Fabrication of Hybrid Surface Composites AA6061/(B4C + MoS2) via Friction Stir Processing

2019 ◽  
Vol 141 (5) ◽  
Author(s):  
Daulat Kumar Sharma ◽  
Vivek Patel ◽  
Vishvesh Badheka ◽  
Krunal Mehta ◽  
Gautam Upadhyay
Keyword(s):  
Wear Resistance ◽  
Aluminum Alloys ◽  
Friction Stir Processing ◽  
Solid Lubricant ◽  
Hybrid Composites ◽  
Aluminum Matrix ◽  
Friction Stir ◽  
Surface Composite ◽  
Surface Composites ◽  
Structural Applications

Poor tribological properties restrict structural applications of aluminum alloys and surface composites of aluminum alloys have gained more attention in material processing. The addition of solid lubricant reinforcement particles along with abrasive ceramics contributes to the enhancement of tribological performance of surface composites. In the present study, the solid-state technique, friction stir processing (FSP) was used to develop mono (B4C) and hybrid (B4C + MoS2) surface composites in the AA6061-T651 aluminum alloy. The hybrid surface composites were produced by varying an amount of MoS2. Multipass FSP with different direction strategies was adopted for achieving uniform distribution of reinforcement powders in the aluminum matrix. Microstructure analysis showed a uniform dispersal of reinforcement particles without any clustering or agglomeration in the processing zone. Microhardness and wear performance of mono and hybrid composites improved in comparison with the base metal. The mono surface composite exhibited the highest hardness while the hybrid surface composite (75%B4C + 25%MoS2) achieved the highest wear resistance. This was attributed to the solid lubricant nature of MoS2. Furthermore, dissolution of the strengthening precipitate condition during multipass FSP without reinforcement particles resulted in the reduction of hardness and wear resistance.

scholarly journals The Role of Friction Stir Processing (FSP) Parameters on TiC Reinforced Surface Al7075-T651 Aluminum Alloy

2016 ◽  
Vol 21 (4) ◽  
pp. 508-516 ◽  
Author(s):  
Felipe García-Vázquez ◽  
Benjamín Vargas-Arista ◽  
Rodrigo Muñiz ◽  
Juan Carlos Ortiz ◽  
Héctor Hernández García ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Aluminum Alloys ◽  
Friction Stir Processing ◽  
Weight Ratio ◽  
Nano Particles ◽  
Friction Stir ◽  
Surface Composite ◽  
Surface Composites ◽  
Structural Applications ◽  
Composite Distribution

Abstract: Aluminum alloys are very promising for structural applications in aerospace, military and transportation industries due to their light weight, high strength-to-weight ratio and excellent resistance to corrosion. In comparison to unreinforced aluminum alloys, aluminum/aluminum alloy matrix composites reinforced with ceramic phases exhibit higher strength and hardness, improved tribological characteristics. A novel surface modifying technique, friction stir processing (FSP), has been developed for fabrication of surface composite with an improved performance. The effect of FSP parameters such as number of passes, direction of each pass, sealed or unsealed groove on microstructure was investigated. In this work, nano-particles of TiC (2% in weight) were added to aluminum alloy AA7075-T651 to produce a functional surface. Fixed parameters for this AA7075 alloy were used; rotation speed of 1000 rpm, travel speed of 300 mm/min and pin penetration of 2.8 mm. Optical microscopy (OM), scanning electron microscopy (SEM) and atomic force microscopy (AFM) were employed to study the microstructure of the fabricated surface composites. The results indicated that the selected FSP parameters influenced the area of surface composite, distribution of TiC particles and micro-hardness of the surface composites. Finally, in order to evaluate rate wear the pin on disk test was carried out.

Improving the Wear Resistance of Aluminum Fly Ash Composites by Multipass Friction Stir Processing

2015 ◽  
Vol 642 ◽  
pp. 55-59 ◽  
Author(s):  
Shueiwan Henry Juang ◽  
Liang Jing Fan ◽  
Hsu Shuo Chang
Keyword(s):  
Wear Resistance ◽  
Fly Ash ◽  
Friction Stir Processing ◽  
Sliding Wear ◽  
Normal Load ◽  
Aluminum Matrix ◽  
Dry Sliding Wear ◽  
Dry Sliding ◽  
Wear Rates ◽  
Friction Stir

In this study, the multi-pass friction stir processing (MP-FSP) technique was performed on ADC6 aluminum alloy + 5 wt% fly ash composite (A5FC) castings to increase their surface area. The dry sliding wear behaviors of the ADC6 alloy, A5FCs, and MP-FSPed A5FCs were evaluated. Dry sliding wear tests were performed using a ring-on-washer machine at a constant rotation speed of 100 rpm for 60 min, and the normal load was 10, 20, 30, and 40 N. The results showed that the MP-FSPed A5FCs had the lowest wear rates in the load range from 10 to 40 N, and adhesive wear was the major wear mechanism in these tests. The increased wear resistance was mainly due to grain refinement and elimination of casting defects after subjecting the ash composite to MP-FSP. The microstructure of the MP-FSPed A5FCs reveals that the sizes of the added raw fly ash particles decreased from micro-to nanoscale levels, and the nanoscale fly ash was uniformly dispersed in the aluminum matrix.

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.

Wear and Mechanical Properties of Aluminum Alloy Based Hybrid Composites [(SiC+Gr) and (SiC+Al2O3)] Fabricated by Friction Stir Processing

2013 ◽  
Author(s):  
A. Kumar ◽  
A. Devaraju ◽  
B. Kotiveerachari
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
Friction Stir Processing ◽  
Rotational Speed ◽  
Solid Lubricant ◽  
Hybrid Composites ◽  
Optical Microscope ◽  
High Wear Resistance ◽  
Nugget Zone ◽  
Friction Stir

In this investigation, the influence of tool rotational speed on wear and mechanical properties of Aluminum alloy based surface hybrid composites fabricated via Friction stir processing (FSP) was studied. The fabricated surface hybrid composites have been examined by optical microscope for dispersion of reinforcement particles. Microstructures of all the surface hybrid composites revealed that the reinforcement particles (SiC, Gr and Al2O3) are uniformly dispersed in the nugget zone. It is observed that the microhardness is decreased with increasing the rotational speed and exhibited higher microhardness value in Al-SiC/Al2O3 surface hybrid composite at a rotational speed of 900 rpm, due to presence and pining effect of hard SiC and Al2O3 particles. It is also observed that high wear resistance exhibited in the Al-SiC/Gr surface hybrid composites at a rotational speed of 900 rpm due to presence of SiC and Gr acted as load bearing elements and solid lubricant respectively. The observed wear and mechanical properties have been correlated with microstructures and worn morphology.

WEAR ANALYSIS OF ALUMINUM–NICKEL INTERMETALLIC SURFACE COMPOSITE FABRICATED BY FRICTION STIR PROCESSING

2020 ◽  
pp. 2050057
Author(s):  
MORTEZA SHAMANIAN ◽  
MOHAMMAD REZA NASRESFAHANI ◽  
EBRAHIM BAHRAMI ◽  
HOSSEIN EDRIS
Keyword(s):  
Wear Resistance ◽  
Friction Stir Processing ◽  
Traverse Speed ◽  
Friction Stir ◽  
Surface Composite ◽  
Wear Analysis ◽  
2024 Alloy ◽  
Ni Powder ◽  
The Matrix ◽  
Stable Stage

In low-strength metals, the main purpose of enhancing surface properties is to increase the abrasion resistance. One of the new methods for improving the microstructure of the surface layer of metals is the surface composite. In this research, the friction stir processing (FSP) was used to develop an aluminum–nickel intermetallic surface composite. Aluminum 2024 alloy and Ni powder were used as the matrix and reinforcement agent, respectively. Comparison of composite and non-composite FSP samples indicates that adding reinforcements improves the wear resistance of a monolithic metal in all condition. Also, the wear resistance of fabricated composites using activated Al–Ni powder is higher than the others due to the presence of Al3Ni2 and Al3Ni intermetallic compounds. At low traverse speed of the FSP, powder agglomeration occurs, and the powders are not uniformly distributed, as a result, the friction coefficient rises. SEM micrographs of scratched particles of activated composite confirm the delamination mechanism in the wear stable stage.

scholarly journals A New Approach to Direct Friction Stir Processing for Fabricating Surface Composites

Crystals ◽  
2021 ◽  
Vol 11 (6) ◽  
pp. 638
Author(s):  
Abdulla I. Almazrouee ◽  
Khaled J. Al-Fadhalah ◽  
Saleh N. Alhajeri
Keyword(s):  
Friction Stir Processing ◽  
Composite Layer ◽  
Aluminum Matrix ◽  
Cylindrical Body ◽  
Processing Parameters ◽  
Metallographic Examination ◽  
New Approach ◽  
Plunge Depth ◽  
Friction Stir ◽  
Surface Composites

Friction stir processing (FSP) is a green fabrication technique that has been effectively adopted in various engineering applications. One of the promising advantages of FSP is its applicability in the development of surface composites. In the current work, a new approach for direct friction stir processing is considered for the surface fabrication of aluminum-based composites reinforced with micro-sized silicon carbide particles (SiC), eliminating the prolonged preprocessing stages of preparing the sample and filling the holes of grooves. The proposed design of the FSP tool consists of two parts: an inner-threaded hollow cylindrical body; and a pin-less hollow shoulder. The design is examined with respect to three important tool processing parameters: the tilt angle of the tool, the tool’s dispersing hole, and the tool’s plunge depth. The current study shows that the use of a dispersing hole with a diameter of 6 mm of and a plunge depth of 0.6 mm, in combination with a tilting angle of 7°, results in sufficient mixing of the enforcement particles in the aluminum matrix, while still maintaining uniformity in the thickness of the composite layer. Metallographic examination of the Al/SiC surface composite demonstrates a uniform distribution of the Si particles and excellent adherence to the aluminum substrate. Microhardness measurements also show a remarkable increase, from 38.5 Hv at the base metal to a maximum value of 78 Hv in the processed matrix in the surface composites layer. The effect of the processing parameters was also studied, and its consequences with respect to the surface composites are discussed.

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