Abstract
Possibility of the formation of Al–Al3Ni composite layers on commercial pure aluminium plates by friction stir processing (FSP) has been studied. It is believed that the hot working nature of FSP can effectively promote the exothermic reaction between Al and added Ni powder to produce Al3Ni intermetallic compounds in the aluminium matrix. In this study, the effects of the rotational and traverse speed of the tool as well as the number of FSP passes on the in situ formation of Al3Ni in aluminum matrix were examined. Besides, the microstructure and microhardness of the fabricated surface layers were also studied. The results showed that the ratio of tool rotational speed to traverse speed (ω/υ) is the main controlling parameter of the heat generated during FSP and hence the reaction between aluminium and nickel. Increasing the number of FSP passes also promoted the reaction between Ni and Al and improved the distribution of Al3Ni compounds, too. The composite layer achieved by six passes of FSP showed the highest hardness, which was almost twice of that of the base metal.
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