Mechanical and Corrosion Behaviour of Dissimilar AA2024-AA3003 Aluminum Matrix Composites Reinforced with TiC and ZrC Joined by Friction Stir Welding

¹ Professor, Department of Mechanical Engineering, Aarupadai Veedu Institute of technology, Vinayaka Mission’s Research foundation, Salem, TamilNadu
² PG Scholar,Department of Mechanical Engineering, Aarupadai Veedu Institute of technology, Vinayaka Mission’s Research foundation, Salem, TamilNadu
³ Assistant Professor, Department of Mechanical Engineering, Aarupadai Veedu Institute of technology, Vinayaka Mission’s Research foundation, Salem, TamilNadu

^* Corresponding author: This email address is being protected from spambots. You need JavaScript enabled to view it.

Published online: 16 April 2026

Abstract

Aluminum was a highly favored material because of its affordability, lightweight nature, excellent formability, and ease of machinability. The incorporation of non-metal, like ceramics, into aluminum alloys results in the formation of composite materials. Metal Matrix Composites are being developed as substitutes for traditional metals owing to their capacity to endure substantial loads, superior resistance to wear and corrosion, and relatively high toughness and hardness. The results showed that ultimate tensile strength (UTS) of AA3003 alloy welded with AA2024/5% TiC was the highest at 140.82 MPa, while the lowest UTS was observed in the AA2024/5% ZrC welded with Al 3003/5% TiC at 88.06 MPa. In terms of hardness, the highest Brinell Hardness Number (BHN) of 74.25 was observed in the Al 3003/5% ZrC welded with Al 2024/5% ZrC. Regarding corrosion resistance, the specimens with alumina reinforcement showed the best performance, with acidic corrosion rates (CR_A) as low as 0.8 mpy and basic corrosion rates (CR_B) as low as 0.57 mpy for AA2024/5% TiC welded with AA3003/5% TiC. Aluminum Matrix Composites were the predominant category under Metal Matrix Composites (MMCs) appealing characteristics, including elevated hardness, high strength-to-weight ratio, exceptional tribological performance, and significant impact strength, facilitate their application in automotive components, aerospace structures, and maritime parts. This research endeavors to synthesize Aluminum Matrix Composites (AMC) and Aluminum Alloys via the widely employed synthesis method known as stir casting, followed by joining them through friction stir welding. Different grades of aluminum alloy, specifically AA 2024 and AA 3003, are utilized for experimental work. Alumina and zirconium carbide serve as reinforcements within the aluminum matrix. MCDM numerical optimization method, specifically the Multi-Attribute Border Approximation Area comparison (MABAC) and the Criteria Importance Through Intercriteria Correlation (CRITIC), with a coefficient of 0.01 (combination of AA2024/5% TiC welded with AA3003/5% TiC), was used, making it the best solution for achieving the best balance between mechanical properties and corrosion resistance.