FABRICATION OF SURFACE COMPOSITE BY FRICTION STIR PROCESSING USING A NOVEL DIRECT PARTICLE INJECTION TOOL

2019 ◽  
Vol 26 (04) ◽  
pp. 1850182
Author(s):  
P. MUTHUKUMAR ◽  
S. JEROME ◽  
R. JOHN FELIX KUMAR ◽  
S. PRAKASH
Keyword(s):  
Friction Stir Processing ◽  
Composite Layer ◽  
Aluminum Matrix ◽  
Homogeneous Distribution ◽  
Particle Injection ◽  
Friction Stir ◽  
Surface Composite ◽  
Surface Composite Layer ◽  
The Matrix ◽  
The Impact

In this work, aluminum/titanium carbide (Al/TiC) surface composite has been fabricated by friction stir processing using a novel modular Direct Particle Injection Tool (DPI–FSP). The tool has a unique feature wherein the TiC particles have been transferred from the tool itself by spring adjusted plunger movement into the matrix. The microstructural observations from optical and scanning electron microscope (SEM)-EDS results revealed the homogeneous distribution of particles in the stirred zone (SZ) and the thickness of the formed surface composite layer (SCL) is approximately 0.34[Formula: see text]mm. X-ray diffraction results confirmed that the particles are reinforced in the aluminum matrix, and no intermetallics have been formed in the composite. The microhardness of composite was increased from 68 to 135[Formula: see text]Hv, and the impact test results showed that the toughness was almost comparable to that of the base metal.

Effect of Ceramic Particles on Microstructure and Mechanical Properties of Aluminium Surface Composite Fabricated Using Friction Stir Processing

2015 ◽  
Vol 830-831 ◽  
pp. 440-443 ◽  
Author(s):  
A. Thangarasu ◽  
N. Murugan
Keyword(s):  
Friction Stir Processing ◽  
Processing Speed ◽  
Composite Layer ◽  
Homogeneous Distribution ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Surface Composite ◽  
Surface Composites ◽  
Sic Particles ◽  
Surface Composite Layer

Friction stir processing (FSP) is a novel technique used to fabricate surface composites. This investigation is an attempt to made Al/Al2O3 and Al/SiC surface composite using FSP and compare the mechanical and metallurgical properties influenced by the types of reinforcement particles. Two plates were grooved with 0.8 mm in width, 5 mm in depth and 100 mm in length in the middle of the aluminium plate using wire EDM and compacted with Al2O3 and SiC powder. The FSP was carried out automatically on an indigenously built FSW machine at tool rotational speed of 1200 rpm, processing speed of 60 mm/min and axial force of 10 kN. The optical and Scanning Electron microstructures are precisely revealed the homogeneous distribution of Al2O3 and SiC particles in the stir zone of surface composite layer (SCL). The microhardness was measured across the cross section of SCL layers of Aluminium and Aluminium with SiC and Al2O3. The higher microhardness was obtained in Aluminium with SiC and Al2O3 composites fabricated by FSP. This is because of the higher hardness value of SiC particles than Al2O3 particles.

Friction stir processing strategies to develop a surface composite layer on AA6061-T6

2018 ◽  
Vol 33 (10) ◽  
pp. 1133-1140 ◽  
Author(s):  
Carmen María Abreu Fernández ◽  
Roberto Acuña Rey ◽  
María Julia Cristóbal Ortega ◽  
David Verdera ◽  
Carlos Llovo Vidal
Keyword(s):  
Friction Stir Processing ◽  
Composite Layer ◽  
Friction Stir ◽  
Surface Composite ◽  
Processing Strategies ◽  
Surface Composite Layer

Fabrication and Characterization of CU/B4C Surface Dispersion Strengthened Composite using Friction Stir Processing

2014 ◽  
Vol 59 (1) ◽  
pp. 83-87 ◽  
Author(s):  
R. Sathiskumar ◽  
N. Murugan ◽  
I. Dinaharan ◽  
S.J. Vijay
Keyword(s):  
Friction Stir Processing ◽  
Matrix Material ◽  
Composite Layer ◽  
Copper Surface ◽  
Chromium Steel ◽  
Copper Plate ◽  
Homogeneous Distribution ◽  
Scanning Electron Micrographs ◽  
Friction Stir ◽  
The Matrix

Abstract Friction stir processing has evolved as a novel method to fabricate surface metal matrix composites. The feasibility to make B4C particulate reinforced copper surface matrix composite is detailed in this paper. The B4C powders were compacted into a groove of width 0.5 mm and depth 5 mm on a 9.5 mm thick copper plate. A tool made of high carbon high chromium steel; oil hardened to 63 HRC, having cylindrical profile was used in this study. A single pass friction stir processing was carried out using a tool rotational speed of 1500 rpm, processing speed of 40 mm/min and axial force of 10 kN. A defect free interface between the matrix and the composite layer was achieved. The optical and scanning electron micrographs revealed a homogeneous distribution of B4C particles which were well bonded with the matrix. The hardness of the friction stir processed zone increased by 26% higher to that of the matrix material.

FABRICATION OF Mg/SiC NANOCOMPOSITE SURFACE LAYER USING FRICTION STIR PROCESSING TECHNIQUE

2011 ◽  
Vol 10 (04n05) ◽  
pp. 1073-1076 ◽  
Author(s):  
YOONES ERFAN ◽  
SEYED FARSHID KASHANI-BOZORG
Keyword(s):  
Uniform Distribution ◽  
Friction Stir Processing ◽  
Composite Layer ◽  
Processing Technique ◽  
Speed Ratio ◽  
Friction Stir ◽  
Sic Particles ◽  
The Matrix ◽  
Tool Rotation

Friction stir processing (FSP) was employed to incorporate nano-sized SiC particles into the surface of AZ31 magnesium substrate in order to produce surface nanocomposite layers. Characterization of the microstructure of the processed layers exhibited powders agglomeration which was found to disperse with increasing the tool rotation speed/advancing speed ratio. A uniform distribution of SiC particles with a mean particle size of ~95 nm was achieved after second FSP passes. The matrix grain size was found to decrease by increasing the tool advancing speed and number of FSP passes; however, increasing the advancing speed resulted in introduction of defects which leads to tunnels. The micro hardness value of the composite layer with uniform distribution of nano-size SiC particles was found to be almost twice of that of the AZ31 substrate.

scholarly journals Electrical Discharge Machining of SiC Reinforced 6061-T6 Aluminum Alloy Surface Composite Fabricated by Friction Stir Processing

2021 ◽  
Vol 309 ◽  
pp. 01044
Author(s):  
Murahari Kolli ◽  
Devaraju Aruri ◽  
Saikumar Gadakary ◽  
Satyanarayana Kosaraju
Keyword(s):  
Friction Stir Processing ◽  
Removal Rate ◽  
Alloy Surface ◽  
Aluminum Surface ◽  
Machining Parameters ◽  
Friction Stir ◽  
Surface Composite ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
The Impact

Engineered materials with high hardness, great wear tolerance, high high-temperature power, and a low thermal expansion coefficient are aluminum-based composites. These materials are widely used in the automotive and aerospace industries. Friction stir processing (FSP) method used to prepare SiC reinforced aluminium alloy surface composite. Material removal rate (MRR) and surface roughness (SR) are measured with the impact of pulse on time, discharge current, and pulse off time (add one or two outcomes remark at SR and MRR optimal condition) is examined. For each of the three machining parameters, L9 orthogonal arrays (OA) of three levels were used in conducting the experiments. The validity of the Aluminum Surface Composite experiment programme is determined using MINITAB.

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.

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