Abstract
Friction stir processing (FSP) carried out on a commercial AA2024Al alloy using different tool rotation rates (200–1000rpm) led to significant change in size and morphology of the constituent particles. The size of insoluble Al6(Cu,Mn,Fe) particles presentin the stir zone was substantially reduced as a function of tool rotation rate whereas smaller soluble Al–Cu–Mg based particles exhibited significant reduction in amount only at higher tool rotation rates. Severe plastic deformation, peak temperature and constituent particle characteristics influenced their evolution.
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