Abstract
Segregation of in situ formed particles at the grain boundaries is a major drawback of in situ composites. In this study, it has been demonstrated that friction stir processing (FSP) can be used as an effective tool to homogenize the particle distribution in Al based in situ composites and FSP processing parameters were optimized for this purpose. An Al-5 wt% TiC composite was processed in situ using K2TiF6 and graphite in Al melt and subjected to FSP. Processing parameters for FSP were optimized to get a defect free stir zone and homogenize the particle distribution. It was found that a rotation speed > 800 rpm is needed. A rotation speed of 1000 rpm and a traverse speed of 60 mm/min were found to be an optimum combination. The grain size was also refined in addition to homogenization of the as-cast microstructure. This resulted in significant improvement in the mechanical properties of the processed composite.
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