Abstract
In the current study, a new approach for surface modification and surface hardening of aluminum alloys is developed. The method is based on the logic of in-situ reinforcing FSP strategies. The novelty of the proposed process is the application of a bulk reinforcing metallic material instead of metallic powders. The FSP was carried out on aluminum alloy AA5083—thick plates. A thin sheet of pure copper (cross-section 4 × 0.8 mm2) was placed in a machined groove on the upper surface of the aluminum plate, and both materials were FSPed together. Samples with one, two and three FSP passes were manufactured respectively. Results indicate that the copper thin sheet was successfully integrated in the AA5083 stir zone. By increasing the FSP passes, almost all copper was integrated in the stir zone, mainly in the form of coper-based micron-sized intermetallic particles, and secondly, by copper diffusion in the AA5083 matrix. Due to the presence of complex intermetallic compounds created by the high heat input and intense plastic deformation, the hardness inside the stir-zone was found highly increased from 77 to 138 HV.
Highlights
Today, aluminum and its alloys are used in different areas of manufacturing and technology [1]
Results and Discussion a FSPed specimen without copper addition (AA5083 plate with three friction stir process (FSP) passes without any Al–Cu intermetallic compound reinforcements)
It can observed that the not-integrated copper areas one FSPtopass, large copper are introduced in the More upperspecifically, area of thein stir zone
Summary
Aluminum and its alloys are used in different areas of manufacturing and technology (e.g., automotive and aerospace) [1]. Modern industries have been aggressively pushing the limits of aluminum alloys in strength, damage tolerance and corrosion resistance fronts to develop strong and tough aluminum alloys for various parts to increase the overall efficiency [2,3]. The aluminum alloy 5xxx series is widely utilized in marine applications, such as ship hulls. AA5083 is considered one of the well-known representatives of the 5××× series, with many applications in aircraft, marine structural parts and automobiles [4]. Welding of aluminum alloys is important for fabricating structural constructions and mechanical fabrications such as aircraft and marine vessels. Welding exhibits problems and can be challenging in many cases. Indicative welding defects common to aluminum include incomplete fusion, hot cracking and porosity [5]
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