Machinability of AA7075-T6/carbon nanotube surface composite fabricated by friction stir processing

2018 ◽  
Vol 233 (4) ◽  
pp. 839-848 ◽  
Author(s):  
Ramin Mehdizad Tekiyeh ◽  
Mohsen Najafi ◽  
Saeid Shahraki
Keyword(s):  
Carbon Nanotube ◽  
Friction Stir Processing ◽  
Aluminum Matrix ◽  
Wear Test ◽  
Travel Speed ◽  
Raw Material ◽  
Subsequent Formation ◽  
Friction Stir ◽  
Surface Composite ◽  
Uniform Dispersion

Chip adhesion on rake face of cutting tool and subsequent formation of built-up-edge are critical problems in machining of aluminum alloys. In the current work, carbon nanotube as a solid lubricant has been integrated with aluminum 7075-T6 alloy through friction stir processing and the machinability of fabricated surface composite has been evaluated. Here, firstly, a series of friction stir processing experiment has been carried out to find optimum pass number regarding uniform dispersion of carbon nanotube in aluminum matrix. Then, a total number of 27 drilling experiments under different values of spindle speed and travel speed have been carried out on raw material, friction stir processed material without addition of carbon nanotube, and friction stir processed with addition of carbon nanotube. The obtained results showed that addition of carbon nanotube as reinforcement causes reduction of machining thrust force and surface roughness due to excellent lubrication property. Tribological observations through scanning electron microscopy and wear test revealed that the main mechanism for enhancing the machinability is reduction of friction coefficient as a result of carbon nanotube addition.

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.

Fabrication of polyethylene-based surface composite reinforced by carbon nano-tube and nano-clay through friction stir processing

2017 ◽  
Vol 233 (4) ◽  
pp. 580-587 ◽  
Author(s):  
Yasser Rostamiyan ◽  
Meysam Zaferani
Keyword(s):  
Friction Stir Processing ◽  
Polymer Surface ◽  
Travel Speed ◽  
Polyethylene Matrix ◽  
Friction Stir ◽  
Uniform Dispersion ◽  
Nano Clay ◽  
Process Factors ◽  
Rotary Speed ◽  
Carbon Nano Tube

In the present work, friction stir processing has been utilized to fabricate in situ polymer surface hybrid composite. The surface of polyethylene matrix was reinforced by the combination of multi wall carbon nano-tube and nano-clay powders. Here, L9 Taguchi orthogonal array was used to design the experiment taking into account the effects of tool rotary speed, travel speed, and reinforcement type on tensile strength flexural strength and modulus of electricity. The results showed that both tensile and flexural strengths varied in a similar manner by varying the process factors. Homogeneity in reinforcement, higher value of tool rotary speed (i.e. 1600 r/min), and low value of travel speed (i.e. 40 mm/min) cause appropriate material flow and uniform dispersion of reinforcement in friction stir processed zone. Also, it was shown that the middle value of tool rotary speed (1200 r/min) and travel speed (60 mm/min) along with applying pure nano-clay enhances the elasticity modulus.

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.

Effect of Friction Stir Processing on Mechanical Properties of Surface Composite of Cu Reinforced with Cr Particles

2013 ◽  
Vol 829 ◽  
pp. 851-856 ◽  
Author(s):  
Bahram A. Khiyavi ◽  
Abdolhossein Jalali Aghchai ◽  
Mohammadreza Arbabtafti ◽  
Mohamad Kazem Besharati Givi ◽  
Jalal Jafari
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Processing ◽  
Metal Matrix ◽  
Wear Test ◽  
Traverse Speed ◽  
Mechanical Behaviors ◽  
Wear Properties ◽  
Friction Stir ◽  
Surface Composite ◽  
Wear Tests

The main aims of this study is to produce copper reinforced metal matrix composite (MMC) using micron sized chromium particles via friction stir processing (FSP) in order to studying effects of adding Cr particles to copper based matrix by FSP.Microstructures, microhardness and wear properties have been studied in order to evaluate the microstructures and mechanical properties of fabricated composites. the microstructure properties are evaluated by optical microscopy (OM) and field emission scanning electron microscopy (FESEM). The mechanical behaviors of the samples are determined by microhardness and wear tests. The results showed that the grain size of fabricated composite reduced. also it is indicated that in comparison to base copper microhardness of FSPed composites in stir zone (SZ) have been increased significantly. the results of wear test showed that in comparison with specimen with traverse speed of 80 mm/min , higher traverse speed of 160 mm/min increase wear rate of cylindrical pins.

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