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The main aim of this experiment is to investigate the effects of Nano-size Al2O3 on the mechanical properties and microstructure of multi-passes friction stir welding of Al 2024 lap joint. Nano particles were added into the joint line. A combination of rotational speed and travelling speeds were performed. Optical microscopy and scanning electron microscope were used to investigate the microstructure and fracture surface of samples respectively. Optimum condition (sample) was selected due to highest ultimate tensile strength (UTS). It was seen that sample which included Nano particles and fabricated by 1400 rev/min rotational speed and 16 mm/min travelling speed in second pass of continues welding had improvement in UTS in comparison to one pass welded sample of particle free and after that increasing the number of passes reduce the UTS. The average micro hardness of the sample which was particle rich were increased in comparison to particle free sample in nugget zone. Increasing the number of passes was not effect average micro hardness in nugget zone significantly. Grain sizes were reduced by 2 passes welding and after that no significant reduction has been seen.

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In the current work, a modified method of friction stir process (FSP) based on ultrasonic vibration and modified FSP tool design was developed to disperse multi-walled carbon nano-tube (MWCNT) throughout nylon 6 matrix. To this end, Field emission scanning electron microscopy, X-ray diffraction, Vickers’ micro-hardness, and visual inspection were used to evaluate the fabricated nano-composites. Also, a modified design of FSP tool together with ultrasonic vibration were used to improve the impact and efficiency of FSP. Several experiments were conducted to approach an optimum range of FSP parameters (rotational speed and traverse speed). The scanning electron microscopy observations and X-ray diffraction patterns (XRD) declare that MWCNT was dispersed homogeneously throughout nylon 6 matrix. Micro-hardness results illustrate that homogeneous dispersion of MWCNT throughout nylon 6 matrix results in 33% increase of micro-hardness. In general, the obtained results declare that ultrasonic vibration causes an increase in traverse speed and production speed of nano-composite without affecting the homogeneous dispersion and hardness of nano-particles throughout the matrix. Also, it is clear that ultrasonic vibrations did not noticeably affect superficial form of nano-composites due to low traverse speeds used in ultrasonic assisted friction stir process.