Enhancing Hardness In 2024 Aluminum Alloy Hybrid Composites: Friction Stir Welding With Mos2 & Sic Particles

Abstract

This study investigates the enhancement of hardness properties in 2024 aluminum alloy hybrid composite plates joined through Friction Stir Welding (FSW) by incorporating varying percentages of Molybdenum Disulfide (MoS2) and Silicon Carbide (SiC) particles. Known for its high strength-to-weight ratio, 2024 aluminum alloy is extensively used in the automotive and aerospace sectors. Earlier studies have defined that ceramic particles like SiC enhance the hardness and mechanical properties of aluminum alloys, and MoS2 enhances wear resistance. However, the combined effect of MoS2 and SiC on 2024 aluminum alloy, particularly when subjected to FSW, has not been thoroughly explored. In this research, composite plates were fabricated by mixing 2024 aluminum alloy with up to 6% MoS2 and 10% SiC particles, followed by FSW processing. The Rockwell hardness test was performed on both the base composites and the welded joints. Results showed a significant increase in hardness with the addition of MoS2 and SiC, with the base composites’ hardness increasing from 63.0 HRN to a peak of 109.5 HRN, and the welded composites’ hardness rising from 116.0 HRN to a maximum of 148.9 HRN. The results designate that particle reinforcement and the FSW process significantly enhance the alloy's hardness. The optimal composition of 4% MoS2 and 8% SiC achieved the highest hardness values, highlighting the potential of this hybrid composite for high-performance applications. This study suggests valuable insights into the development of advanced aluminum alloy composites for industrial use.