the
specimens at V4 and V8 of Al 2O3 particles reinforced MMCs of TMAZ and HAZ were not
clearly distinguished. This will attribute when the tool rotates at high rotational speed
(1260rpm) and lower traveling speed (20mm/min) that produces high heat generation than a
metal undergoes intense plastic deformation at elevated temperature resulting fine grain are
formed. [3,16]. Indeed, Specimen V8 FSWed composite joints are observed in the elongated
grains which is formed by transaction of heat from SZ to TMAZ is considerably low compared
to V4 specimen. On the other hand, specimens V12, V16 and V20 of MMCs joints have
achieved partial grain refinement within the TMAZ and HAZ. It is evident that Fig. 7(c-e) in the
formation of partially formed elongated grains and unaffected grains are observed from the
joints respectively. It could be concluded that in specimens V4 to V20, when the gap between
the reinforcement particles in decrease then, the boundary layer between the zones is thicker
that leads to decreases in the heat transfer rate between the zones [11].It is further evident from
that the Fig. 7(a-e), the increased content of Al 2O3 particles was traveled along the parallel band
structure and improvisation of band thickness from V4 to V20 in increasing order. According to
the Fig 7a, 7b and 7c the uniform distribution of Al2O3 particles was observed in the SZ, no
discontinuities identified, except the V16 and V20 specimens of Fig 7d and 7e.

3.2.2 Particle distributions of AZ31B-H24/Al2O3 composite joints

The Optical microstructure of the received matrix material of AZ31B-H24 and base
metal welded joint are presented as shown in Fig. 8(a-b). Fig. 8a as represents a received matrix
alloy having distinguished grain boundary layers with average grain size of 78µm to 82µm.The
optical microstructure shown in Fig. 8b obtained from the stir zone of FS welded AZ31B-H24
joint (it refers to zero volume fraction) is average grain size of 4µm to 6µm. It is clearly evident
that Fig. 8b has fine equiaxed grains formed by vigorous stirring action of rotating tool. High
rotational speed leads to vigorous stirring action of tool that will produce more frictional heat
within the SZ and coarsened the grains.
 Fig. 9(a-e) shows the optical micrographs of various volume fractioned AZ31B-
H24/Al2O3 composite FSWed joints obtained from the stir zone. When increasing the stir zone
volume fraction, the dispersion of Al2O3 nano particles in the SZ is an important issue during the
FSW process. It is clearly evident from that Fig. 9(a-c) nano sized Al2O3 reinforcement particles
were successfully distributed along the magnesium matrix. As can be seen from Fig. 9(d-e), the
distribution of Al2O3 particles was non-uniform because of particles agglomeration. There are
two responsible factors that lead to produce good particles distributions in the SZ: 1) Dynamic
recrystallization 2) Pinning effect of Al2O3 nano particles [17].Due to high rotational speed and
lower travelling rate of FSW process, the material undergoes severe plastic deformation at peak
temperature which leads to produce more heat within the stir zone and molten matrix are
coarsened to form fine grains. This phenomenon is known as dynamic recrystallization (DRX)
[18]. Besides nano sized Al2O3 particles create nucleating sites in the SZ, which will break the
initial grains and produce more amounts of low angle, disoriented grain boundaries during
recrystallization. This effect is known as pinning effect [19,20].The grain boundary refinement
can be attributed to the formation of complete onion ring pattern in the SZ irrespective of
volume fractions. This will attribute material flow pattern along with nano Al 2O3 particles from
the warmer zone in the top to cooler zone below, as a result of pin driven flow [21]. Several
investigators observed an onion ring structure, particles rich and free fields during FSW/FSP
[3,9,19,20]. M.Bahrami et al. [19] found an onion ring pattern in the tapered pin tool profile
during friction stir welding of AA7075/SiC joints. Azizieh et al.[9] found onion ring structure
during FSP of AZ31B/Al2O3 within the stir zone, alternate layers of coarse and fine grains in the
onion rings are due to small and large volume fractions of reinforcement phase respectively.

The regular onion ring structure was obtained in the specimens of V4, V8 and V12
which are represented in Fig. 9(a-c). Generally, in variable SZ volume fraction at constant tool
pin diameter, the amount of plasticization of molten matrix in the SZ is an important
phenomenon for producing good particle distributions and avoiding cluster formations during
FSW process [10, 11, 16]. It is evident that Fig. 9(a-c) clearly indicates that the amount of
matrix material reduces from V4 to V12 achieving by improving the width of slot as well as
increasing the reinforcement that leads to distribute the Al2O3 particles within the SZ. It is
further evident that, continuous dark thick lines indicating the reinforcement flow (particles rich
field) and continuous thin lines indicate molten matrix material flow (Particles free regions)
formed by alternatively. Thus, it could be inferred that the specimens from V4 to V12 had
received sufficient heat input around the tool pin profile from advancing side to retracting side
during FSW process. [12,19,20]. On the other hand, Fig. 9(d-e) show the incomplete onion ring
pattern obtained from the specimens V16 and V20. According to these specimens, the
dispersion of Al2O3 reinforcement particles is not clear about molten matrix causing clusters in
the weld nugget zone. This can be attributed, to the amount of reinforcement which increases as
well as reduces in the spacing between the reinforcement particles when the stir zone volume
fraction is increased. Moreover, reduction of space between Al 2O3 particles leads to reduction of
the temperature in weld nugget zone [11,16]. Thus, it could be inferred that the V16 and V20
specimens had produced insufficient heat during FSW and attributed to inadequate stirring and
material flow around the tool pin profile which causes formation of clusters in the nugget zone.

Fig. 10 represents the admixture pattern of parent metal and reinforcements in SZ of

V16 specimen FSWed composite joint. Uniform dispersion of Al2O3 particles can be attributed
to higher welding heat input at high tool rotational speed that leads way for more plastic
deformation mixed with the reinforcement with parent material together [11,16]. As can be seen
in Fig. 10, the variations in the distribution of Al2O3 particles in the SZ were indicated in letters
‘a’ and ‘b’. It is evident that, an increase in the reinforcements in the SZ decreased the quality of
material mixing to the reinforcement particles. Besides the specimen V16 possesses inadequate
material flow from advancing side to retracting side during FSW due to loss of heat generation.

Fig. 11 represents the particles that are rich and free regions of AZ31B-H24/Al 2O3
FSWed composite joint of V20 Specimen. Particles agglomeration leads to the production of
large amount of clusters in the stir zone. Due to the large cluster formations, poor mechanical
strength of the FSWed composite joints is produced [22]. It is evident that Fig. 11a, as a
constant rotational speed & feed, the volume of Al 2O3 particles increased which leads to
production of clusters formation which is due to low heat generation indicated in the round
marks. During recrystallization, nano Al2O3 particles act as a grain refiner and produce fine
grains within the SZ. The effective grain refinement produces good particles dispersion and fine
grains are formed. On the other hand, unaffected grain boundaries and particles agglomeration
were formed due to low heat input. It is evident that Fig. 11b represents Al 2O3 particles in the
V20 specimen which do not mix with the magnesium molten matrix properly. Hence clusters
are formed.
Fine dispersion of Al2O3 particles in the stir zone is represented in SEM micrograph in
Fig. 12(a-e). It is evident that, the improvisation of particles within the stir zone irrespective of
volume fractions leads to improvement of the Al2O3 particles density in the grain structure.
Because of the pinning effect of nano sized Al 2O3 particles are effective grain refiner, the grain
structures are in ultra-fine nature of specimens V4, V8 and V12 and it can be seen in Fig .12(a-
c). According to these figures, there is no interface between Al 2O3 particles and magnesium
matrix appears to be clean and is not surrounded by any voids or reaction products. Several
factors such as constant rotational speed and feed, improved volume fractions and inadequate
heat generations influence the formations of the clusters in the SZ [9]. Most uniform cluster
distribution was achieved in the specimens which are followed by the sequence of
V4>V8>V12>V16>V20. Average results of cluster size and grain size of all specimens are
listed in Table 2. Remarkably bigger size clusters are observed in the specimens V16 and V20
compared to other volume specimens. The prominent reason is that the inadequate material
mixing with Al2O3 particles is due to lack of heat generation. Moreover, dispersion of particles
is a significant issue of various volume fractioned welded joints that could be enhanced by
means of introducing more speed and feed during FSW which is the next study of authors. Fig.
13 shows the EDAX peak points of AZ31B-H24/Al 2O3 reinforced composite welded joints are
observed in the specimen V16 of arrow mark indicated area. The presence of Al 2O3 particles in
the SZ is clearly conformed.

3.3 Mechanical properties AZ31B-H24/Al2O3 composite joints

The ineffectual tool rotation speed and tool travelling feed lead to good agreement
between the FSW joints and it will produce promising mechanical properties such as Ultimate
Tensile Strength (UTS), hardness and remarkable fracture surface. The stir zone mechanical
properties are very sensitive to the following three important factors. (i) Grain size in the nugget
zone (ii) Pinning effect of the particle or bonding between reinforcement and matrix (iii) cluster
size [10, 15, 23]. Mechanical properties of AZ31B-H24/Al2O3 nano composite FSWed joints are
presented in Table-2.

3.3.1 Tensile properties

Comparative analysis of tensile strength and percentage of elongation on AZ31B-
H24/Al2O3 nano composite joints is presented in Fig. 14(a-b). Addition of nano particles in the
stir zone is a significant effect on tensile strength during FSW process. Gopalakrishnan et.al
[22] found that the tensile strength value decreases upto 3% addition of TiC particles in the
aluminum matrix composite (Al-TiC) when compared to cast aluminium strength. When beyond
the limit of % addition of TiC, the UTS values are found to be increasing steadily. As can be
seen in Table-2, Initially UTS values and percentage of elongation increase with the increase in
the % addition of Al2O3 particles within the stir zone upto the maximum limit of specimen V12.
Due to continuous addition of Al2O3 nano particles in the stir zone offered more resistance to
plastic deformation during tensile test. Besides, the smallest grain size value leads to improve
highest tensile strength in the ascending order followed by specimen number V4, V8 and V12.
Due to proper stirring action, fine grains are formed in the SZ and the results showed a good
agreement with the Hall-petch relationship [24].But in the case of specimens V16 and V20 the
above trend is non-linear. Further addition of Al2O3 reinforcement in the stir zone UTS value
and percentage of elongation also decrease the considerable amount when compared to above
said specimens. Non-uniform dispersion of Al2O3 particles and cluster formations are very
serious issues for reduction of UTS values. Bahrami et al. [19] found large clusters formation as
well as coarse grains in the four flute cylindrical specimen that lead to reduce UTS value
compared to other pin profiled tools. The values of cluster size in of Table-2, could be inferred
that, the increase in the cluster size leads to reduction the UTS value. Cluster size in the
specimens V4, V8 and V12 is negligible amount due to fine dispersion of Al2O3 particles and
good bonding between Al2O3 and AZ31B-H24 magnesium alloy is in the stir zone. UTS value
of specimen V12 increased upto 21% compared to V0 specimen. Hence increment of tensile
strength and percentage of elongation enhance the reduced grain size and cluster size is
inevitable.

3.3.2 Fractography analysis

Typical fractured region of FS welded Al2O3 reinforced AZ31B-H24 magnesium matrix

nano composite with various volume fractioned samples are presented in Fig. 15. According to
the figure, tensile samples of V4, V8 and V12 failed in between TMAZ and HAZ at the
advancing side. These are attributed to the following reasons: (i) dislocation density increased in
TMAZ due to inadequate plastic deformation. (ii) Continuous applied tensile stress in these
zones until it reaches the level of the crack nucleation stress. (iii) On the other hand, interfacial
bonding between Al2O3 nano particles and the magnesium matrix in the SZ restrict the
formation of crack. It means that lack of plasticization is the responsible factor which is
produced larger grain boundaries within the TMAZ and HAZ. This seems to be poor wettability
of Al2O3 and magnesium matrix phases leading to a weak cohesion of these phases.
 During tensile testing specimens V16 and V20 failed in SZ and fracture surfaces indicate
in a brittle manner. It is reason that lower level of dispersion and agglomeration of Al 2O3 nano
particles are in the SZ as addressed earlier. According to Amin Abdolahzadeh et al [3], cohesive
bonding between accumulated Al2O3 and magnesium matrix reduced the strength and elongation
as well as adhesive bonding between reinforcements and substrates improved the strength and
elongation of FSWed joints. However specimens V4, V8 and V12 produces good bonding
between Al2O3 nano particles and magnesium matrix due to adequate thermal heat generation
and fractured surface were indicated in ductile manner. It is evident that, SEM images of
fractured surface of the Al2O3 reinforced AZ31B-H24 FSWed joints represented in Fig. 16(a-e).
It can be seen from Fig. 16(a-c), that the fractured surface shows large number of dimples and
voids. Indeed, the presence of dimples and voids directly influence the elongations of the
specimen during tensile testing [25]. Some of the tear drops were observed in V12 specimen
(Fig. 16c) which will gives the moderate elongation. Although, specimens V16 and V20
fractured from the Al2O3 nano particles accumulated area. It is evident that a bigger size Al 2O3
cluster has indicated in fractured surface of specimen V16 (Fig. 16d). This result is in good
agreement with Mohsen Bahrami et al [20] in the case of aluminum and Sun and Fujii et al [12]
in the case of copper. V20 specimen however showed no major elongation. Cleavage type
fracture mode was observed in a fracture location and produced low elongation.

3.3.3. Microhardness

Fig. 17 represents the effect of hardness distribution of various volume fractioned

AZ31B-H24/Al2O3 composite FSWed joints. The ebb and flow shaped profile clearly confirmed
that the presence of Al2O3-rich and Al2O3-free regions in the weld nugget zones. Nevertheless
low hardness value was observed in particles free field and high hardness value was observed in
particles rich field. The microhardness values were taken from the cross section of specimens
across the weld centre line and as the norm of comparison, the average microhardness value of
composite joints is listed in Table-2. It could be inferred that the average microhardness value in
the SZ of AZ31B-H24 with dispersed Al2O3 nano particles is higher than that of zero volume
fractioned counterparts irrespective of volume fractions. On the other hand, average
microardness value of specimens V4, V8 and V12 increased while increasing Al2O3
reinforcement according to the % addition. This phenomenon can be attributed to the following
reasons. (a) The uniform distribution of Al 2O3 particles and grain size refinement (as per Hall-
Petch theory) in the SZ enhances the microhardness values [9]. (b) According to Orowan theory,
reinforcements and matrix alloy exhibit different coefficient of thermal expansion which is leads
to the improvement of the dislocation density due to the formation of residual stresses during
cooling time. Hence the volume fraction increases the number of dislocations in the AZ31B-
H24 alloy due to more number of Al2O3 particles [10]. (c) According to Sathiskumar et al [16] at
constant volume fraction the interparticle spacing increases in the SZ due to increase in ASC
and hence decrease in the microhardness value. From the evidence in Fig. 5(a-c), it is observed
interparticle spacing decrease in the SZ due to the decrease in the ASC and hence the increase in
the microhardness value.

As a matter of fact, insufficient heat generation during FSW process which leads to
produce the formation of clusters and accumulation of reinforcements (non uniform dispersion)
are increases the microhardness value. In Specimen V16, average microhardness value
decreases due to non-homogeneous distribution of TMAZ and SZ. Hence the hardness
distribution in the TMAZ is reaches the maximum value. Out of the above four composite
welded joints V20 specimen showed highest average microhardness value compared to other
welded joints. In other words, the Al 2O3 particles are accumulated in the bottom of welded
sample and hence it has more average microhardness value. Moreover, hardness profile of V4,
V8 and V12 specimens produce uniform dispersion of nano particles as well as fine grain sizes
within the SZ comparing V16 and V20 specimen.

Acknowledgements
The authors are grateful to the Management and Department of Mechanical Engineering,
Jayalakshmi Institute of Technology, Dharmapuri, Tamilnadu, India for extending the facilities
to carry out this investigation successfully.
CONCLUSION

FSW of AZ31B-H24 magnesium alloy was successfully reinforced with Al2O3 nano
particles at five different stir zone volume fractions and studied the significant effect of
macrostructure, microstructure and mechanical behavior of composite joints. From that
research, the following findings are made and listed as follows.

i. Absence of defect free composite welded joints is achieved in the constant tool
rotational speed of 1260rpm and tool travelling speed of 20mm/min irrespective of
volume fractions.
ii. Areas of Surface Composite (ASC) of welded joints of specimens V4 to V20 were
decreased from 67.45mm2 to 42.35mm2 respectively. It is concluded as volume
fractions of FSWed composite joints are indirectly proportional to the ASC.
iii. Specimens V4, V8 and V12 are obtained as homogeneous particle dispersion within
the stir zone at given welding condition. In the contrary, Specimens V16 and V20 are
observed as severe Al2O3 particles accumulations as well as cluster formations due to
insufficient heat generation around the tool pin profile.
iv. Heat transfer was decreased between the transition zones while increasing the volume
fractions as well as increasing the density of Al2O3 nano particles in the SZ.
v. Al2O3 nano particles influence both tensile strength (UTS) and percentage of
elongation (POE) values of composite welded joints. The UTS & POE value increase
with the increase in the volume fractions of joints from V4 to V12 and decrease when
there is further increase of volume fractions upto specimen V20 by inadequate material
mixing with reinforcement.
vi. Fractography of failed samples shows, brittle fracture mode was observed in the Al 2O3
particles accumulated joints which loosened the bonding structure within the stir zone
(specimens V16 and V20) whereas, others followed as ductile fracture mode and failed
in between TMAZ and HAZ (specimens V4, V8 and V12).
vii. Uniform hardness distribution in specimens V4, V8 and V12 maintained a good
conformity with grain size and dispersion of Al2O3 particles. Other specimens were not
upto the level.