Challenges in Fabrication of Surface Composites by Friction Stir Processing Route

Friction stir processing is an avant-garde technique of producing new surface composite or changing the different properties of a material through intense, solid-state localized material plastic deformation. This change in properties depends upon the deformation formed by inserting a non-consumable revolving tool into the workpiece and travels laterally through the workpiece. This research work highlights the effect of process parameters on mechanical properties of fabricated surface composites by friction stir processing. By using various reinforcing materials like Ti, SiC, B4C, Al2O3 with waste elements like waste eggshells, rice husks, coconut shell and coir will be used to fabricate the green composites which are environmentally friendly and reduces the problem of decomposition. The parameter for this experiment is considered as the reinforcing materials, tool rotation speed and tool tilt angle. The SiC/Al2O3/Ti along with eggshell are selected asreinforcement materials. The main effect of the reinforcement is to improve mechanical properties, like hardness, impact strength and strength. The results revealed that the process parameters significantly affect the mechanical properties of friction stir processed surface composites.

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Recent development in friction stir processing of aluminum alloys: Microstructure evolution, mechanical properties, wear and corrosion behaviors

Proceedings of the Institution of Mechanical Engineers Part E Journal of Process Mechanical Engineering ◽

10.1177/09544089211058007 ◽

2021 ◽

pp. 095440892110580

Author(s):

Behrouz Bagheri ◽

Amin Abdollahzadeh ◽

Farzaneh Sharifi ◽

Mahmoud Abbasi ◽

Ahmad Ostovari Moghaddam

Keyword(s):

Mechanical Properties ◽

Friction Stir Processing ◽

Mechanical Vibration ◽

Friction Stir ◽

Microstructure Modification ◽

Surface Composites ◽

Wear And Corrosion ◽

Corrosion Behaviors ◽

Strengthening Particles ◽

Aluminum Alloy Surface

In this paper, the effect of mechanical vibration with reinforcement particles namely Silicon Carbide (SiC) on microstructure, mechanical properties, wear, and corrosion behaviors of aluminum alloy surface composites fabricated via friction stir processing (FSP) was investigated. The method was entitled friction stir vibration process (FSVP). The results revealed that recrystallized fine grains formed in all processing samples as a result of dynamic recovery and recrystallization, while samples processed in friction stir vibration processing resulted in better grain refinement in the stir zone than in conventional friction stir processing. Compared to conventional friction stir processing, in friction stir vibration processing, the hardness and tensile strength increased due to microstructure modification and better reinforcing distribution. From corrosion analysis, the corrosion resistance of the friction stir vibration processed samples showed a significant increase compared to the friction stir processed specimens. The wear results indicated that the wear resistance of friction stir vibration processed specimens is higher than friction stir processed specimens due to the development of smaller grains and a more homogenous distribution of the strengthening particles as the vibration is applied.

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Significance of Al2O3 addition in the aluminum 6063 metal foam formation through friction stir processing route – A comprehensive study

Proceedings of the Institution of Mechanical Engineers Part L Journal of Materials Design and Applications ◽

10.1177/14644207211034531 ◽

2021 ◽

pp. 146442072110345

Author(s):

Sharaf U Nisa ◽

Sunil Pandey ◽

PM Pandey

Keyword(s):

Friction Stir Processing ◽

Metal Foam ◽

Aluminum Matrix ◽

High Energy ◽

Processing Route ◽

Alumina Powder ◽

Foam Formation ◽

Porous Aluminum ◽

Friction Stir ◽

Blowing Agent

Closed-cell porous aluminum is expected to be a prominent material in near future because of its light weight, high specific modulus of elasticity, high energy absorption efficiency and high sound-insulating capacity in the automotive and aerospace industries. Recently, a new method of foaming has been developed in which a precursor is formed using friction stir processing. In the friction stir processing route, a precursor is fabricated by embedding a mixture of blowing agent powder and stabilization agent powder into aluminum alloy plates by the significant stirring action of friction stir processing. By applying the friction stir processing route precursor method, the cost-effective Al-foam formation along with high productivity can be accomplished. In this study, titanium hydride powder has been used as the blowing agent as it is reported to be most compatible with aluminum matrix. The effect of percentage of stabilization agent, i.e. alumina powder on porosity of aluminum foams formed using friction stir processing route is analyzed. The porous aluminum formed with three different percentages of alumina is observed and their porosity is calculated. Also, the compressive performance of the obtained samples is observed in order to examine the alumina powder addition on mechanical properties of the obtained metal foam. This study aims at analyzing the significance of addition of the alumina into the blowing agent while developing the metal foam through friction stir processing route.

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