Investigation of the effect of tool probe profile on reinforced particles distribution using experimental and CEL approaches

Abstract

In this study, to explore the dispersion of particle reinforcement in the base metal, aluminum-6061/SiC composites were made utilizing friction stir processing (FSP) tools with various probe profiles such as cylindrical, triflate, square, triangular, and hexagonal. A light microscope was used to examine the dispersion of SiC particles in the composite substrate. Then the mechanical properties of the composite were investigated using hardness and tensile tests. In addition, the coupled Eulerian-Lagrangian (CEL) approach is used to model the process and investigate particle dispersion further. The workpiece is modeled employing Eulerian formulation, whereas the tool is described using Lagrangian formulation. The model forecasts temperature and strain variations in composites made with various probe profiles. The result showed that the cylindrical pin could not spread particles in the base alloy, indicating that it was not viable for composite manufacture. Flat-surfaced tools, such as square and triangle probe profiles, have dispersed particles better in aluminum. The findings revealed that the inclusion of eccentricity and pulse creation in these tools enhanced particle dispersion. Hexagonal and triflate probes offer the highest performance in terms of particle dispersion in the base metal. As the number of smooth tool probe surfaces rises from triangular to hexagonal, the hardness distribution becomes more uniform, and the amount of hardness in the composite increases.