Abstract
Multipass friction stir processing of brittle as-cast hypereutectic Al–Si alloy resulted in bimodal distribution of ultrafine silicon particles in nano-size aluminum matrix. As compared to the as-cast material, the stress–strain curves revealed simultaneous increase in strength by four times and in ductility by 14 times after three overlap multipass FSP. The transformation from brittle cleavage fracture to completely ductile fracture is confirmed by the fractographs of tensile samples taken before and after the friction stir processing.
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