Formation of functionally graded hybrid composite materials with Al2O3 and RHA reinforcements using friction stir process

Abstract

ABSTRACT In the present investigation, hybrid aluminium based composite material was developed by using two dissimilar aluminium alloys with Al2O3 and RHA reinforcement particles via Friction Stir Process. Equally proportions of Al2O3 ceramic particles and RHA were used as filler (reinforcement) material in between the two aluminium plates (Al6063 and Al8011). Microstructures results showed a uniform distribution of reinforcement particles in between two aluminium alloys plates. The tensile strength of Al2O3 andRHAreinforced FGM composite is better for lower tool rotational speed i.e. 560 rpm but as the tool speed increases the tensile strength decreases. The least tensile strength can be observed for 1460 rpm. The tensile strength reduces with the increase in tilt angle. The tensile strength is better for triangular tool shape but continuously decreases with the smoothness of the tool. However, the hardness of Al2O3 and RHAreinforced FGM composite is better for the triangular tool shape and minimum tool speed i.e. 560 rpm but as the smoothness of the tool increases the hardness decreases. The least hardness can be observed for the circular tool. The hardness decreases as the tool angle increases. The better hardness can be seen for minimum tool angle i.e. 00.