scholarly journals Investigation of microstructural and wear behavior of Al6061 surface composites fabricated by friction stir process using Taguchi approach

2022 ◽  
Author(s):  
Pragya Saxena ◽  
Arunkumar Bongale ◽  
Satish Kumar ◽  
Priya Sachin Jadhav
Keyword(s):  
Aluminum Alloys ◽  
Wear Rate ◽  
Wear Behavior ◽  
Maximum Effect ◽  
Taguchi Approach ◽  
Friction Stir Process ◽  
Friction Stir ◽  
Surface Composites ◽  
Al6061 Alloy ◽  
Tool Pin

Abstract The surface composites of aluminum alloys have a higher scope of applications encountering surface interactions in the aerospace, automobile, and other industries compared to the base aluminum alloys. The friction stir process (FSP) is recently the preferred method to prepare aluminum-based surface composites due to its capability to produce improved physical properties and refined microstructure at the surface. The study examines the Al6061 alloy-based surface composite fabricated by FSP for their wear behavior and microstructure. In this study, the Al6061 alloy-based hybrid surface composites are prepared with varying weight% of copper and graphite microparticles mixture as reinforcement by FSP with two tools having unique pin profiles, i.e., threaded cylindrical and plain cylindrical. These prepared composites are investigated for the dry sliding wear test on a pin-on-disc test set-up. The experiments are designed using the L9 orthogonal array and analyzed by the Taguchi approach to obtain the influence of disc speed, load, and reinforcement weight% on wear rate. The significant parameters influencing the wear rate of the samples tested are obtained using ANOVA. Later the effects of the friction stir process and the wear tests on the microstructure of the workpieces are investigated using FE-SEM/EDS tests. It is concluded that the decrease in wear rate with the rise in reinforcement weight% (Cu + graphite) from 2% to 6%. The load has the maximum effect on the wear rate for the samples prepared by threaded cylindrical FSP tool pin profile, while reinforcement weight% affects significantly the wear rate of the samples prepared by FSP with plain cylindrical pin profile tool.

Influence of Fly Ash and Emery based particulate reinforced AA7075 surface composite processed through friction stir processing

2022 ◽  
pp. 095440892110727
Author(s):  
K. Suganeswaran ◽  
R. Parameshwaran ◽  
R. Sathiskumar ◽  
T. Ram Prabhu ◽  
N. Nithyavathy
Keyword(s):  
Fly Ash ◽  
Impact Toughness ◽  
Wear Rate ◽  
Recrystallization Process ◽  
Dispersion Strengthening ◽  
Tribological Behaviour ◽  
Friction Stir Process ◽  
Friction Stir ◽  
Surface Composites ◽  
The Impact

The novel friction stir technology is adopted in modern automotive industries to meet the desired properties like hardness, impact toughness and tribological behaviour over the conventional techniques like stir casting, compo casting, squeeze casting, electroplating and infiltration methods. AA7075 surface composites fabricated with different volume fractions of fly ash and emery particles is said to enhance the aforementioned properties. The composites are processed through friction stir process (rotational speed −1200 rpm, transverse speed – 56 mm/min, tool tilt angle – 2 °). During characterization, the Microstructural examination of surface composites depicts fine and homogenous distribution of reinforcements in the friction stir process region owing to severe plastic deformation and dynamic recrystallization process. Substantially, good interface is formed between the reinforcement particulates and base substrate. Inclusion of Fe3O4, Al2O3 and SiO2 constituents through fly ash and emery reinforcements associated with the homogenous dispersion strengthening mechanism favours for the superior hardness of surface hybrid composite specimen 50E50FA. Decremented grain size and load bearing capacity of the reinforcements is beneficial for the crack propagation resistance that enhances the impact toughness behaviour (17.4 J/cm2) of the same specimen. Wear rate of the specimens are evaluated through pin on disc tribometer. The decrease in the wear rate of hard specimen 50E50FA is observed due to the reduced contact area between its surface and counter disc. The morphology of worn specimens using SEM analysis shows the combined abrasive and adhesive wear as the worn mechanism.

scholarly journals Finite Element Analysis of Stress-Strain Response at the Tool Pin During Friction Stir Process

2015 ◽  
Vol 76 ◽  
pp. 522-527
Author(s):  
M. Shamil Jaffarullah ◽  
Nur’Amirah Busu ◽  
Cheng Yee Low ◽  
J.B. Saedon ◽  
Armansyah ◽  
...  
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Strain Response ◽  
Stress Strain ◽  
Element Analysis ◽  
Friction Stir Process ◽  
Friction Stir ◽  
Tool Pin

scholarly journals Optimization of Friction Stir Process Parameters for Enhancement in Surface Properties of Al 7075-SiC/Gr Hybrid Surface Composites

Coatings ◽  
2019 ◽  
Vol 9 (12) ◽  
pp. 830 ◽  
Author(s):  
Namdev Ashok Patil ◽  
Srinivasa Rao Pedapati ◽  
Othman Bin Mamat ◽  
Abdul Munir Hidayat Syah Lubis
Keyword(s):  
Wear Rate ◽  
Surface Properties ◽  
Base Alloy ◽  
Nano Particles ◽  
Micro Hardness ◽  
Wear Properties ◽  
Friction Stir ◽  
Surface Composites ◽  
Al 7075 ◽  
Independent Parameters

Friction stir processing (FSP) has evolved as an important technique in fabrication of metal matrix composites. The surface properties enhancement is obtainable by insertion of desired discontinuous particular reinforcements into base alloy using FSP. Despite having high specific strength, more applications of Al alloys are restricted due to their poor surface properties under various loading conditions. In this study, the main focus is on enhancing the microhardness and wear properties of Al 7075 base alloy by means of uniform dispersion of silicon carbide and graphite (SiC/Gr) nano particles into the base alloy using the FSP technique. The tool rotational speed (w: 500, 1000, 1500 rpm), tool traverse speed (v: 20, 30, 40 mm/min), reinforcement particles hybrid ratio (HR: 60:40, 75:25, 90:10) and volume percentage (vol%: 4%, 8%, 12%) are used as independent parameters. The effect of these parameters on microstructure, micro hardness and wear properties of surface composites are studied in detail. For desired wear rate and microhardness as responses, the aforementioned independent parameters are optimized using response surface methodology (RSM). The significance of factors and their interactions for maximizing hardness and minimizing wear rate and coefficient of friction (COF) were determined. Analysis of variance (ANOVA) for responses has been carried out, and the models were found to be significant in all three responses. The minimum wear rate of 0.01194 mg/m was obtained for parameters w 1500 rpm, v 40 mm/min, HR 60:40, vol% 4 (Run 10). The maximum micro hardness of 300 HV obtained for parameters w 1000 rpm, v 30 mm/min, HR 75:25, vol% 12 (Run 14). The presence and uniform distribution of SiC and Gr into the base alloy was confirmed through field-emission scanning electron microscopy (FESEM) imaging, energy-dispersive X-ray spectroscopy (EDX) and mapping tests. The wear rate and COF decreased significantly due to graphitized mechanically mixed layer developed at the sliding contacts. The microhardness of resultant composites observed to be dependent on effect of the independent parameters on extent of inherent precipitates dissolution and grain size strengthening in the resultant materials.

Effect of Tool Rotational Speed on Microstructure and Microhardness of AA6082/TiC Surface Composites using Friction Stir Processing

2014 ◽  
Vol 592-594 ◽  
pp. 234-239 ◽  
Author(s):  
A. Thangarasu ◽  
N. Murugan ◽  
I. Dinaharan ◽  
S.J. Vijay
Keyword(s):  
Friction Stir Processing ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Surface Composite ◽  
Surface Composites ◽  
Homogenous Distribution ◽  
Tool Pin ◽  
Scanning Electron

Friction stir processing (FSP) is as a novel modifying technique to synthesize surface composites. An attempt has been made to synthesis AA6082/TiC surface composite using FSP and to analyze the effect of tool rotational speed on microstructure and microhardness of the same. The tool rotational speed was varied from 800 rpm to 1600 rpm in steps of 400 rpm. The traverse speed, axial force, groove width and tool pin profile were kept constant. Scanning electron microscopy was employed to study the microstructure of the fabricated surface composites. The results indicated that the tool rotational speed significantly influenced the area of the surface composite and distribution of TiC particles. Higher rotational speed provided homogenous distribution of TiC particles while lower rotational speed caused poor distribution of TiC particles in the surface composite. The effect of the tool rotational speed on microhardness is also reported in this paper.

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