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Studying the Effect of Processing Parameters on the Microstructure, Strength,

Hardness, and Corrosion Characteristics of Friction Stir Dissimilar Welded
AA5083 and AA7075 Aluminum...

Article in Heliyon · December 2024

DOI: 10.1016/j.heliyon.2024.e41362

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Research article

Studying the effect of processing parameters on the

microstructure, strength, hardness, and corrosion characteristics
of friction stir dissimilar welded AA5083 and AA7075 aluminum
alloys reinforced with Al-SiC matrix
Noha M. Abdeltawab a,b, Mohamed Elshazly a , Ahmed Y. Shash a,b,*, M. El-Sherbiny a
a
Department of Mechanical Design and Production, Faculty of Engineering, Cairo University, Giza, 12316, Egypt
b
Faculty of Engineering and Materials Science, German University in Cairo, Cairo, Egypt

A R T I C L E I N F O A B S T R A C T

Keywords: The complementary properties of corrosion resistance and ballistic resistance of AA5083 and
Dissimilar friction stir welding AA7075, respectively, explain the significance of welding these two alloys in the marine armor
Aluminum silicon carbide matrix industry. This study investigates a novel Al-SiC matrix reinforcement with a different SiC weight
Processing parameters
ratio in dissimilar friction stir welding of the AA5083/AA7075 joint at different transverse and
AA5083/AA7075 welding
rotational speeds. The study deduced that the novel matrix can play an important role in
improving strength and ductility simultaneously. Maximum strength takes place under conditions
of 50 % SiC in Al-SiC matrix, 900 rpm rotational speed, and 40 mm/min transverse speed of value
209.8 MPa, which is equal to 90 % strength of the base metal AA5083, and the maximum strain
takes place at 25 % SiC in Al-SiC matrix, 900 rpm rotational speed, and 20 mm/min transverse
speed, with improved strain by 2 % than the softer alloy AA5083. Corrosion weight loss decreased
by increasing the SiC weight ratio in the Al-SiC matrix, where it improved by 47.9 % compared to
the base metal alloy of AA5083 at 75 % SiC in the Al-SiC matrix, 900 rpm rotational speed, and
20 mm/min transverse speed.

1. Introduction

The alloys of AA5083 and AA7075 alloys offers a number of promising and desirable properties, AA7075 has the advantage of
ballistic resistance [1,2] while AA5083 is renowned for corrosion resistance that nominate the assembly structures to replace steel
armor in many application like marine industry, aerospace, and automobiles [3,4]. Al-Zn-Mg-(Cu) (AA7xxx) alloys are a heat-treatable
precipitation hardenable series [3,5]. The hardening isothermal process takes place in the sequence starting from a supersaturated
solid solution followed by the forming of Guinier-Preston (GP) zones and η-phase along the grain boundaries [6]. AA7075 alloys have
the advantage of a high strength-to-weight ratio, good ductility, energy absorption capacity, and high cryogenic properties [7].
However, applications of AA7075 face challenges of low corrosion resistance and the high content of Cu (1.75 wt%) susceptible the
alloy to cracks and elevated residual stresses during fusion welding [8]. Additionally, the thermal cycle and severe plastic deformation
welding processes like Friction Stir Welding FSW lead to dissolving the precipitates (ηʹ phases), softening, and reduction in mechanical

* Corresponding author. Department of Mechanical Design and Production, Faculty of Engineering, Cairo University, Giza, 12316, Egypt.
E-mail address: [email protected] (A.Y. Shash).

https://doi.org/10.1016/j.heliyon.2024.e41362
Received 16 September 2024; Received in revised form 16 December 2024; Accepted 18 December 2024
Available online 19 December 2024
2405-8440/© 2024 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY license
(http://creativecommons.org/licenses/by/4.0/).
N.M. Abdeltawab et al. Heliyon 11 (2025) e41362

properties [9,10]. AA5083 is an aluminum-magnesium alloy where the presence of secondary phases such as Al6Mn and Mg2Al3 plays
critical roles in precipitation hardening as it obstacles dislocation motion and improves strength. Additionally, on account of the
presence magnesium, AA5083 has high resistance to corrosion and stress corrosion cracking [11]. Fusion welding can adversely affect
AA5083 through melting and solidification, causing brittle intermetallic compounds and grain growth [12].
FSW is a solid-state welding process where a rotating pin tool is imposed on the workpiece, causing high friction and induced heat
that raises metal plasticity in the presence of stirring movement to merge the interfaces of the welding joint [13,14]. FSW has suc­
cessfully overcome the drawbacks of fusion welding of aluminum alloys, such as cracks, distortion, and porosity inclusions [15].
Keeping the welding joint in solid states prevents melting and solidification problems like brittle dendritic structures, coarse grains,
and eutectic phases that take place in fusion welding. Reinforcing FSW joints with nanoparticles allows controlling their micro­
structure by preserving the fine and equiaxed grains in the welding nugget zone, which enhance mechanical properties. The role that
nanoparticles (SiC, Al2O3, SiO2, B4C, and TiC) play in improving the joint corrosive and wear resistance raises the concern of its
applicability in FSW [16,17]. The silicon carbide (SiC) nanoparticles as compared to other reinforcements have a lower density and
show high wettability and compatibility with aluminum alloys. The addition of SiC nanoparticles in FSW intercepts grain growth and
dissolving (ηʹ phases) in AA7075 through the pinning effect as it pins the grain boundary movement during welding [13,18]. Previous
results show that the tensile strength and elongation of AA7075-O were enhanced by up to 7.2 % and 137.7 %, respectively, with the
addition of SiC nanoparticles. Compared to SiC free specimens, SiC reinforced specimens had higher levels of hardness and ductile
fracture modes in the base material. On the other hand, in SiC free specimens, tensile fracture happened in the Thermo-Mechanically
Affected Zone (TMAZ) since it did not pass through recrystallization [19]. Microstructure investigation of AA7075 friction stir welding
reinforced by SiC shows that SiC reinforcements and aluminum matrix have a good bond where the enhancement in tensile strength,
toughness, and fatigue life is due to grain refinement and effective load transfer across the matrix in the presence of uniform distri­
bution of SiC nanoparticles [17].
The FSW process parameters of rotational speed, transverse speed, tool shape, and number of passes have a significant effect on the
quality of the welding joint and the dispersion of SiC nanoparticles [13,18]. In an investigation of a similar AA7075/SiC-reinforced
joint produced by FSW, it was found that as rotation speed increases, a good dispersion of SiC nanoparticles occurs, leading to an
improvement in mechanical properties. Samples of higher rotational speed 1250 rpm have a uniform reinforcement distribution, and
finer grains take place due to high stirring action [20–22]. In a study of dissimilar FSW joints of AA7075/AA6061 reinforced by SiC
nanoparticles, results showed that at a low rotation speed of 700 rpm, inadequate dispersion and bonding of SiC nanoparticles were
noted, reflecting poor mechanical properties compared with a higher rotation speed of 1100 rpm [23]. Tensile strength and hardness
increase as transverse speed increases as a consequence of lower heat input, which leads to grains getting finer and the dissolution of
hardening participants getting lower [24]. Microstructure investigation of AA5083 friction stir welding reinforced with SiC and TiC on
the reinforcing nanoparticle distribution deduced that a uniform dispersion of nanoparticles is favored by a high number of processing
passes along with low traversal and high rotating speeds [25]. The influence of process parameters in reinforced friction stir welding of
AA5083 by TiO2 shows that the hardness and ultimate tensile strength after four passes with a rotational speed of 710 rpm and a
forward speed of 14 mm/min were increased by 40 % and 25 % when compared to that of unreinforced AA5083 alloy [26].
Friction stir welding of AA5083 with AA7075 is significant for applications requiring a combination of strength, corrosion

Fig. 1. Flow of experimental work.

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N.M. Abdeltawab et al. Heliyon 11 (2025) e41362

resistance, and ballistic resistance, like armor and marine industry. The exploration of novel reinforcements may assist in regulating
heat input and material flow during welding, hence minimizing the formation of brittle phases. Reinforcements can also restrict the
formation of intermetallic compounds that weaken the joints and reduce porosity and void development as Well-distributed re­
inforcements can assist fill voids and reduce the production of welding flaws. Reinforced the joint with the novel matrix of Al-SiC is
supposed to improve wettability and compatibility between the joint and reinforced matrix at different rotational speed and transverse
speed to enhance mechanical and corrosion properties.

2. Experimental procedure

2.1. Input material specification and experimental setting configuration

In this paper, the flow of experimental work is illustrated in Fig. 1. A strip of AA5083 and AA7075 of equal dimension (200 × 50 × 3
mm3) was used as the substrate for FSW. Table 1 shows the chemical composition of the samples for each alloy measured by the
spectrometer. The mechanical properties of the two alloys of base material were tested and mentioned in Table 2. To prepare the
reinforcement matrix powder, mechanical powder ball milling takes place of ALPOCO© aluminum powder and SiC with particle size
25, 2 μm, respectively, mixed with weight percent wt.% of silicon carbide 25 wt%, 50 wt%, and 75 wt%. The powder mixture un­
dergoes a total of 6 h of mechanical powder ball milling with a ball-to-powder ratio of 5:1 and a milling speed of 400 rpm to ensure
good dispersion and complete encapsulation of SiC particles with aluminum.
A shown in Fig. 2-a, To prepare the welding joint, a groove of 3 mm in width and 2.5 mm in depth was machined across the center of
the two substrates along the length of the samples. The reinforcement powder was packed in the groove using a pin-less tool of 25 mm
in diameter, as shown in Fig. 2-b. A conventional vertical milling machine was used in the friction stir welding process, where the pin
tool, which is made off K110 tool steel, has a detailed dimension shown in Fig. 2-c. The experimental setting configuration, rotational
and transverse speed direction, is shown in Fig. 2-d. To ensure effective bonding, the harder alloy of AA7075 is placed on the advanced
side, as it needs more heat due to the collective influence of the rotational and translational speed of the tool. However, the more
ductile alloy AA5083 is placed on the retreating side to attain a balanced temperature distribution through the welding joint [23]. The
values for the process parameters are determined based on previous research, the experimental capabilities that are available, and trial
experiments carried out on AA5083 and AA7075. In these experiments, the L27 orthogonal array, whose rotation speed varies from
700, 800, and 900 rpm and transverse speed is 20, 40, and 60 mm/min as shown in Table 3, three repetitions was used as the basis for
design of experimental settings.

2.2. Microstructure investigation

To examine the microstructure of the sample, an optical microscope and a Zeiss LEO SUPRA 55-Field Emission Scanning Electron
Microscope (SEM, Selangor, Malaysia) were utilized, and the joint surface was analyzed by means of energy dispersive X-ray spec­
troscopy (EDX) within the SEM.

2.3. Vickers hardness test

Vickers hardness measurement was applied to welding nugget cross-section polished samples. A microhardness HV-50A (Vickers,
London, UK) tester is used to assess hardness under 10 N load applied and 11 S dwell duration. Eleven readings along the welding joint,
ranging from the center to the base material, yield the results that are presented.

2.4. Tensile test

Using a wire cutting process, tensile specimens were trimmed out perpendicular to the welding zone in accordance with precise
dimensions that complied with ASTM E8 [27], as illustrated in Fig. 3. Universal tensile testing equipment is used for uni-axial tensile
testing at ambient temperature. The average of three samples from three distinct welded plates was used as the basis for all results.

Table 1
Chemical composition of AA5083 and AA7075.
AA5083 Chemical Composition

Element Al Mg Mn Fe Si Zn Ti Cu
Content Bal. 4.2 0.59 0.38 0.39 0.15 0.1 0.08

AA7075 Chemical Composition

Element Al Mg Mn Cr Si Zn Ti Cu
Content Bal. 2.8 0.25 0.21 0.2 5.92 0.1 1.8

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N.M. Abdeltawab et al. Heliyon 11 (2025) e41362

Table 2
Mechanical properties of AA5083 and AA7075.
AA5083 Mechanical Properties

Property Maximum Strength(Mpa) Maximum Strain % Hardness (HV) Corrosion Weight loss (mgm/cm2)
Value 230 1.97 % 85 2.5

AA7075 Mechanical Properties

Property Maximum Strength(Mpa) Maximum Strain % Hardness (HV) Corrosion Weight loss (mgm/cm2)
Value 505 1.35 220 3.5

Fig. 2. Friction stir welding process (a) groove preparation, (b) packing powder in the groove, (c) pin tool dimension and (d) experimental setting of
plates and welding rotational and transverse direction.

Table 3
L27-OA of experimental investigation.
Run Number SiC % wt in Al-SiC Matrix Rotational Speed(rpm) Transverse Speed(mm/min)

1 25 700 20
2 25 700 40
3 25 700 60
4 25 800 20
5 25 800 40
6 25 800 60
7 25 900 20
8 25 900 40
9 25 900 60
10 50 700 20
11 50 700 40
12 50 700 60
13 50 800 20
14 50 800 40
15 50 800 60
16 50 900 20
17 50 900 40
18 50 900 60
19 75 700 20
20 75 700 40
21 75 700 60
22 75 800 20
23 75 800 40
24 75 800 60
25 75 900 20
26 75 900 40
27 75 900 60

2.5. Corrosion test

In order to evaluate the corrosion rate using immersion test method by weight loss, the samples were cut to the dimensions of 10
mm × 10 mm × 3 mm. The weights of the samples were measured before immersion, and the samples were immersed in a 3.5 % NaCl
solution. To remove the corrosion outcomes, a solution of 50 g chromium trioxide (CrO3), 2.5 g silver nitrate (AgNO3), and 5 g barium
nitrate (Ba(NO3)2) in 250 ml distilled water was utilized. Following that, the weight of the samples was measured, and the net weight

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N.M. Abdeltawab et al. Heliyon 11 (2025) e41362

Fig. 3. Tensile sample dimension ASTM E8 standards.

Table 4
Tensile test results.
No SiC % wt in Rotational Transverse Speed Ultimate Tensile Max. Observations Fracture Zone
Al-SiC Matrix Speed (rpm) (mm/min) Strength Mpa Strain

1 25 700 20 191.4 1.85 flash defect and reduction in Weld metal + ductile
thickness fracture
2 25 700 40 186.2 1.75 Flash defect Weld metal + ductile
fracture
3 25 700 60 179.7 1.7 voids, cracks Weld metal + ductile
fracture
4 25 800 20 196.6 1.86 flash defect and reduction in Weld metal + ductile
thickness fracture
5 25 800 40 189.4 1.85 Prefect welding Weld metal + ductile
fracture
6 25 800 60 187.1 1.79 Voids and cracks Weld metal + ductile
fracture
7 25 900 20 201.4 2.01 Flash defect reduction in thickness Weld metal + ductile
fracture
8 25 900 40 198.8 1.94 Flash defect Weld metal + ductile
fracture
9 25 900 60 191.5 1.87 Minor voids and porosity can be Weld metal + ductile
detected in welding cross section fracture
10 50 700 20 197.9 1.6 Prefect welding Weld metal + ductile
fracture
11 50 700 40 195.3 1.52 Minor voids and porosity can be Weld metal + ductile
detected in welding cross section fracture
12 50 700 60 191.3 1.48 voids, cracks Weld metal + ductile
fracture
13 50 800 20 203.6 1.62 Prefect welding Weld metal + ductile
fracture
14 50 800 40 198.4 1.56 Prefect welding Weld metal + ductile
fracture
15 50 800 60 194.9 1.48 Minor voids and porosity can be Weld metal + ductile
detected in welding cross section fracture
16 50 900 20 209.8 1.67 Prefect welding + formation of Weld metal + ductile
minor burrs fracture
17 50 900 40 200.8 1.62 Prefect welding Weld metal + ductile
fracture
18 50 900 60 194.8 1.52 Minor voids and porosity can be Weld metal + ductile
detected in welding cross section fracture
19 75 700 20 184.7 0.93 voids, cracks AA5083 interface +
brittle conchoidal
20 75 700 40 183.5 0.85 voids, cracks Weld metal + brittle
conchoidal
21 75 700 60 175.3 0.68 voids, cracks AA5083 interface +
brittle conchoidal
22 75 800 20 191.4 0.9 Prefect welding Weld metal + brittle
conchoidal
23 75 800 40 183.5 0.89 voids, cracks AA5083 interface +
brittle conchoidal
24 75 800 60 179.6 0.72 voids, cracks Weld metal + brittle
conchoidal
25 75 900 20 196.7 1.2 Prefect welding + formation of Weld metal + ductile
minor burrs fracture
26 75 900 40 188.9 0.9 voids, cracks Weld metal + brittle
conchoidal
27 75 900 60 183.3 0.78 Minor voids and porosity can be AA5083 interface +
detected in welding cross section brittle conchoidal

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N.M. Abdeltawab et al. Heliyon 11 (2025) e41362

loss was evaluated according to ASTM G31-72 criteria, as weight loss per lateral surface area [28].

3. Results and discussion

L27 orthogonal array experimental settings were carried out according to Table 3. Overall, it could be observed that joint strength
and quality are highly affected by the presence of reinforcement matrix, rotational speed, and transverse speed, where the welding
observations are mentioned in Table 4. Samples at the highest rotational speed of 900 rpm and low transverse speed of 20 mm/min
suffer from flash defects along the edges of the weld seam that could extend to thickness reduction at low SiC wt.% in the Al-SiC matrix;
however, as SiC wt.% increases, it changes to minor burr formation, which is an indication of good weld consolidation, material flow,
and mixing [29]. At the high transverse speed of 60 mm/min and mostly when it is combined with low rotational porosity, cracks and
voids appear in the cross-section of the welding joint that extend to high brittleness as it serves as initiation points for fracture
propagation. This contemplates the importance of balancing and tailoring between parameters that affect the mixing and material flow
experimentally or by numerical modeling and optimization [30].

3.1. Microstructure investigation

Cross-section micrograph investigation by SEM of reinforcement joint with different SiC wt.% in Al-SiC matrix at contestant
rotational speed and transverse speed of 900 rpm and 20 mm/min, respectively. Fig. 4-a shows the microstructure of sample 7 with 25
% SiC in the Al-SiC matrix. While the SiC shows uniform dispersion, the sample has some microvoids that increase the potential for
concentrated stresses. On the other hand, sample 16, which has the highest strength, as shown in Fig. 4-b, has good dispersion of SiC in
the joint, which improves the load-transfer efficiency and enhances the mechanical properties of the joint, consistent with previous
studies [18]. Increasing SiC wt.% in Al-SiC to 75 % in Fig. 4-c shows agglomeration of SiC particles that decrease tensile strength as
they work as localized stress concentration points, and inhomogeneity reduces load-bearing capacity [20]. A further magnification is
shown in Fig. 5-a for sample 7 in the nugget zone, where it shows the interface between the AA7075 and the nugget zone with overlap,
and the onion shape ensures good cohesion in the welding joint [18]. The advancing side of the AA7075 alloy has a more refined grain
structure because of the high plastic deformation and heat generation, which supports dynamic recrystallization. Fig. 5-b shows mixing
bands of the grain gradient between the nugget zone as well as the presence of microvoids and porosity in the interface that stabs the
structural integrity. In Fig. 5-c, SiC particles can be seen along the grain boundaries in the nugget zone that work in grain refinement
and improve mechanical properties. It confirms what has been proposed in previous studies [19]. The EDX investigation for the nugget
zone in Fig. 5-d confirms the presence of SiC on the grain boundary that can improve joint phase distribution, decreasing the formation
of agglomeration of intermetallic compounds that would decrease ductility while the existence of Mg is indication of formulation of
Al-Zn-Mg-Cu intermetallic compound.
In cross-section micrographs and optical microscope investigations of samples, it could be noted that the absence of any falling or
remaining reinforcement filler is an indication of its complete dissolution and mixing in the base material. The effect of different
transverse speeds is illustrated in Fig. 6 at constant studied parameters of 50 % SiC wt.% in the Al-SiC matrix and rotational speed of
800 rpm. Fig. 6-a shows sample 13 at a transverse speed of 20 mm/min, where it has relative coarser grains due to high heat input
generated and a low cooling rate at a low transverse speed, while in Fig. 6-b the grain is finer at a transverse speed of 40 mm/min. At
the highest transverse speed in Fig. 6-c, the presence of porosity is noted, and a smaller grain size. This may take place due to trapped
gases during the welding process. This may come as a result of the way the reinforcement filler was packed in the groove or insufficient
heat to mix the boundaries between joints at high transverse speed, which is consistent with the importance of previously studied
thought-out of the transverse speed [23]. Furthermore, the AA7075 alloy requires higher heat input for proper plasticization, while the
AA5083 and the reinforcement matrix are overheated. This irregular heat distribution can cause poor mixing and insufficient bonding,
forming voids or trapped gases. Cross-section micrographs and optical microscope investigation of samples at different rotational
speeds is illustrated in Fig. 7 and at constant 50 % SiC weight in the Al-SiC matrix and transverse speed of 40 mm/min. At the low
rotational speed of 700 rpm in Fig. 7-a, porosity and microvoids can be noted due to poor material flow, and the stirring effect at low
rotational speed leads to incomplete bonding. Furthermore, inadequate stirring of the AA7075, due to its higher strength and lower
plasticity, results in voids or porosity in the weld nugget. However, at higher rotational speeds in Fig. 7-b and 7-C, the porosity and void
defect decrease, which is consistent with previous analyses [31].

Fig. 4. Microstructure of Welding Joint a) Sample 7 Under Condition 25 % SiC wt.% in Al-SiC, 900 rpm, 20 mm/min, b) Sample 16 Under Condition
50 % SiC wt.% in Al-SiC, 900 rpm, 20 mm/min and c) Sample 25 Under Condition 75 % SiC wt.% in Al-SiC, 900 rpm, 20 mm/min.

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N.M. Abdeltawab et al. Heliyon 11 (2025) e41362

Fig. 5. SEM Microstructure of Sample 16 Under Condition 50 % SiC wt.% in Al-SiC, 900 rpm and 20 mm/min, a)Interface Between The Two Alloys,
b) Further Magnification, C) AA5083 alloy, d)EDX Investigation.

Fig. 6. Microstructure Investigation Under Different Transverse Speed a) Sample 13 Under Condition 50 % SiC wt.% in Al-SiC, 800 rpm, 20 mm/
min, b) Sample 14 Under Condition 50 % SiC wt.% in Al-SiC, 800 rpm, 40 mm/min and c) Sample 15 Under Condition 50 % SiC wt.% in Al-SiC, 800
rpm, 60 mm/min.

Fig. 7. Microstructure Investigation Under Different Rotational Speed a) Sample 11 Under Condition 50 % SiC wt.% in Al-SiC, 700 rpm, 40 mm/
min, b) Sample 14 Under Condition 50 % SiC wt.% in Al-SiC, 800 rpm, 40 mm/min and c) Sample 17 Under Condition 50 % SiC wt.% in Al-SiC, 900
rpm, 40 mm/min.

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N.M. Abdeltawab et al. Heliyon 11 (2025) e41362

3.2. Tensile Test Results

Over all, the ultimate tensile strength value of the welding joint is from 70 % to 90 % of the AA5083 base alloy strength, which is the
softer material that dominates the performance of the joint, which is an indication of a successful welding process. Similarly, the
maximum strain value is close to the softer alloy AA5083, and the fracture takes place in the nugget zone at the interface between the
weld and the AA7075, as mentioned in Table 4. It is consistent with previous tests [32]. It could be noted that the novel reinforcement
of the Al-SiC matrix improves the ductility and maximum strain of the joint and overcomes the problem of embrittlement that takes
place in the AA5083/AA7075 joint [32] and SiC-AA5083/AA7075 reinforcement joint in previous research [33]. Fig. 8-a shows the
ultimate strength of the welding joint, where it can be deduced in general terms that as transverse speed decreases and fixing the other
parameters, the ultimate strength increases. As well the ultimate tensile is increase in fixing other parameters and increasing the
rotational speed. There are one or two results that do not correspond to the aforementioned behavior. This general behavior is
consistent with previous results and microstructure analyses, which, by means of reducing the transverse speed, the time for joint
interaction in the stir zone increases, which gives sufficient plasticization and mixing of materials [33]. Otherwise, reducing rotational
speed reduces the stirring effect, leaving gaps that can generate porosity, voids, and cracks, and the joint failed to properly consolidate
the two alloys, as illustrated in the previous microstructure investigation. Fig. 8-b demonstrates the relationship between wt% SiC,
rotational and transverse speed, and their effects on the material’s maximum strain. Average wt% SiC values (50 %) result in
considerable strain values, ranging from 1.48 to 1.94 depending on rotational and transverse speeds. High-speed conditions with a
higher SiC content (75 %) appear to result in lower strain values, implying decreased material ductility or increased brittleness under
high reinforcement and processing speeds.
Fracture zone and mode in the tensile test mentioned in Table 4 of friction stir welding give an important indication of the welding
quality that is governed by reinforcement dispersion and a tailored balance of rotational and transverse speeds. Fracture takes place in
weld metal refers to the zone where the joint experiences stress and strain, ultimately. Ductile fracture in weld metal and a strength
value close to AA5083 alloy strength denote that the softer alloy AA5083 is the limiting factor for the weld’s overall strength. While
brittle fracture in weld metal is a high indication of cracks and voids that work as localized stress points. The stress-strain curve of the
critical samples of maximum strength, minimum stress, strain, and maximum strength is shown in Fig. 9-a. In Fig. 9-b, the maximum
strength sample 16 is shown under conditions of 50 % SiC in the Al-SiC matrix, 900 rpm rotational speed, and 40 mm/min transverse
speed. Sample 16 has fracture ductile mode with a dimpled surface in the weld metal zone, which is an indication of good

Fig. 8. Tensile Test Results a) Ultimate Tensile Strength, b) Maximum Strain.

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N.M. Abdeltawab et al. Heliyon 11 (2025) e41362

Fig. 9. a) Stress Strain Curve of Maximum Strength, Minimum Strength and Strain, Maximum Strain Sample (b) Tensile Fracture of Maximum
Strength Sample 16 (c) Tensile Fracture of Minimum Strength and Strain Sample 21 (d) Tensile Fracture of Maximum Strain Sample 7.

reinforcement dispersion and a good balanced rotation and transverse speed. In Fig. 9-c, fracture of sample 21 of minimum strength
and strain is shown at conditions of 75 % SiC in the Al-SiC matrix, 700 rpm rotational speed, and 60 mm/min transverse speed. It has a
crumbly fracture in the AA5083 interface, which is an indication of the presence of voids and cracks that work as initial cracks and help
in crack propagation. This takes place at the highest SiC wt.%. and may face agglomeration in combination with low rotational speed
and high transverse speed. On the other hand, sample 7 of the maximum strain in Fig. 9-d shows ductile fracture mode in the weld
metal with a very good mixing situation at 25 % SiC in the Al-SiC matrix, 900 rpm rotational speed, and 20 mm/min transverse speed.
From the results, it can be deduced that the presence of the novel reinforcement matrix can improve strength and ductility through
orowan strengthening and grain refinement at a good balance of reinforcement matrix dispersion and a balance between rotational
speed and transverse speed that goes with previous research deductions [33].
The hardness of dissimilar materials varies dramatically between these zones because each material responds differently to the FSW
process. Hardness profiles aid in figuring out how alloys interact during the process, particularly metallurgical compatibility,
developing intermetallic compounds, distributing thermal and mechanical stress, and dispersing reinforcement [34]. The hardness
distribution across the welding joint in samples of maximum strength, maximum strain, and minimum strength and strain is shown in
Fig. 10, where the hardness value is increasing gradually from the base metal of AA5083 to the welding metal of AA7075. That reflects
the effect of mechanical processing, grain refinement, good dispersion of reinforcement matrix, and formation of intermetallic
compounds to improve the weld joint hardness over the soft base metal in AA5083. As well, the heat-affected zone at the center of the
welding has the highest hardness value in the hardness distribution only on the sample of minimum strength and strain that takes place
at the highest transverse speed and lower rotational speed, which is an indication of insufficient heat input and a high cool rate under
that condition that leads to hardening and the presence of residual stresses [33].
Corrosion behavior is affected by microstructural changes that take place in reinforcement, dissimilar friction stir welding of grain
refinement, residual stresses, and intermetallic compounds. Comparing to the base material, the overall total corrosion weight loss per
centimeter squared at 90 days is lower than the results shown in Fig. 11, which is an indication of the good impact of reinforcement Al-
SiC matrix and grain refinement due to mechanical processing to improve the corrosion properties of the joint, which is a repetitive
deduction in previous research [35]. Over all, it can be deduced that increasing SiC wt.% in the Al-SiC matrix with the other parameters
installed improves corrosion behavior as its grain refinement effect decreases the amount of grain boundaries that work as corrosion
initiation locations. As well, fixing other parameters and increasing the rotational speed improve reinforcement dispersion and in­
crease the formation of intermetallic compounds that barrier joint exposure to the corrosive solution. The lowest corrosion weight loss
takes place in sample 25 at 75 % SiC in the Al-SiC matrix, 900 rpm rotational speed, and 20 mm/min transverse speed. High transverse
speed resulted in coarse grains that form locations of differing corrosion potential that increase corrosion. The highest corrosion weight
loss takes place in sample 6 at 25 % SiC in the Al-SiC matrix, with an 800 rpm rotational speed and 60 mm/min transverse speed that
alert the integration effect of rotational and transverse speed on corrosion resistance to balance the microstructure of the produced
joint.

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N.M. Abdeltawab et al. Heliyon 11 (2025) e41362

Fig. 10. Hardness results of critical samples.

Fig. 11. Corrosion Weight Loss of Samples with Different wt. % SiC, Rotational Speed and Transverse Speed.

4. Conclusion

The novel reinforcement matrix of Al-SiC with different SiC wt.% was applied to AA5083/AA7075 dissimilar friction stir welding at
different rotational and transverse speeds. A microstructure investigation, tensile test, hardness test, and corrosion test were conducted
to study the effect of these different parameters and deduce that.

• The novel reinforcement of the Al-SiC matrix at balanced rotational and transverse speeds can improve both ductility and strength
of joints through grain refinement and reduction of stress concentration points. As well as decreasing corrosion weight loss due to
grain refinement, reduces the quantity of grain boundaries that serve as sites for the start of corrosion.
• Compared to base material, the maximum welding joint ultimate strength is 90 % of AA5083 ultimate strength (the softer side),
which is accepted and expected range in friction stir welding, while in favor of the presence of an reinforcement matrix, maximum
strain is improved by 2 %. Corrosion weight loss improved by 47.9 % and 107.1 % compared to the base alloys AA5083 and
AA7075, respectively, due to the reinforcement matrix, the formation of intermetallic compounds, and grain refinement.
• The maximum strength takes place at 209.8 MPa at sample 16 under conditions of 50 % SiC in the Al-SiC matrix, 900 rpm rotational
speed, and 40 mm/min transverse speed. Sample 21 of minimum strength and strain of value 175.3 MPa and 0.68, respectively,
conditions of 75 % SiC in an Al-SiC matrix, 700 rpm rotational speed, and 60 mm/min transverse speed. Sample 7 of maximum
strain of value 2.01 at 25 % SiC in Al-SiC matrix, 900 rpm rotational speed, and 20 mm/min transverse speed.
• Tailoring the proper parameters of SiC wt% in the Al-SiC matrix, transverse speed, and rotational speed can improve tensile
strength, maximum strain, and corrosion weight loss by 20 %, 195.5 %, and 72.3 %, respectively, which reflect the significance of
the studied parameters in mixing the dissimilar alloys and grain refinement.
• The minimum weight loss of 1.69 mgm/cm2 takes place in sample 25 at 75 % SiC in Al-SiC matrix, 900 rpm rotational speed, and
20 mm/min transverse speed, and the maximum weight loss takes place at sample 6 at 25 % SiC in Al-SiC matrix, 800 rpm
rotational speed, and 60 mm/min transverse speed.

Microstructural investigation shows good dispersion of SiC particles in a 50 % wt.% Al-SiC matrix that has higher effectiveness in
strength and hardness results. At low rotational speeds, the mixing effect is reduced, and samples show porosity, voids, and even cracks
if combined with low transverse speed, which leads to lower strength. At low transverse speed, insufficient heat input takes place, and
microstructural investigation finds coarse grain and embrittlement that decrease the strength and strain.

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N.M. Abdeltawab et al. Heliyon 11 (2025) e41362

CRediT authorship contribution statement

Noha M. Abdeltawab: Writing – original draft, Visualization, Validation, Resources, Investigation, Formal analysis. Mohamed
Elshazly: Visualization, Validation, Supervision. Ahmed Y. Shash: Writing – review & editing, Visualization, Validation, Supervision,
Resources, Methodology, Investigation, Formal analysis, Conceptualization. M. El-Sherbiny: Writing – review & editing, Visualiza­
tion, Validation, Supervision, Investigation.

Data availability

Data will be made available on request.

Declaration of competing interest

The authors declare that they have no known competing financial interests or personal relationships that could have appeared to
influence the work reported in this paper.

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