This research uses a rotation friction welding system with 360Al and 360Al/5v-%-10v-% (v-% = volume fraction percent) SiC particulate composites utilizing both identical and different materials and two joint designs. In joint design 1, one side is a lead angle and the other is a plane. In joint design 2, both sides are planes. From the experiment, it was noted that using joint design 1 achieved better joint strength. The joint strength is best with 360Al-360Al and worst with 360Al/10v-%-360Al/10v-% SiC particulate composites. 360Al-360Al has a ductile fracture with dimples, while the 360Al/10v-%-360Al/10v-% SiC particulate composite has a low-ductile fracture. The 360Al/10v-%-360Al/10v-% SiC particulate composites are fractured in the Zpl zone, while the others are fractured in the interface between the Zpl zone and the Zpd zone. For the joint systems using different materials, the fracture is in the interface between the Zpl zone and Zpd zone, where the quantity of SiC particulate is higher. In the heat-affected zone (HAZ) for identical materials, the Zpl hardness value is smaller than Zud; for the different materials, the hardness in Zpl is half of the two Zud hardness total values.
