Abstract
In this research work, ample study was conducted on the material characterization of aluminium (Al) and titanium carbide
(TiC) metal matrix composites produced via friction stir welding. Different process parameters were employed for the
welding process. Rotational speeds of 1600 rpm to 2000 rpm at an interval of 200 rpm and traverse speeds of 100 to 300
mm/min at an interval of 100 mm/min were employed for the welding conducted on an Intelligent Stir Welding for
Industry and Research (I-STIR) Process Development System (PDS) platform. The characterizations carried out include
optical microscopy and the scanning electron microscopy analyses combined with Energy Dispersive Spectroscopy
(SEM/EDS) techniques to investigate the particle distribution, microstructural evolution and the chemical analysis of the
welded samples. Vickers microhardness tests were used to determine the hardness distribution of the welded zone and
tensile testing was conducted to quantify the strength of the welded area to the base metal in order to establish the optimal
process parameters. Based on the results obtained from the characterization analysis, it was found that the process
parameters played a major role in the microstructural evolution. Homogenous distribution of the TiC particles was
observed at high rotational speed of 2000 rpm and low traverse speed of 100 mm/min. The highest hardness value was
measured at the stir zone of the weld due to the presence of the TiC reinforcement particles. The tensile strength also
increased as the rotational speed increased and 92% joint efficiency was recorded in a sample produced at 2000 rpm and
100 mm/min. The EDS analysis revealed that Al, Ti and C made up the composition formed at the stir zone. The optimum
process parameter setting was found to be at 2000 rpm and 100 mm/min and can be recommended.