Abstract
In this work, friction stir processing (FSP) was used to prepare graphite (Gr) / A356 alloy composites with superior tribological properties. The Gr content and number of FSP passes (up to three passes) were used as processing variables. The microstructure, hardness and wear resistance of the composites were studied and compared with a neat sample. The microstructural studies demonstrated that super-fine Gr particles were uniformly distributed and in-situ sub-micron Al4C3 particles were formed after three FSP passes. Hardness measurements proved that all composites exhibited higher hardness than the neat sample. The composite prepared using two Gr loading rounds and three FSP passes achieved the highest hardness value of 331 kg.f/mm2, which is more than 4 times that of the neat sample. Additionally, the wear rate of this composite was approximately 57 % lower than that of the neat sample. The superior hardness and wear resistance of the fabricated composites are attributed to the in-situ exfoliation of graphite and the formation of super-fine Al4C3 particles during FSP.
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