Aluminium Metal Matrix Composites Research Articles

A Review: Characterization Of Aluminium-Metal Matrix Composite Reinforced with Zirconium Diboride

Composite materials with aluminium matrices are used in thermal management, defence, aerospace, automotive and aviation. As the prices of useful items decreased, their usefulness increased. Aluminium is reinforced with other metals, non-metals and ceramics to give it the required physical and mechanical properties such as high tensile strength, great hardness and corrosion resistance. Aluminium-metal matrix composites are known for their exceptional physical and mechanical properties and performance. This work also focuses on the fabrication and characterization of zirconium diboride reinforced aluminium-metal matrix composite. Zirconium diboride particles were used as reinforcement material to fabricate aluminium metal matrix composites by the stir casting method. The microstructure, hardness and tensile strength of aluminum-metal matrix composites and its corrosion behaviour were investigated. The results showed that the inclusion of zirconium diboride particles increased the hardness and tensile strength of aluminum-metal matrix composites. Field emission scanning electron microscopy and x-ray diffraction analysis are used to investigate the microstructural properties of aluminum-metal matrix composites reinforced with zirconium diboride particles. Field emission scanning electron microscopy images showed a uniform distribution of zirconium diboride particles in the aluminum-metal matrix composites matrix. X-ray diffraction analysis showed the formation of an intermetallic compound of aluminium and zirconium diboride. From the review that have been made, we can conclude that the inclusion of zirconium diboride particles increased the mechanical properties and corrosion of aluminium-metal matrix composites.

Advances in hybrid aluminium metal matrix composite produced by stir casting route: A review on applications and fabrication characteristics

The sustained demand for lightweight parts, superior strength, and high-efficiency products has made material researchers interested to study and explore new materials with superior properties. One of the most promising materials for meeting this demand is aluminium metal matrix composite. Due to its tailored properties, the usage of composite is currently increasing in the automotive, aerospace, marine, electronic, defence, domestic, and sports sectors. Simplicity, affordability, and bulk production in the stir casting method have attracted the attention of many researchers across the globe. This paper reviews the need for hybrid aluminium metal matrix composites, various aluminium alloys, and reinforcement materials produced by the stir casting technique. In addition, the applications, morphological, mechanical, and tribological behavior of aluminium hybrid metal matrix composites are discussed. This review will assist materials researchers in selecting the matrix and reinforcements for a specific application of aluminium matrix composites using the stir casting route.

Microstructure and Mechanical properties of CMT welded AA6063-T6/B4C/ES metal matrix composite using ER5356 filler wire

Aluminium alloy 6063-T6 is a popular choice among different industrial sectors as it portrays various desirable properties like moderate strength, improved corrosion resistance, better weldability and formability etc. These advantages make AA6063-T6 a common choice for matrix in a metal matrix composite. Mostly conventional fusion welding methods like Metal Inert Gas (MIG) and Tungsten Inert Gas (TIG) seem preferable options for welding aluminium and its alloys but it remains a challenge to use them to weld aluminium metal matrix composite. A modified version of MIG i.e. CMT welding, can be explored to overcome the challenges. In this study, an aluminium metal matrix composite has been fabricated with AA6063-T6 as matrix and two reinforcements −one organic, i.e., Eggshell (ES) and one inorganic, i.e., Boron Carbide (B4C), using the conventional stir casting method. CMT welding has been performed on plates cut out from the composites. Microstructure, hardness, tensile strength and residual stress of weld joint of composite have been observed. From micrographs, it is observed that a finer grain has been formed at the Fusion Zone (FZ) in comparison to the Heat Affected Zone (HAZ) and Parent Material (PM). XRD analysis at the fusion line has identified several intermetallic stoichiometric compounds (Al12Mg17, Mg2Si, CaMgSi, CaO, B2O3) and reinforcement B4C and CaCO3 within the matrix volume. The FZ exhibits higher hardness than the HAZ and the PM. Further, the tensile strength of the FZ exceeds that of the unwelded composite due to the presence of metastable strengthening phases of Mg2Si in the FZ, along with reinforcement (B4C and ES) particles. Residual stress analysis reveals tensile stress in the FZ and more compressive stress in the HAZ than in the PM.

Corrosion, wear and machinability studies on scrap aluminium alloy wheel based metal matrix composite

Recycled materials, especially scrap aluminum alloy wheels with reinforcement castings, are gaining applications in various fields such as aerospace, naval, military, and automobile. In this research, Honda car alloy wheels are stir-cast with 5% alumina as reinforcement and subjected to corrosion, wear, and machinability studies. Corrosion studies were conducted to evaluate the corrosion current density (ICorr), corrosion potential (ECorr), and corrosion rate for the cast aluminum metal matrix composite. The wear studies with different loads, i.e., 50 N, 60 N, 70 N, and 80 N, were performed on the specimen and investigated the coefficient of friction, frictional force, and pin temperature. The sliding load has a significant effect on wear performance, and for the sliding load of 80 N, the wear recorded was 2574.83 µm. The electrochemical machinability studies with voltage, duty cycle, and concentration of citric acid electrolyte are performed on the machining rate and surface corrosion factor. Analysis of the electrochemical machining process with PROMETHEE-II shows that 7 V, 60% duty cycle, and 30 g/L electrolyte concentration are estimated to be the best combination for a higher machining rate and a lower surface corrosion factor. KEY WORDS: Alumina, Machining rate, Nyquist plot, Electrochemical machining, PROMETHEE-II Bull. Chem. Soc. Ethiop. 2024, 38(4), 1163-1175. DOI: https://dx.doi.org/10.4314/bcse.v38i4.27

Fabrication and investigation of microstructural, mechanical and wear properties of in situ ZrB2/fly ash/AA7075 hybrid composite

This research explores the microstructural, mechanical and wear characteristics of hybrid aluminum metal matrix composites (HAMMCs). Initially ZrB2 is fabricated by melt reaction and then fly ash incorporated into the aluminum composite melt as secondary reinforcements to fabricate HAMMCs through the ultrasonic agitated stir casting method. Micrographic and phase analysis of the HAMMCs and base alloy is conducted x-ray Diffraction (XRD), and Energy-Dispersive x-ray Spectroscopy (EDS). A wear test was conducted to study the wear properties of alloy and hybrid composite material. The generated wear scar was analyzed using a profilometer to find the wear rate. The tensile strength and hardness of the hybrid aluminum metal matrix composites (HAMMCs) improved remarkably as compared to base alloy. The wear resistance of the fabricated composite also increases on increasing the in situ ZrB2 up to 3 weight fractions.

Investigation on mechanical behavior of Al6061- coconut shell ash- granite dust reinforced hybrid metal matrix composites manufactured using stir casting technique

Owing to the superior qualities, aluminum metal matrix composites (AMMC) have recently been accepted and suggested as a replacement for traditional materials in a variety of sectors, including automotive, agriculture, aerospace, sports, marine, and many more. To satisfy the industrial requirement, it is necessary to develop economical material with higher mechanical properties like strength, hardness, impact resistance etc. To minimise the environmental impact and depletion of natural resources , it is necessary to Reduce, Recycle and Resuse the solid waste created across the world. This work aims to study the mechanical behavior of hybrid composite of Al6061 reinforced with coconut shell ash (CSA) and granite dust solid waste. Hybrid composite specimens were successfully manufactured using stir casting method. The proportion of granite dust was kept constant at 2 wt percent, whereas the percentage of CSA varied, ranging from 0% to 12% with a multiple of 3. Tests for tension, compression, hardness, and impact were performed to examine the mechanical behavior of the created hybrid composites. SEM & EDAX analysis were carried out to study the microstructure and elemental composition of the hybrid composites. Experimental testing shows that, when the percentage of CSA in the hybrid composite increased, its tensile strength, compressive strength, hardness, and impact strength increased maximum upto 23.65%, 10.12%, 60.89% and 17.38% respectively as compared to base alloy. The experimental findings demonstrated that when compared to matrix and other hybrid composites, the Al6061 alloy reinforced with 2% granite dust and 12% CSA hybrid composite had superior mechanical properties.

Effects of hot extrusion on compressive strength and densification of aluminium-based metal matrix composites

ABSTRACT Metal matrix composites (MMC) made from powder metallurgy (PM) require post-processing to improve the mechanical properties or achieve the final shape. In this experimental study, Aluminium metal matrix composite (Al-MMC) was first fabricated through PM, followed by a hot extrusion process to study the effects of extrusion on compressive strength and density. Hot extrusion of Al-MMC results in microstructure refinement, enhanced dispersion of reinforcement particles and improved mechanical properties. The experimental findings revealed that hot extrusion of Al-MMC resulted in densification, reflected as an average improvement of 5% in the density. An average improvement of up to 22% was observed in the compressive strength of the Al-MMC. Therefore, hot extrusion can be considered an effective post-processing method for enhancing the Al-MMC fabricated through PM. It was also found experimentally that the extrusion ratio also affects the mechanical properties and performance of Al-MMC. It was revealed that the compressive strength is enhanced with an increase in extrusion ratio. It is also important to note that the PM process is one of the processes which offers reasonable control over the utilisation of starting material. Hence, reinforcement retention is higher than other methods like stir casting.

Optimizing friction stir processing parameters for aluminium alloy 2024 reinforced with SiC particles: A taguchi approach of investigation

The present investigation focuses on the microstructural behavior and mechanical properties of Aluminium alloy 2024 reinforced with SiC nanoparticles by applying the Friction Stir Processing (FSP) technique. Taguchi L9 orthogonal array was used to find the optimal process parameters. The experiment used the expected best process parameters, which confirmed the predicted highest value for the mechanical characteristic. Traverse speed, axial load, and rotating speed are the main factors affecting aluminum metal matrix composite. Hence, this experiment examined the effects of five different tool spinning speeds, specifically 800, 900, 1000, 1100, and 1200 rpm. Weld samples are fabricated wherein the stir zone contains SiC nanoparticles. The results of the study indicate that the optimal welding rotational speed of 1000 rpm has a significant impact on the microstructure, wear rate, and microhardness. Specifically, it was observed that the stirred zone exhibited enhanced wear resistance compared to other zones. The study's findings revealed that after implementing friction stir processing (FSP), a well-defined shear zone was observed on the advancing side of the stir zone. Additionally, it is found that the uniform dispersion and strong bonding of SiC particles with an aluminium matrix further enhance wear resistance.

Experimental investigation to assess the surface integrity in WEDM of Al-based hybrid composite material

Aluminum-based hybrid composites are used in various engineering applications due to their unique properties, such as high strength, good wear resistance, excellent corrosion resistance, and low density. Aluminum metal matrix (AMMC) composites reinforced with ceramic particles can be more difficult to machine than traditional aluminum alloys because of their increased hardness and abrasiveness. Wire electric discharge machining is a non-traditional machining process that uses a thin metal wire, typically made of molybdenum, brass or tungsten to cut through a workpiece using electrical discharge sparks. This process is useful for precision machining of complex shapes and profiles in hard or difficult to machine materials. WEDM is a commonly used process for cutting Al-SiC-ZrO2 HAMMCs due to their hardness and difficulty in machining using conventional techniques. The present study examines the relationship between machining parameters like pulse on time (TON), pulse off time (TOFF), peak current (IP) and wire feed (WF) and material removal rate (MRR) and surface roughness ( Ra) for Al-SiC-ZrO2 in WEDM. The Box-Beckham Design was used to plan the experiments, and response surface method was employed to develop the models. The pulse duration, TOFF, IP, and quadratic terms of [Formula: see text] and [Formula: see text] are the most influential factors of the MRR. The TON, IP and interaction term (TON × IP), and [Formula: see text] were the most significant factors for Ra. Multi-response optimization of process parameters was obtained using the desirability function approach. Furthermore, the machined samples were analyzed for surface integrity using SEM techniques. The prediction from this model validated the confirmation results.

A critical review on the effect of various sustainable reinforcements on armor grade aluminum alloys

To deflect projectiles with kinetic energy by blunting them upon impact, armor with an exceptionally hard surface is required.In order to absorb and disperse the projectile's kinetic energy, the next material needs to be exceedingly tough and have a high work of fracture; hence, it needs to be metallic. To maximize the strength to weight ratio, it must also be composed of a versatile material, such as ceramic. Thus, the application requires a range of qualities, ranging from ceramic to metallic. Aluminum alloys (AAs) are sought-after materials for a variety of engineering and defense uses owing to their excellent low-temperature characteristics, good specific strength, and acceptable corrosion resistance. The main issues with AAs are poor heat tolerance and wear resistance, which makes them unsuitable for military applications owing to their heavy weight, which can exacerbate the deterioration of mechanical components and impair vehicle maneuverability and speed. This paper offers the possibility of modifying the properties of monolithic aluminum materials by adding reinforcement and replacing conventional particulates with low-cost wastes derived from agriculture and industry, which are rich in oxides and other debris, such as fly ash (FA) and rice husk ash (RHA). The result is the development of hybrid aluminum metal matrix composites, or HAMMCs, which combine the best features of both metals with a variety of sustainable inorganic and organic reinforcements that can enhance the mechanical and tribological performances by 40–62 % in comparison to the basic matrix. So, they can be tailored to meet the needs that make their performance superior compared to unreinforced AAs. Through a review of existing literature, this paper will provide an outline of the effect of various kinds of reinforcements on armor-grade aluminum alloys.

Effect of Short Heat Treatments on the Microstructural Evolution and Hardness of Thixoformed Graphene Reinforced Aluminium Composites

Aluminium metal matrix composites are increasingly being used in numerous industries due to their lightweight nature and high strength. The incorporation of graphene into aluminium metal matrix composites has garnered significant interest owing to graphene's capacity to enhance numerous properties concurrently. Hence, this study aimed to fabricate a 0.3 wt.% graphene nanoplatelets reinforced A356 alloy (GNP-A356) composite through stir casting followed by thixoforming and short T6 heat treatment processes. It also evaluated the microstructure and mechanical properties of GNP-A356 after the thixoforming process and short T6 heat treatment. The microstructure of alloy and composite was confirmed by optical microstructure, field emission scanning electron microscopy images, and X-ray diffraction. Microstructure investigations demonstrate the impact of the stirring process on the structural transformation of the 𝛼-Al phase from the dendritic into a rosette-like and globular-like structure. The result also indicated that there was a transformation of eutectic silicon from the shape of a needle-like to spheroid structure after a short heat treatment, showing the efficiency of T6 heat treatment with a shorter time of solution treatment and ageing. Moreover, the increase in relative density and addition of reinforcement led to a significant increment in hardness. The result shows the hardness improved by 35.77% and 77.8% for as-cast and heat-treated composites, respectively, compared to A356 alloy.

A Taguchi Optimization of Stir Casting Process Parameters for graphene Nanoplatelets/ A356 Alloy Composite

Aluminum metal matrix composite (AMC) is a potential material for diverse applications in the field of automotive and aerospace owing to their superior mechanical properties, lightweight behavior, and low thermal expansion. Graphene nanoplatelets (GNP) have emerged as the preferred reinforcement in AMC. They are incorporated into the matrix by stir-casting methods to generate semi-solid feedstock suitable for thixoforming. The effects of the stirrer parameter and GNP content were examined using Taguchi design of experiments with an L8 (23) orthogonal array. The parameters tested were stirring speed (300-500rpm), GNP content (0.3- 0.7 wt%) and stirring time (5-10 minutes). The signal-to-noise ratio (S/N) and hardness of the GNP /A356 composite were used as response variables. The contribution of three factors in enhancing hardness has been identified. The optimum parameter obtained with stirring speed, GNP content, and stirring time is 500rpm, 0.7wt.%GNP and 5 min respectively.

Role of ilmenite particles on high temperature wear behavior and coefficient of friction of LM30 aluminium alloy composites

In this study, experimental approach involves material preparation via stir casting, extensive testing, and characterization. Optical microscopy, Scanning Electron Microscopy (SEM), and X-ray Diffraction (XRD) analysis reveal the uniform distribution of ilmenite particles within the alloy matrix and the formation of intermetallic phases. The thermal characteristics analysis demonstrates reduced 29 % coefficient of thermal expansion (CTE) in the composites, in the case of 15 wt% fine ilmenite particles reinforced composite. Hardness tests improvements in hardness, with the 15 wt% (32–50 μm) ilmenite Aluminium Metal Matrix Composite (AMC) exhibiting a 69% increase over the base alloy. Wear testing at various temperatures and loads showed the superior wear resistance of the composites compared to the base alloy, with the C3-15 composite outperforming cast iron typically used in brake drums. The wear rate of LM30 and LM30 + 15 wt% ilmenite (32–50 μm) (C3-15) sample is 38.8671 x 10−4 mm3/m and 10.50768 x 10−4 mm3/m at 200 °C and 68.67 N applied load, respectively. The coefficient of friction analysis further supports the enhanced performance of the composites. The coefficient of friction (COF) of LM30 + 15 wt% ilmenite (32–50 μm) (C3-15) is 0.29898, 0.47645 at 9.81 N and 68.67 N load, respectively measured at a temperature of 200 °C. Examining worn surfaces and debris provides insights into the wear mechanisms, including adhesion and abrasive wear. Overall, this research suggests the potential suitability of ilmenite-reinforced LM30 alloys as alternatives to traditional brake drum materials, offering improved thermal stability and wear resistance.

Influence of Tool Pin Profiles on Aluminium Alloy A356 and Ceramic-Based Nanocomposites for Light Weight Structures by Friction Stir Processing

In this research, the main aim is to focus the enhancement of aluminium-based metal matrix composites for improving the attributes of light weight metals, aerospace structures and other tailor blank material properties. By this way, the friction stir processing (FSP) was the suited alternate technique to enhancing the mechanical attributes and superior microstructural amendment in the processed MMCs. Therefore, this study investigates the dispersion of ceramic-based strengthening particles of chromium oxide (Cr2O3) in the aluminium base matrix of A356 alloy. During the processing, the different tool pin sizes having the conical threaded tool pin profiles. Similarly, the tool spinning speed and tool travel speed also varied while in FSP. Before the processing, the A356 alloy was prepared by the grooved surfaces for packing the chromium oxide particles to compose the aluminium metal matrix composites. The tensile strength and hardness was employed to carry out from the friction stir processed A356 alloy with influencing of Cr2O3. The maximum occurred tensile processing parameters are 1500 rpm of spinning speed, 6 mm of tool pin sizes and 90 mm/min of tool travel speed. Similarly, the maximum obtained hardness processing parameter are 2000 rpm of spinning speed, 5 mm of tool pin sizes and 90 mm/min of tool travel speed. A scanning electron microscope was utilized to investigate the dispersed Cr2O3 in the A356 alloy for confirming the refinement grains in the nugget zones of FSPed A356 alloy. The increased grain boundary by the influence of different tool pin sizes was the major reason to produces the better mechanical properties in the processed A356/Cr2O3.

Recycling of agro-industrial waste by fabricating laminated Al-metal matrix composites: a numerical simulation and experimental study

AbstractThe utilization of agriculture waste as a recycling process in aluminium metal matrix composites (AMMCs) has gained significant attention as a novel approach in environmental toxicology. This technique aims to mitigate environmental hazards to humans by reducing the negative impact of waste materials. It has been recognized as an effective means to fabricate and enhance the properties of AMMCs. Furthermore, the use of these agro-industrial waste materials has the potential to mitigate both human and environmental risks, including pollution, while also leading to cost savings in manufacturing processes. The present investigation involves the fabrication of a novel metal matrix composite incorporating rice husk ash particles as reinforcement. The initial phase of the work involved the fabrication of novel composites. Subsequently, the focus shifted towards investigating the mechanical, physical, and wear characteristics of these composites. The forming process of the accumulative rolling was investigated by the numerical simulation using the ABAQUS program. Additionally, this study emphasizes the present utilization and prospective advancements of composites reinforced with agricultural and industrial wastes in diverse sectors, particularly in the fabrication of materials for vessels, autos, and construction industries. Furthermore, an examination of the scanning electron microscopy (SEM) of the fracture surfaces in the vicinity of layer interfaces has been conducted to investigate the quality of bonding.

Towards a self-healing aluminum metal matrix composite: Design, fabrication, and demonstration

This paper presents a novel approach to designing and synthesizing a self-healing aluminum-based metal matrix composite (MMC) at the macro-scale. The composite comprises an Al 5083 matrix embedded with low melting point particles (LMPPs) that act as healing agents. A two-step electroless micro-encapsulation process is developed to create LMMPs with a diffusion and thermal barrier designed to protect the Zn-8Al core with a Co-P shell. The MMC is fabricated using spark plasma sintering. Following controlled total fracture under tension, external compressive force is applied during heat treatment to heal the fracture effectively. The evolution of phases and interfaces is characterized using electron microscopy, and transient liquid phase bonding (TLPB) is identified as the fracture-healing mechanism, facilitated in areas with sufficiently high Zn concentration to fill the crack. The design can be expanded to incorporate other matrix and LMMP materials, mechanical crack volume reduction by integrating shape memory alloy (SMA) reinforcement during MMC synthesis, and processing of the self-healing MMC using Directed Energy Deposition additive manufacturing.

Numerical Study of Reinforced Aluminum Composites for Steering Knuckles in Last-Mile Electric Vehicles

The steering knuckle is a critical component of the suspension and steering drive systems of electric vehicles. The electrification of last-mile vehicles presents a challenge in terms of cost, driving range and compensation of battery weight. This work presents a numerical methodology to evaluate 60XX series aluminum metal matrix composites (AMMCs) with reinforcement ceramic particles for steering knuckle components in medium heavy-duty last-mile cargo vehicles. The use of AMMCs provides lightweight knuckles with sufficient strength, stiffness and safety conditions for electrical vehicle cargo configurations. The numerical study includes three aluminum alloys, two AMMC alloys and an Al 6061-T6 alloy as reference materials. The medium-duty heavy vehicle class < 12 t, such as electrical vehicle cargo configurations, is considered for the numerical study (class 1–4). The maximum von Mises stress for class 4 AMMC alloys exceeds 350 MPa, limited by fracture toughness. The weight reduction is about 65% when compared with commercial cast iron. Moreover, Al 6061-T6 alloys exhibit stress values surpassing 300 MPa, constraining their suitability for heavier vehicles. The study proposes assessing the feasibility of implementing AMMC alloys in critical components like steering knuckles and suggests solutions to enhance conventional vehicle suspension systems and overcome associated challenges. It aims to serve as a lightweight design guide, offering insights into stress variations with differing load conditions across various cargo vehicles.

Effect of jute stick charcoal powder on characterization of aluminum metal matrix composite

The present work indicates the fabrication of Aluminum Metal Matrix Composites (MMCs) reinforced jute stick charcoal powder (JSCP) using stir casting process and investigates different properties of fabricated composites. Mechanical properties such as flexural strength, tensile strength, hardness, and impact tests are investigated. Additionally, the morphology of the MMCs were analyzed using scanning electron microscopy (SEM). Furthermore, X-ray diffraction (XRD) analysis was used to identify the phase of the MMCs. From the investigation it was found that the tensile and flexural strength of the Al+3% JSCP composite decreased by 27.1% and 1.32% respectively compared to the Al+1% JSCP composite. On the other hand, impact strength and hardness were slightly greater for Al+3% JSCP composite. SEM analysis revealed micro-cavities and charcoal powder particle size and distribution differences. XRD patterns of the prepared composite revealed the presence of JSCP and lattice parameter of the composite. The investigation of surface roughness under different cutting speed reveals that, composite with 1% JSCP exhibited a higher surface roughness than the composite with 3% JSCP because the micro-cavity and porosity was less in Al+3% JSCP.

A comparative study on combined compromise solution (CoCoSo)-based optimization of drilling of aluminium metal matrix composites in fuzzy environments

A comparative study on combined compromise solution (CoCoSo)-based optimization of drilling of aluminium metal matrix composites in fuzzy environments

In-depth characterization of FSP-enhanced aluminum metal matrix: A study in materials modeling and computational techniques

The production of aluminum metal-matrix composites (AMM) involves reinforcing aluminum and its alloys with various powders, with the addition of ceramic reinforcements expected to enhance the mechanical properties, corrosion resistance, and the wear resistance behaviour. However, suboptimal production techniques often result in reduced ductility and toughness when incorporating non-deformable ceramic reinforcements. To address this, friction stir processing (FSP) was employed as a novel surface modification process, using Ti–6Al–4V particles to reinforce 1100 Aluminum Alloy. Microstructures of the composites were analyzed through Scanning Electron Microscopy (SEM), revealing a mean particle size of 2.69 × 103μm for a one-pass FSP at X155 magnification. Notably, the two-pass sample with a particle size of 2.69 × 103μm displayed fewer spherical structures and more irregular structures, indicating a change in the flow mechanism. The three-pass sample exhibited a mean particle size of 1.36 × 103μm, indicating a more uniform distribution and significant size reduction compared to one and two passes.Additionally, a torque-based predicted heat-input analysis indicated that higher temperatures resulting from increased heat production rate and power input led to a decrease in the torque with rising rotational speed. The threaded taper tool generated more heat, potentially facilitating plastic deformation. Finite Element Analysis (FEA) using ABAQUS predicted how this heat affected composite quality, closely aligning with experimental data, with less than a 10 °C difference between processing temperatures in experimental and simulated data. The peak temperature increased as the tool rotated at various tool speeds in line with the projected temperature history of FSP. This study is a significant contribution to enhancing aluminium metal matrix composite through the FSP technology.