Materials Letters 60 (2006) 565 – 568

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Evaluation of microstructure and mechanical properties in friction

stir welded A356 + 15%SiCp cast composite
M. Amirizad, A.H. Kokabi 1 , M. Abbasi Gharacheh ⁎, R. Sarrafi, B. Shalchi, M. Azizieh
Materials Science and Engineering Department, Sharif University of Technology, P.O. Box 11365-9466, Tehran-Iran
Received 7 May 2005; accepted 21 September 2005
Available online 7 October 2005

Abstract

Friction Stir Welding (FSW) is a novel solid state welding process for joining materials. In this process a high speed tool is introduced into the
weld seam and due to localized frictional heat, plastic deformation and transverse movement along the weld seam, joining is accomplished. In this
study aluminum matrix composite A356 + 15%SiCp is chosen for friction stir welding. Fragmentation of SiC particles and silicon needles existing
in eutectic phase as well as their homogenous distribution as a result of stirring with high plastic strains, improve mechanical properties such as
modulus of elasticity, yield and ultimate strength, elongation and hardness in the weld zone compared to that of the base composite. Results of this
research indicate that FSW is a suitable process for joining aluminum matrix composite castings.
© 2005 Elsevier B.V. All rights reserved.

Keywords: Friction stir welding; A356 + 15%SiCp composite; Microstructure; Mechanical properties

1. Introduction of the material surrounding the tool, joining is accomplished [3].

Friction Stir Welding (FSW) is a novel joining process,
deserving much attention due to its special advantages. One
of the most dominant advantages is to use this process for
joining of those alloys that have low weldability by con-
ventional fusion welding methods. Aluminum matrix compo-
sites, despite extensive use in the aerospace and automotive
industries, have difficulties in joining and welding. The most
effective joining method for composites is solid state welding. In
solid state processes, the problem of undesirable chemical
reactions between the reinforcement particles and the matrix is
decreased and defects such as brittle intermetallic compounds,
porosity and cracks are minimized [1]. FSW process owing to
giving sound welds in most of unweldable alloys is used for
joining of metal matrix composites. In this process a rotating
threaded tool involving two parts, pin and shoulder, has been
used [2]. The tool rotates and moves forward along the weld seam
with a high speed of stirring. As a result of the localized frictional
heat, softening, plastic deformation and increase in workability
⁎ Corresponding author.
E-mail address: Gharacheh@mehr.sharif.edu (M.A. Gharacheh).
1 6.7
Fax: +98 21 6005717.
In non-composite alloys strengthened by mechanical and
thermomechanical methods, loss of strength, ductility and
hardness is witnessed in the weld zone, due to restoration
processes (involving recovery, recrystalization and grain growth)
which occur in the stir zone and transitional zone [4]. It is
remarked in the literature that in friction stir welded castings, an
increase in strength and ductility is observed as a result of
modification in the solidification microstructure [4–6].
Fernandez and Murr [7] have reported that SiC particles
mean size were decreased and their number were increased in
the stir zone of A359 + 20%SiCp composite. As a consequence,
the hardness was increased in the stir zone.
Storjohann et al. [1] examined 2124 + 20%SiCp and 6061 +
20%Al2O3p composites in terms of chemical reactions between
reinforcement and matrix, as well as mechanical properties
achieved by FSW process in comparison with that of other
fusion welding processes. According to their observations,
Table 1
Chemical composition of matrix (in wt.%)
Si Mg Cu Fe Ti Al
0.3 0.12 0.17 0.01 Rest

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doi:10.1016/j.matlet.2005.09.035
566 M. Amirizad et al. / Materials Letters 60 (2006) 565–568
Fig. 1. Schematic of FSW process that was used in this research.
Fig. 2. Optical macrograph of friction stir welded joint cross-section.
reinforcement particles are homogenously distributed through
matrix without having extensive reactions. Hardness test results
showed an insignificant difference between weld metal and base
composite, while in fusion welded composites, a brittle and hard
weld metal was produced as a result of undesirable reactions
between the matrix and the reinforcement.
Shinoda et al. [8] studied the modification in solidification
microstructure of friction stir welded aluminum alloy castings.
According to their observations, due to the modification,
breaking up and homogenization of the silicon needles in the
eutectic phase, hardness increase in the stir zone was observed,
in comparison with the matrix.
A356/SiCp composites are widely used in aerospace and
automotive industries. Moreover FSW process is an applicable
method in joining metal matrix composites. Considering these
facts, this study has been carried out to evaluate mechanical
Fig. 3. SiC particles distribution in: a) base composite, b) transitional zone and c) stir zone.
properties achieved by microstructural changes in stir zone and
transitional zone with respect to base metal. Mechanical
properties such as modulus of elasticity, ultimate and yield
strength, elongation and hardness along with microstructural
changes such as distribution and size of SiC particles and silicon
needles in eutectic phase have been studied.
2. Experiments
Cast plates of A356 + 15%SiCp composites with 6 mm
thickness and chemical composition shown in Table 1, were
welded. The mean size of SiC particles were 40 μm.
The applied tool is made of D2 tool steel which was
quenched-tempered to 58 HRC.
A threaded pin is chosen and the tool shoulder diameter, pin
diameter and pin height are 20, 6 and 5.5 mm, respectively.
Transverse and rotating speeds are 3 cm/min and 1200 rpm,
respectively, which were chosen according to the optimum
results reported in the Ref. [9].
In order to minimize the effect of tool wear on results, weld
length are chosen equal to the maximum length of 6 cm (Fig. 1).
For metallographic study and hardness testing, transverse
sections of the joints were prepared. Metallographic images and
Brinell hardness tests using 1 mm ball and 10 Kg force along
different zones were accomplished. Tensile specimens were
made from longitudinal direction of the stir zone and the base
metal as well. Tensile test is carried out using Instron 1115
machine at the cross-head speed of 2 mm/min. SiC particles and
silicon needles dimensional evaluations are carried out with
optical microscope equipped with an image analyzer. The
morphology and size of silicon needles are evaluated in the
eutectic region of the base metal and the stir zone using optical
microscope.
3. Results and discussion
A joint section made by FSW process in this study is shown in
Fig. 2. Different regions such as stir zone (SZ), transitional zone
(TZ) and base metal (BM) are seen in this section.
Fig. 3 shows macroetched metallographs taken from transverse
section of the joint involving stir zone, transitional zone and base
composite.
In general, transitional zone consists of two zones: heat affected
zone (HAZ) and thermomechanically affected zone (TMAZ). Since the
composite has a little sensitivity to thermal variations, the transitional
zone is limited to TMAZ. Inhomogeneous distribution of SiC particles
and their agglomeration in the base metal due to composite fabrication
 M. Amirizad et al. / Materials Letters 60 (2006) 565–568
Fig. 4. Optical micrographs of different zones: a) base composite, b) transitional zone, c) stir zone.
and solidification is apparently observable (Fig. 3-a). In transitional
zone, SiC particles are distributed along some parallel bands in the
matrix (Fig. 3-b). Application of high stresses and the heat produced
by stirring tool are responsible for composite plastic deformation in
this region so that agglomerated particles are stretched along the
shear stress directions. SiC particles are distributed homogeneously
in the stir zone and neither agglomerated distribution in base metal
nor band-like distribution in transitional zone are observable (Fig. 3-
c). Stirring causes a high plastic strain [10] which is resulted in re-
arrangement of particles from agglomerated and inhomogeneous
distribution in the base metal to homogeneous distribution in the stir
zone. Microetched metallographs from different zones of the joint
are shown in Fig. 4.
Fig. 4-a, depicts globular structure of primary α-Al phase along
with interdendritic eutectic phase. SiC particles are distributed in the
interdendritic zone as a result of solidification mode of the composite.
In transitional zone silicon needles accompanied by SiC particles are
observed in the form of parallel bands adjacent to the stretched bands of
α-Al former globules (Fig. 4-b). In the stir zone a homogeneous
distribution of silicon needles as a result of modification caused by
stirring with high plastic strains is observable, similar to that of SiC
Fig. 5. Modification in shape and size of silicon needles: a) silicon needles in
Al–Si eutectic in the base metal, b) modified silicon particles in the stir zone.
Fig. 6. Aspect ratio variations for silicon particles in different regions.
567
particles (Fig. 4-c). Heavy deformations in the stir zone cause breaking
of silicon needles in eutectic phase (Fig. 5).
Fig. 6 shows silicon needles aspect ratio (length / thickness)
variations in different zones.
Mean size of silicon needles decreases from 20 μm in the base
composite to 10 μm in the transitional zone and to 6 μm in the stir
zone. This is due to fragmentation of silicon needles because of
applying heavy deformations in the transitional zone and the stir
zone. Transverse section hardness test results of the joint are shown
in Fig. 7.
Maximum and minimum hardness are detected in the stir zone and
the base composite, respectively. The hardness of the transitional zone
varies between those of the stir zone and the base composite. Decrease
in size of silicon particles and increase in number of them as well as
band-like or homogeneous distribution of silicon and SiC particles in
the transitional zone and the stir zone cause to weld zone hardness
Fig. 7. Brinell hardness profile of the transverse section of the joint.
Fig. 8. Engineering stress–strain diagrams of longitudinal specimens from stir
zone and base metal.
568 M. Amirizad et al. / Materials Letters 60 (2006) 565–568
Fig. 9. Tensile properties of the stir zone (SZ) in comparison with the base metal
(BM).
improvement. Hardness results are in good agreement with the reported
results in Refs. [1] and [7].
Tensile test results from longitudinal direction of the weld metal and
the base composite are given in Fig. 8.
Each curve shows mean value of the results for three tensile
specimens. From stress–strain curves given in Fig. 8, it can be
concluded that tensile properties such as modulus of elasticity, yield
strength, tensile strength and elongation of the stir zone are improved
significantly compared to that of the base composite. The basic
reasons for this improvement are homogeneous distribution of SiC
and silicon particles in the stir zone as well as decrease in the
amount of microporosities, because of modification in solidification
microstructure. These microstructural changes in stir zone affect
modulus of elasticity and yield strength directly [11]. On the other
hand, modification of the shape of silicon needles and decrease in
their aspect ratio along with spreading or de-agglomeration of SiC
clusters existing in the base composite and lessening of micro-
porosities reduces the stress concentration points and thus, causes an
improvement in elongation to failure and tensile strength. Tensile
properties for stir zone in comparison with the base metal are shown
in Fig. 9.
It can be seen that elongation of the stir zone has the largest increase
with respect to the other tensile properties. This is due to decrease in
localized deformations which are nucleated from microporosities and
agglomerated particles in the stir zone, as a result of modification and
homogenization of solidification microstructure.
4. Conclusions
Friction stir welding of A356 + %15SiCp cast composite
leads to an improvement in tensile properties and joint
hardness due to modification in solidification microstructure
of the base composite. Homogeneous distribution of SiC
particles as well as spherodization of silicon needles and their
spreading through the matrix are the dominant reasons for
property improvement in the stir zone. Band-like arrangement
of SiC particles and silicon needles leads to an increase in the
hardness of the transitional zone in comparison with the base
composite. Modulus of elasticity, yield strength, tensile strength
and elongation to failure of the stir zone show an increase in the
order of 57%, 26%, 34% and 154% with respect to the base
composite, respectively. Finally, considering the results of this
research and problems of fusion welding methods for joining
metal matrix composites, FSW is proposed as a very suitable
alternative for MMC's.
Acknowledgments
The authors wish to thank Dr. R. Bagheri for helpful
discussions, Dr. M. Ghaznavi in aerospace research center for
technical assistance; Mr. M. Shareh, Mr. O. Kazemi and Mr. A.
Asadpoor in University of Tehran for material preparation.
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