1 Department of Mechanical Design and Production Engineering Dept., Faculty of Engineering, Zagazig University, Egypt

2 Welding Technology Department, Central Metallurgical R & D institute (CMRDJ),. P.O. Box 87 Helwan, Egypt

3 QA/QC Department, Petroleum Projects Company (PETROJET)


Due to their high specific-strength, SiC reinforced aluminum metal matrix composites (Al/Sic
IvilviCs) are becoming popular for wide range of applications including vehicles, aircraft, rockets
and shipbuilding. It is difficult to fhsion weld such material due to porosity and aluminum carbide
(A14C3) formation in weld zone (WZ) which result in degradation of mechanical properties ofthe
welded joints. In this study, several sets of AJ/SIC-MMC5 samples having 0,5, 15 and 20 vol.%
Sic particulates were fabricated by powder metallurgy technique using hot compaction of Al and
SiC powders followed by hot extrusion. Effect of welding conditions such as heat input filler wire
type (AA4043 and non-commercial AITiSB 1) and without filler using AC-GTAW (TIG) process
was studied to find out appropriate conditions to get sound welded joints. Microstructure was
examined using optical and SEM. Phases were identified and analyzed using XRD and EDX
analysis. It was found that porosity and AL4C3 formed in WZ during welding without filler and
with AA4043 filler. Using non-commercial AITiSB 1 filler, porosity and AI4C3 were reduced and
suppressed at 20 vol.% Sic and 5.86Kj/cm heat input. Whereas, hardness values in w~ remain as
high as base metal when using. non-commercial AlTi5Bl filler, but drastically reduced when
welding without and with AA4043 filler. The new filler wire of AITi5B 1, was examined for the
first time and proved as promising filler in welding AIJSiC-MMC