Abstract
In low-strength metals, the main purpose of enhancing surface properties is to increase the abrasion resistance. One of the new methods for improving the microstructure of the surface layer of metals is the surface composite. In this research, the friction stir processing (FSP) was used to develop an aluminum–nickel intermetallic surface composite. Aluminum 2024 alloy and Ni powder were used as the matrix and reinforcement agent, respectively. Comparison of composite and non-composite FSP samples indicates that adding reinforcements improves the wear resistance of a monolithic metal in all condition. Also, the wear resistance of fabricated composites using activated Al–Ni powder is higher than the others due to the presence of Al3Ni2 and Al3Ni intermetallic compounds. At low traverse speed of the FSP, powder agglomeration occurs, and the powders are not uniformly distributed, as a result, the friction coefficient rises. SEM micrographs of scratched particles of activated composite confirm the delamination mechanism in the wear stable stage.
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