Optimisation of friction stir processing parameters to fabricate AA6063/SiC surface composites using Taguchi technique

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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Optimization of friction stir processing parameters for enhanced microhardness of AA5083/Al-Fe in-situ composites via Taguchi technique

Material Science, Engineering and Applications ◽

10.21595/msea.2021.22179 ◽

2021 ◽

Author(s):

Vivek Kumar Jain ◽

Manoj Kumar Yadav ◽

Arshad Noor Siddiquee ◽

Zahid A. Khan

Keyword(s):

Friction Stir Processing ◽

Processing Parameters ◽

Taguchi Technique ◽

In Situ Composites ◽

Friction Stir

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A Review on Fabrication of Surface Composites on Magnesium Alloys by Friction Stir Processing

Materials Science Forum ◽

10.4028/www.scientific.net/msf.969.839 ◽

2019 ◽

Vol 969 ◽

pp. 839-845

Author(s):

P.R. Surya ◽

Prabhu Ram ◽

M. Arivarasu ◽

P.L. Rozario ◽

R.K. Mishra

Keyword(s):

Magnesium Alloys ◽

Friction Stir Processing ◽

Surface Engineering ◽

Research Work ◽

Tool Material ◽

Processing Parameters ◽

Tool Geometry ◽

Friction Stir ◽

Surface Composites ◽

Processing Cost

Friction stir processing (FSP) is emerging as a singular solid-state surface engineering technique to fabricate surface composites (SC) since its adaption from Friction Stir Welding (FSW) from the early 90s. FSP is a promising technique to overcome the barrier of magnesium being a poor material in terms of wear and corrosion resistant without adding much on the processing cost and thus, widen its applications.The targeted property enhancement by forming surface composites via FSP are strength, ductility, hardness, wear resistance, toughness, fatigue life, formability, corrosion resistance, etc. Although, a decade of research work has been carried out on FSP for different metal alloys, the advantages of the process particularly on magnesium alloys is yet to be understood clearly. The present review is focused on understanding the response of magnesium alloys for friction stir processing to fabricate surface composites. The available literatures have been thoroughly reviewed to present the microstructure evolution during processing and the mechanism of strengthening; the works on magnesium has been summarized to understand the effect of various processing parameters such as tool speed (rotation and traverse), number of passes, etc. and the tool geometry on the resulting properties. Also, details regarding the selection of suitable tool material and reinforcing particles to achieve optimum properties for specific magnesium alloys is included. Important suggestions and scope for further research regarding fabrication of surface composites on magnesium alloy are provided.

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