The main aim of this investigation is to produce a welding joint of higher strength than that of base metals. Composite welded joints were produced by friction stir welding process. 6061 aluminum alloy was used as a base metal and alumina particles added to welding zone to form metal matrix composites. The volume fraction of alumina particles incorporated in this study were 2, 4, 6, 8 and 10 vol% were added on both sides of welding line. Also, the alumina particles were pre-mixed with magnesium particles prior being added to the welding zone. Magnesium particles were used to enhance the bonding between the alumina particles and the matrix of 6061 aluminum alloy. Friction stir welded joints containing alumina particles were successfully obtained and it was observed that the strength of these joints was better than that of base metal. Experimental results showed that incorporating volume fraction of alumina particles up to 6 vol% into the welding zone led to higher strength of the composite welded joints as compared to plain welded joints.
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