Abstract
The reinforced friction stir processing (FSP) improves tribological qualities like wear resistance and mechanical qualities like tensile strength, hardness, and fatigue. This study used FSP to introduce silicon carbide granules onto AA 6061 Al alloy, often used in automotive components, to alter the surface morphology. The fabricated surface metal composites showed superior wear resistance to the base metal. The tribological analysis was done on the 1000 m sliding distance, 40 mm wear track diameter and applied load 5 N to 15 N. The wear of the sample FSP at 1000 rpm and 80 mm/min feed found maximum wear at 5 N, 10 N and 15 N, and the minimum wear yielded 1000 rpm, 80 mm/min at indirect cooled FSP condition. Similar results were obtained for friction force and coefficient of friction. The wear was increased at a very high rotational speed value in FSP. Developing a brittle intermetallic compound (IMC) reduced the microstructural properties of dry FSP. It was revealed through scanning electron microscopy (SEM) images. The indirect cooling mechanism controlled the development of IMC. The maximum tensile strength of 122.21 MPa was obtained at 1200 rpm and indirect cooled FSP. The indirect cooling in the process of FSP improves the microhardness value.
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