Optimization of Rotational Speed Parameters for Enhanced Weld Quality and Fatigue Performance in Aluminium Alloy 6061/Sic Composites

  • Unique Paper ID: 179382
  • PageNo: 6239-6243
  • Abstract:
  • Aluminium matrix composites (AMCs), especially Aluminium Alloy 6061 reinforced with silicon carbide (SiC), are widely valued in aerospace, automotive, and structural applications due to their excellent mechanical and thermal properties. However, effective joining of these composites poses challenges. Friction Stir Welding (FSW), a solid-state process, is highly suitable for joining aluminium-based composites. This study focuses on optimizing the rotational speed in FSW to improve weld quality and fatigue resistance in Al 6061/SiC composites. Composite plates were prepared via stir casting and rolling, then welded at rotational speeds of 600, 800, 1000, 1200, and 1400 rpm, with constant traverse speed and axial force. Mechanical evaluations included tensile strength, hardness, and fatigue life testing, while microstructural features were analyzed using optical and scanning electron microscopy. Results indicate that speeds between 1000–1200 rpm produced defect-free welds with enhanced mechanical and fatigue properties. This research highlights the importance of rotational speed in achieving highperformance FSW joints in AMCs.

Copyright & License

Copyright © 2026 Authors retain the copyright of this article. This article is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.

BibTeX

@article{179382,
        author = {SUTHAHAR M and Dr.J.MANIVANNAN and Dr.Y.ROBINSON and Dr.P.ELAMURUGAN},
        title = {Optimization of Rotational Speed Parameters for Enhanced Weld Quality and Fatigue Performance in Aluminium Alloy 6061/Sic Composites},
        journal = {International Journal of Innovative Research in Technology},
        year = {2025},
        volume = {11},
        number = {12},
        pages = {6239-6243},
        issn = {2349-6002},
        url = {https://ijirt.org/article?manuscript=179382},
        abstract = {Aluminium matrix composites (AMCs), especially
Aluminium Alloy 6061 reinforced with silicon carbide (SiC), are
widely valued in aerospace, automotive, and structural
applications due to their excellent mechanical and thermal
properties. However, effective joining of these composites poses
challenges. Friction Stir Welding (FSW), a solid-state process, is
highly suitable for joining aluminium-based composites. This
study focuses on optimizing the rotational speed in FSW to
improve weld quality and fatigue resistance in Al 6061/SiC
composites. Composite plates were prepared via stir casting and
rolling, then welded at rotational speeds of 600, 800, 1000, 1200,
and 1400 rpm, with constant traverse speed and axial force.
Mechanical evaluations included tensile strength, hardness, and
fatigue life testing, while microstructural features were analyzed
using optical and scanning electron microscopy. Results indicate
that speeds between 1000–1200 rpm produced defect-free welds
with enhanced mechanical and fatigue properties. This research
highlights the importance of rotational speed in achieving highperformance FSW joints in AMCs.},
        keywords = {Friction Stir Welding, Aluminium Matrix Composites, Al 6061/SiC, Rotational Speed, Fatigue Performance, Weld Optimization},
        month = {May},
        }

Cite This Article

M, S., & Dr.J.MANIVANNAN, , & Dr.Y.ROBINSON, , & Dr.P.ELAMURUGAN, (2025). Optimization of Rotational Speed Parameters for Enhanced Weld Quality and Fatigue Performance in Aluminium Alloy 6061/Sic Composites. International Journal of Innovative Research in Technology (IJIRT), 11(12), 6239–6243.

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