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.

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.

The influence of multi-pass friction stir processing on microstructure and sliding wear behavior of Cu/ZrO2 surface composite

2020 ◽  
Vol 111 (10) ◽  
pp. 814-825
Author(s):  
Amin Rabiezadeh ◽  
Saman Ghafaei
Keyword(s):  
Friction Coefficient ◽  
Base Metal ◽  
Friction Stir Processing ◽  
Wear Behavior ◽  
Composite Layer ◽  
Copper Matrix ◽  
Processing Parameters ◽  
Nano Particles ◽  
Matrix Composites ◽  
Friction Stir

Abstract In this study, copper/ZrO2 surface composites were produced using nano-particles via friction stir processing in order to enhance surface tribological properties. The present research aimed to generate copper matrix composites and analyze the effect of processing parameters on the evolving microstructure, microhardness, and wear-resistance behavior. It is worth noting that the processed composite layer had more homogeneity in the four-pass process. In comparison to the base metal and non-powder samples, it had higher mechanical characteristics. Based on the results, the highest recorded hardness, approximately 288 HV, was found in a four-pass state with powder. Remarkably, it showed a double peak compared to 80 HV in the base metal. The lowest friction coefficient of four-passes with the powder sample was about 0.47, which showed a significant efficiency in comparison to the friction coefficient of base metal that was about 0.81.

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.

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.

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

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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