Abstract
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.
Highlights
Wrought aluminum alloys are considered one of the most significant metallic materials in today’s fabrication and manufacturing production, especially in the transportation industries [1,2]
In the case of friction stir processing (FSP) with negligible silicon carbide particles (SiC) dispersion, the results show a reduction in the hardness below the base metal value for all points measured in the processed zone
A new approach and tool design for direct friction stir processing to eliminate the step of preplacing reinforcement particles into the base metal was proposed for developing a surface composite layer on 1100 aluminum alloy
Summary
Wrought aluminum alloys are considered one of the most significant metallic materials in today’s fabrication and manufacturing production, especially in the transportation industries [1,2]. The tool design consists of a pin-less hollow shoulder that is tapered at its lower end This design was shown to allow the efficient spread and mixing of the reinforcement particles into the matrix surface during FSP. A modified design of the FSP tool is proposed for making aluminum-based surface composites reinforced by SiC particles, based on the concept of the tool design reported in [30]. FiguFriegu6r.eP6a.noPraanmoircamimicagime aogfethoef tchroescsr-osescs-tisoenctioofnthoef tphreocpersosceedssseadmspalmespslehsowshionwg itnhge tchoemcpoomspitoesite surfsaucrefaucseinugs:in(ag): a(at)oaoltowoilthwaithhoalehosliezesiozfe6ofm6mmamndanadpalupnlguengdeepdtehptohf o0f.60m.6mm;man; adn(db)(ba)taootolowl iwthith a a hohleolseizseizoefo6f m6 mmmanadnda palpulnugnegde edpetphthofo0f.09.9mmmm. The average microhardness of the as-received 1100 aluminum was 38.5 Hv. In the case of FSP with negligible SiC dispersion, the results show a reduction in the hardness below the base metal value for all points measured in the processed zone
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