A Novel Approach to Friction Stir Welding (FSW): Repairing Cracks in AA6061-T6 Aluminium Alloy Using Aluminium Filler Rod and SiC Nanoparticles

Ahmad H. Bawagnih; Ahmed Ali Gad El-Mawla; Fadi Al-Badour; Filmon Surafiel; Rami K. Suleiman; Necar Merah

doi:10.1007/978-3-031-80896-8_6

A Novel Approach to Friction Stir Welding (FSW): Repairing Cracks in AA6061-T6 Aluminium Alloy Using Aluminium Filler Rod and SiC Nanoparticles

Ahmad H. Bawagnih^*, Ahmed Ali Gad El-Mawla, Fadi Al-Badour^*, Filmon Surafiel, Rami K. Suleiman, Necar Merah

^*Corresponding author for this work

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

Abstract

Friction stir weldingFriction stir welding (FSW) is anAA6061advancedSiC welding technique that effectively addresses surface crack repair. This study investigates the healing of an artificial crack machine with a 2 mm square groove using an innovative technique that incorporates an aluminium filler rod in combination with SiCSiC nanoparticles to ensure complete filling of the crack. FSW was conducted on both cracked and uncracked samples to compare the impact of the repair process irrespective of welding conditions. To evaluate the success of the repair method and identify potential defects in the weld zone, a series of tests, including tensile strength, microhardness, and microstructural examinations, were performed. The results indicated that the crack repair plates demonstrated higher mechanical performance compared to uncracked samples. However, some defects were observed during scanning electron microscopy (SEM) analysis, leading to a discussion on their implications for the overall integrity of the weld. This study highlights the effectiveness of the modified FSW technique in repairing cracks in 6061-T6 aluminium alloy6061-T6 aluminium alloy, suggesting a promising approach for enhancing the reliability and performance of crack healingCrack healing demanding applications.

Original language	English
Title of host publication	Friction Stir Welding and Processing XIII
Editors	Yuri Hovanski, Yutaka Sato, Piyush Upadhyay, Nilesh Kumar, Anton A. Naumov
Publisher	Springer Science and Business Media Deutschland GmbH
Pages	61-71
Number of pages	11
ISBN (Print)	9783031808951
DOIs	https://doi.org/10.1007/978-3-031-80896-8_6
State	Published - 2025
Event	13th symposium on Friction Stir Welding and Processing, FSWP 2025, held as part of the TMS Annual Meeting and Exhibition, TMS 2025 - Las Vegas, United States Duration: 23 Mar 2025 → 27 Mar 2025

Publication series

Name	Minerals, Metals and Materials Series
ISSN (Print)	2367-1181
ISSN (Electronic)	2367-1696

Conference

Conference	13th symposium on Friction Stir Welding and Processing, FSWP 2025, held as part of the TMS Annual Meeting and Exhibition, TMS 2025
Country/Territory	United States
City	Las Vegas
Period	23/03/25 → 27/03/25

Bibliographical note

Publisher Copyright:
© The Minerals, Metals & Materials Society 2025.

Keywords

6061-T6 aluminium alloy
Crack healing
Friction stir welding
Solid-state additive manufacturing

ASJC Scopus subject areas

Electronic, Optical and Magnetic Materials
Energy Engineering and Power Technology
Mechanics of Materials
Metals and Alloys
Materials Chemistry

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

Access to Document

10.1007/978-3-031-80896-8_6

Cite this

Bawagnih, A. H., El-Mawla, A. A. G., Al-Badour, F., Surafiel, F., Suleiman, R. K., & Merah, N. (2025). A Novel Approach to Friction Stir Welding (FSW): Repairing Cracks in AA6061-T6 Aluminium Alloy Using Aluminium Filler Rod and SiC Nanoparticles. In Y. Hovanski, Y. Sato, P. Upadhyay, N. Kumar, & A. A. Naumov (Eds.), Friction Stir Welding and Processing XIII (pp. 61-71). (Minerals, Metals and Materials Series). Springer Science and Business Media Deutschland GmbH. https://doi.org/10.1007/978-3-031-80896-8_6

Bawagnih, Ahmad H. ; El-Mawla, Ahmed Ali Gad ; Al-Badour, Fadi et al. / A Novel Approach to Friction Stir Welding (FSW) : Repairing Cracks in AA6061-T6 Aluminium Alloy Using Aluminium Filler Rod and SiC Nanoparticles. Friction Stir Welding and Processing XIII. editor / Yuri Hovanski ; Yutaka Sato ; Piyush Upadhyay ; Nilesh Kumar ; Anton A. Naumov. Springer Science and Business Media Deutschland GmbH, 2025. pp. 61-71 (Minerals, Metals and Materials Series).

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title = "A Novel Approach to Friction Stir Welding (FSW): Repairing Cracks in AA6061-T6 Aluminium Alloy Using Aluminium Filler Rod and SiC Nanoparticles",

abstract = "Friction stir weldingFriction stir welding (FSW) is anAA6061advancedSiC welding technique that effectively addresses surface crack repair. This study investigates the healing of an artificial crack machine with a 2 mm square groove using an innovative technique that incorporates an aluminium filler rod in combination with SiCSiC nanoparticles to ensure complete filling of the crack. FSW was conducted on both cracked and uncracked samples to compare the impact of the repair process irrespective of welding conditions. To evaluate the success of the repair method and identify potential defects in the weld zone, a series of tests, including tensile strength, microhardness, and microstructural examinations, were performed. The results indicated that the crack repair plates demonstrated higher mechanical performance compared to uncracked samples. However, some defects were observed during scanning electron microscopy (SEM) analysis, leading to a discussion on their implications for the overall integrity of the weld. This study highlights the effectiveness of the modified FSW technique in repairing cracks in 6061-T6 aluminium alloy6061-T6 aluminium alloy, suggesting a promising approach for enhancing the reliability and performance of crack healingCrack healing demanding applications.",

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author = "Bawagnih, {Ahmad H.} and El-Mawla, {Ahmed Ali Gad} and Fadi Al-Badour and Filmon Surafiel and Suleiman, {Rami K.} and Necar Merah",

note = "Publisher Copyright: {\textcopyright} The Minerals, Metals & Materials Society 2025.; 13th symposium on Friction Stir Welding and Processing, FSWP 2025, held as part of the TMS Annual Meeting and Exhibition, TMS 2025 ; Conference date: 23-03-2025 Through 27-03-2025",

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Bawagnih, AH, El-Mawla, AAG, Al-Badour, F, Surafiel, F, Suleiman, RK & Merah, N 2025, A Novel Approach to Friction Stir Welding (FSW): Repairing Cracks in AA6061-T6 Aluminium Alloy Using Aluminium Filler Rod and SiC Nanoparticles. in Y Hovanski, Y Sato, P Upadhyay, N Kumar & AA Naumov (eds), Friction Stir Welding and Processing XIII. Minerals, Metals and Materials Series, Springer Science and Business Media Deutschland GmbH, pp. 61-71, 13th symposium on Friction Stir Welding and Processing, FSWP 2025, held as part of the TMS Annual Meeting and Exhibition, TMS 2025, Las Vegas, United States, 23/03/25. https://doi.org/10.1007/978-3-031-80896-8_6

A Novel Approach to Friction Stir Welding (FSW): Repairing Cracks in AA6061-T6 Aluminium Alloy Using Aluminium Filler Rod and SiC Nanoparticles. / Bawagnih, Ahmad H.; El-Mawla, Ahmed Ali Gad; Al-Badour, Fadi et al.
Friction Stir Welding and Processing XIII. ed. / Yuri Hovanski; Yutaka Sato; Piyush Upadhyay; Nilesh Kumar; Anton A. Naumov. Springer Science and Business Media Deutschland GmbH, 2025. p. 61-71 (Minerals, Metals and Materials Series).

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

TY - GEN

T1 - A Novel Approach to Friction Stir Welding (FSW)

T2 - 13th symposium on Friction Stir Welding and Processing, FSWP 2025, held as part of the TMS Annual Meeting and Exhibition, TMS 2025

AU - Bawagnih, Ahmad H.

AU - El-Mawla, Ahmed Ali Gad

AU - Al-Badour, Fadi

AU - Surafiel, Filmon

AU - Suleiman, Rami K.

AU - Merah, Necar

N1 - Publisher Copyright: © The Minerals, Metals & Materials Society 2025.

PY - 2025

Y1 - 2025

N2 - Friction stir weldingFriction stir welding (FSW) is anAA6061advancedSiC welding technique that effectively addresses surface crack repair. This study investigates the healing of an artificial crack machine with a 2 mm square groove using an innovative technique that incorporates an aluminium filler rod in combination with SiCSiC nanoparticles to ensure complete filling of the crack. FSW was conducted on both cracked and uncracked samples to compare the impact of the repair process irrespective of welding conditions. To evaluate the success of the repair method and identify potential defects in the weld zone, a series of tests, including tensile strength, microhardness, and microstructural examinations, were performed. The results indicated that the crack repair plates demonstrated higher mechanical performance compared to uncracked samples. However, some defects were observed during scanning electron microscopy (SEM) analysis, leading to a discussion on their implications for the overall integrity of the weld. This study highlights the effectiveness of the modified FSW technique in repairing cracks in 6061-T6 aluminium alloy6061-T6 aluminium alloy, suggesting a promising approach for enhancing the reliability and performance of crack healingCrack healing demanding applications.

AB - Friction stir weldingFriction stir welding (FSW) is anAA6061advancedSiC welding technique that effectively addresses surface crack repair. This study investigates the healing of an artificial crack machine with a 2 mm square groove using an innovative technique that incorporates an aluminium filler rod in combination with SiCSiC nanoparticles to ensure complete filling of the crack. FSW was conducted on both cracked and uncracked samples to compare the impact of the repair process irrespective of welding conditions. To evaluate the success of the repair method and identify potential defects in the weld zone, a series of tests, including tensile strength, microhardness, and microstructural examinations, were performed. The results indicated that the crack repair plates demonstrated higher mechanical performance compared to uncracked samples. However, some defects were observed during scanning electron microscopy (SEM) analysis, leading to a discussion on their implications for the overall integrity of the weld. This study highlights the effectiveness of the modified FSW technique in repairing cracks in 6061-T6 aluminium alloy6061-T6 aluminium alloy, suggesting a promising approach for enhancing the reliability and performance of crack healingCrack healing demanding applications.

KW - 6061-T6 aluminium alloy

KW - Crack healing

KW - Friction stir welding

KW - Solid-state additive manufacturing

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DO - 10.1007/978-3-031-80896-8_6

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AN - SCOPUS:86000456378

SN - 9783031808951

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BT - Friction Stir Welding and Processing XIII

A2 - Hovanski, Yuri

A2 - Sato, Yutaka

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PB - Springer Science and Business Media Deutschland GmbH

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Bawagnih AH, El-Mawla AAG, Al-Badour F, Surafiel F, Suleiman RK , Merah N. A Novel Approach to Friction Stir Welding (FSW): Repairing Cracks in AA6061-T6 Aluminium Alloy Using Aluminium Filler Rod and SiC Nanoparticles. In Hovanski Y, Sato Y, Upadhyay P, Kumar N, Naumov AA, editors, Friction Stir Welding and Processing XIII. Springer Science and Business Media Deutschland GmbH. 2025. p. 61-71. (Minerals, Metals and Materials Series). doi: 10.1007/978-3-031-80896-8_6

A Novel Approach to Friction Stir Welding (FSW): Repairing Cracks in AA6061-T6 Aluminium Alloy Using Aluminium Filler Rod and SiC Nanoparticles

Abstract

Publication series

Conference

Bibliographical note

Keywords

ASJC Scopus subject areas

UN SDGs

Access to Document

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Cite this