Abstract
This paper presents a study on friction stir processed 1100 aluminum withincorporation of rice huskash derived, amorphous silica particles and fabricated at different tool rotational speeds. During friction stirring amorphous silica powder was placed into a groove made in the joining line of Al 1100 plates. Friction stirringwas performed with clockwise tool rotational speeds of 600 rpm, 865 rpm, 1140 rpm or 1500 rpm with a constant 45 mm/min travelling speed and a 2° tilt angle. High rotational speed (1140 rpm) facilitated material flow in the stir zone, contributing to fine aluminum matrix grain size (30- 10μm) as a result of dynamic recrystallization. Stirring at this rotational speed also caused the fracturingrelated refinement of silica particles to 10μm particle sizethat isassociated with good distribution in the aluminum matrix. Reduction in wear rate of friction stir processed Al1100 with improved hardness was believed to be due to the presence of hard silicawith high interfacial strength and high hardness of recrystallized aluminum grains in the stir zone.
Highlights
Friction stir welding (FSW), initially developed by The Welding Institute (TWI), has been widely used in welding of magnesium and aluminum alloys [1]
That is,the widest part is in the uppermost portion of the stir zone while the narrow part is at the lowest part of the pin which indirectly suggests the key role of the tool shoulder on the material stirring action
No defects in the form of cracksor porosities were detected in eithersample.The stir zone in alloy without silica particles was larger, covering about 50% of the cross-sectional area of the plate,which is greater than the area covered by the other alloys
Summary
FSW has been identified as a potential technique for introduction of foreign ceramic particles into the stir zone of bulk alloys [2]. Since the main objective of this technique is to modify the microstructure of the alloy rather than to join, the technique has beentermed the friction stir process (FSP)[3,4]. FSP offers a low energy consumption route to introduce reinforcing ceramic phases into the metal matrix and to form bulk composites. Several studies have produced metal matrix composites (MMCs) using FSP. Wang et al [2] have produced bulk SiC-reinforced aluminum MMCs, and Lim et al [5] have succeeded in developing multiwall carbon nanotube reinforced aluminum alloy composites while Ke et al [6]have prepared in-situ Al-Ni intermetallic composites. There is potential especially to use amorphous silica as reinforcement during FSP
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