scholarly journals Another Approach to Characterize Particle Distribution during Surface Composite Fabrication Using Friction Stir Processing

Metals ◽  
2018 ◽  
Vol 8 (8) ◽  
pp. 568 ◽  
Author(s):  
Namrata Gangil ◽  
Sachin Maheshwari ◽  
Emad Nasr ◽  
Abdulaziz El-Tamimi ◽  
Mohammed El-Meligy ◽  
...  
Keyword(s):  
Friction Stir Processing ◽  
Particle Distribution ◽  
Input Parameter ◽  
Traverse Speed ◽  
Net Energy ◽  
Friction Stir ◽  
Surface Composite ◽  
Composite Fabrication ◽  
Shoulder Diameter ◽  
Three Stages

Surface composite fabrication through Friction Stir Processing (FSP) is evolving as a useful clean process to enhance surface properties of substrate. Better particle distribution is key to the success of surface composite fabrication which is achieved through multiple passes. Multiple passes significantly increase net energy input and undermine the essence of this clean process. This study proposes a novel approach and indices to relate the particle distribution with the FSP parameters. It also proposes methodology for predicting responses and relate the response with the input parameter. Unit stirring as derived parameter consisting of tool rotation speed in revolutions per minute (rpm), traverse speed and shoulder diameter was proposed. The particle distribution was identified to be achieved in three stages and all three stages bear close relationship with unit stirring. Three discrete stages of particle distribution were identified: degree of spreading, mixing and dispersion. Surface composite on an aerospace grade aluminum alloy AA7050 was fabricated successfully using TiB2 as reinforcement particles. FSP was performed with varied shoulder diameter, rotational speed and traversing speed and constant tool tilt and plunge depth using single pass processing technique to understand the stages of distribution. Significant relationships between processing parameters and stages of particle distribution were identified and discussed.

Direct Extrusion of Circular Profiles with Surface Composite Produced by Friction Stir Processing

2011 ◽  
Vol 383-390 ◽  
pp. 2747-2752
Author(s):  
Arash Aghagol ◽  
Saeed Mahmoodi Darani ◽  
Karen Abrinia ◽  
Mohammad Kazem Besharati Givi
Keyword(s):  
Base Metal ◽  
Friction Stir Processing ◽  
Composite Layer ◽  
Traverse Speed ◽  
Extrusion Ratio ◽  
Friction Stir ◽  
Surface Composite ◽  
Direct Extrusion ◽  
Shoulder Diameter ◽  
Before And After

In this research, a new application of friction stir processing (FSP) in producing surface composite on circular billets was introduced. Al/Cu composite was fabricated by FSP on the surface of a 1050 aluminium cylinder with the diameter of 60 mm. Then this cylinder with surface composite was extruded with the extrusion ratio of 1.7. Finally, microstructure and microhardness were investigated before and after the extrusion. H13 hot work steel was used as the material of the tool whose pin diameter and length were 6 mm and shoulder diameter was 18 mm. The rotation and traverse speed of the tool were 1000 rpm and 25 mm/min respectively. The microstructural investigations show that the thickness of the composite layer decreases and a uniform layer of the composite remains on the surface after the extrusion. Also the microhardness measurements demonstrated that the hardness of the composite layer was higher than the base metal and the microhardness of all zones increased after the extrusion.

Effect of Friction Stir Processing Parameters on the Properties of AA7075-T73/Al2O3 Surface Metal Matrix Composite

2020 ◽  
Vol 1002 ◽  
pp. 140-150
Author(s):  
Ali H. Al-Helli ◽  
Ahmed R. Alhamaoy ◽  
Ayad Murad Takhakh
Keyword(s):  
Friction Stir Processing ◽  
Particle Distribution ◽  
Surface Hardness ◽  
Base Material ◽  
Processing Parameters ◽  
Optical Microscope ◽  
Friction Stir ◽  
Surface Composite ◽  
Surface Metal ◽  
Number Of Passes

Friction Stir Processing (FSP) technology was wielded to output the Al7075/ Al2O3 surface composite. The effects parameters of processing method on particle distribution have been studied. The microstructure and mechanical characteristics of the samples were examined using the optical microscope, SEM and hardness examination. Acquired consequences, showed that Al2O3 particles were in a good interior distribution inside the basement. This technique produced excellent bonding between the surface composite and the base material. On other hand the surface hardness was increased about 25% as compared with the substrate. In addition, grain matrix refinement and enhanced particle distribution were obtained after each FSP pass. Also the dispersion of Al2O3 particles in the stirred area became more homogeneous and the average hardness improved by increasing the number of passes.

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 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.

Fabrication of Cu Surface Composite Reinforced by Ni Particles Via Friction Stir Processing: Microstructure and Tribology Behaviors

2017 ◽  
Vol 140 (1) ◽  
Author(s):  
Mohsen Pezeshkian ◽  
Iman Ebrahimzadeh ◽  
Farhad Gharavi
Keyword(s):  
Friction Stir Processing ◽  
Traverse Speed ◽  
Optical Microscope ◽  
Wear Properties ◽  
Friction Stir ◽  
Surface Composite ◽  
Hardness Tester ◽  
Different Dimensions ◽  
Pin On Disk ◽  
Tool Rotation

In the present investigation, friction stir processing (FSP) was used to integrate Ni particles into the surface of copper in order to fabricate a surface composite. Determining an optimized percentage of Ni particles, different dimensions of grooves were machined into the Cu plates. Then, the specimens' grooves were filled by nickel reinforcement particles, and friction stir process was performed on the specimens with tool rotation speed of 800 rpm and traverse speed of 50 mm/min. Optical microscope (OM) and scanning electron microscope (SEM) were used to evaluate the microstructure. Pin-on-disk test was performed to evaluate wear properties using pins manufactured from the FSPed zone. Also, Micromet-Buehler Vickers hardness tester was used to test the FSPed surfaces' microhardness. The results show that the best properties are obtained when using 2 × 2 mm groove. In this situation, microhardness and wear properties were improved as 40% and 60% compared to the substrate, respectively.

scholarly journals Influence of Friction Stir Processing Parameters on Mg ZE 41-SiC Surface Composite

2019 ◽  
Vol 8 (2) ◽  
pp. 6058-6061
Keyword(s):  
Process Parameters ◽  
Tilt Angle ◽  
Friction Stir Processing ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Nano Particles ◽  
Micro Hardness ◽  
Friction Stir ◽  
Surface Composite ◽  
Tool Tilt Angle

In this study, the influence of friction stir processing process parameters (FSP), such as tool rotational speed, tool traverse speed, and the tool tilt angle on the mechanical properties of Sic reinforced surface magnesium rare earth ZE41 alloy composite was studied. The process was carried at tool rotational speeds of 710, 900, 1120, 1600, 1400 and 1800 rpm, tool traverse speeds of 16, 25, 40 and 63 mm/min and tool tilt angle of degree 1. Nano-particles of SiC (40 microns) were used as reinforcements to produce a composite surface. The grain refinement of the processed specimens was analyzed using scanning electron microscope. It is observed from the results that FSP process parameters influenced the surface composite area, SiC particles distribution and micro hardness of the composite. The outcomes indicated that the higher micro hardness was obtained at rotational speed of 1100 RPM, traverse speed 40mm/min and tilt angle 10 .

scholarly journals Surface Composite Fabrication by Friction Stir Processing: A Review

2021 ◽  
Vol 309 ◽  
pp. 01150
Author(s):  
Anubhav Sharma ◽  
Sachin Maheshwari ◽  
Pradeep Khanna
Keyword(s):  
Process Parameters ◽  
Friction Stir Processing ◽  
Weight Ratio ◽  
Tool Geometry ◽  
Material Surface ◽  
Surface Processing ◽  
Friction Stir ◽  
Surface Composite ◽  
Composite Fabrication ◽  
Surface Composites

Newer materials with unique properties are needed to cater the ever-increasing industrial demands to meet new challenges concerning technological advancements. Quest for special materials and processes is prevalent as conventional materials fail to level up. Composite materials promisingly bridge this gap by providing controllable properties at reasonable costs. Their scope of application can further be drastically enhanced by subjecting them to special surface processing treatments. Friction stir processing (FSP) is one such promising process that can meet the stringent applicational demands. Composites are increasingly being used in industries for properties like high strength to weight ratio, increased hardness, stiffness, ductility, corrosion resistance, etc. FSP, a solid-state material modification technique, has proved its caliber in surface composite fabrication. Some attention-seeking advantages of FSP include peerless efficiency, less tool wear rate, and ability to modify material locally are some of many attention-seeking advantages. Despite being cost-effective FSP also manages to eliminate the drawbacks of the conventional manufacturing process. FSP reinforces a special material into the parent material surface to attain specific properties. Properties so developed depend on parameters like: tool geometry, traverse speed, rotation speed, number of passes etc. The present paper aims to review comprehensive information on fabrication of surface composites by FSP, process parameters, properties, industrial applications, and future scope. Key Words: Friction stir processing surface processing treatments surface composites material modification process parameters.

scholarly journals Effect of tool plunge depth on reinforcement particles distribution in surface composite fabrication via friction stir processing

2017 ◽  
Vol 13 (2) ◽  
pp. 86-91 ◽  
Author(s):  
Sandeep Rathee ◽  
Sachin Maheshwari ◽  
Arshad Noor Siddiquee ◽  
Manu Srivastava
Keyword(s):  
Friction Stir Processing ◽  
Plunge Depth ◽  
Friction Stir ◽  
Surface Composite ◽  
Composite Fabrication
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