Friction Stir Processing Route Research Articles

Improving Mechanical and Tribological Characteristics of Cast Elektron 21 Alloy by Reinforcing its Surface with Al0.3Cu0.3Ni0.1Si0.1W0.2 High Entropy Alloy via Friction Stir Processing Route

Improving Mechanical and Tribological Characteristics of Cast Elektron 21 Alloy by Reinforcing its Surface with Al0.3Cu0.3Ni0.1Si0.1W0.2 High Entropy Alloy via Friction Stir Processing Route

Investigation on Mechanical and Fracture Behavior of Magnesium Composite Reinforced With Hybrid Fly Ash Particulates Synthesized via Friction Stir Processing Route

Abstract Utilizing waste materials like fly ash in the creation of lightweight magnesium metal matrix composites with a high strength-to-weight ratio is encouraged by the rising demand for in-expensive reinforcements. In the current study, friction stir processing (FSP) was employed to synthesize magnesium surface composites via incorporating hybrid reinforcement particles, including nano titanium carbide and fly ash. The synthesized composite material underwent examination through microscopic images of the stir zone and assessments of microhardness, tensile strength, compressive strength, electrical and thermal conductance, and wear behavior. The results revealed a notable refinement in grain size and a simultaneous improvement in mechanical properties. Notably, there was a substantial increase in wear resistance attributed to the increased hardness and uniform dispersion of hybrid reinforcements within the surface composite. The results demonstrate that the inclusion of reinforcements in magnesium-based alloy led to an enhancement in fracture toughness, mitigation of crack propagation, and an overall improvement in fracture resistance to catastrophic failure.

Author Correction: Recent Advances in Magnesium-Based Metal Matrix Surface Composites Developed via Friction Stir Processing Route—An Overview

Author Correction: Recent Advances in Magnesium-Based Metal Matrix Surface Composites Developed via Friction Stir Processing Route—An Overview

Exploring the mechanical, metallurgical, and fracture characteristics of hybrid-reinforced magnesium metal matrix composite synthesized via friction stir processing route

Low-cost hybrid-reinforced magnesium metal matrix composite (HMMC) materials present a revolutionary category of materials achieved by combining two or more distinct reinforcing elements within the magnesium (Mg) matrix. The main focus of this research is to fabricate Mg-based HMMCs with exceptional mechanical and other characteristics by utilizing Mg substrate AZ61A as the base material. To achieve this, nano-titanium carbide (TiC), nano-silicon carbide (SiC), and fly ash (FA) were selected as hybrid reinforcements, and the friction stir processing technique was employed for their incorporation. The microstructural, thermal, mechanical, wear, and fracture properties of synthesized HMMCs were carefully examined using a conventional testing approach. The findings demonstrate that the grain size of the base AZ61A alloy was measured at 32 µm, whereas the AZ61A/FA/TiC/SiC composite exhibited a remarkable reduction to 3.5 µm. Notably, this reduction in grain size leads to simultaneous enhancement in mechanical properties. The microhardness, ultimate tensile strength, and ultimate compressive strength of the developed HMMC showed an impressive increase, measuring 2.09 times, 2.75 times, and 2.10 times higher, respectively, compared to their initial values of the base material. Moreover, a significant enhancement in wear resistance was also observed, attributed to the increased hardness and homogenous hybrid reinforcement dispersion into the HMMCs. In addition, it was evident that the synergistic combination of different reinforcement particulates in Mg-based alloy improves overall fracture resistance and catastrophic failure and mitigates crack propagation.

Effect of tool profile on wear and mechanical behaviors of CeO2 and ZrO2-reinforced hybrid magnesium matrix composite developed via FSP technique

A dual/double eccentric-pin tool was used for the reinforcement of the CeO2 and ZrO2 particles into a 5 mm thick AZ31B magnesium alloy through the application of the friction stir processing route to develop a composite with improved properties. A comparison of the developed composite's properties with that of the single pin-processed counterpart was carried out to ascertain the improvement recorded. The structure, hardness, shear punching strength, tensile, corrosion, and wear properties of the hybrid AZ31B/(ZrO2 + CeO2)p composite were investigated. The findings show that the dual/double eccentric pin tool widened the stir zone at the shoulder area, eliminated flow-related voids, and improved the flow of material and the particle distributions within the composite. The extra pin-induced plastic shearing/straining and dynamic recrystallization of the tool meaningfully refined the grain structure (5.6–3.35 μm) and the particle size (6.4–4.8 μm) of the composite while aiding even dislocation spread across the stir zone. In relation to the singular probe tool, the dual/double eccentric-pin tool also enhanced the hardness (102–141 HV), the shear punching strength (148–219 MPa), the tensile strength (175–225 MPa), the wear properties (coefficient of friction, rate, and loss), and the corrosion behavior of the hybrid AZ31B/(ZrO2 + CeO2)p composite due to the uniform and fine particle dispersion-strengthening and the elimination of stress raiser. The dual/double eccentric pin tool is thus recommended as a better tool for improving the performances of Mg-based composites.

Development of AA6061/316 stainless steel surface composites via friction stir processing: Effect of tool rotational speed

Metallic and alloy particles are recognized as alternatives to ceramic reinforcements to improve the overall characteristics of Al metal matrix composites. The present study aimed to investigate the friction stir processing/manufacturing of the 316 stainless steel particles reinforced AA6061 Al matrix composites by varying the tool rotational speeds. The microstructure, tensile, hardness, wear, corrosion behavior, and shear punching tests of the composites were studied. The results showed that the friction stir processing route produced no particle-matrix reaction in the composite and dislocation entanglements were formed close to the inherent 316 stainless steel particles within the Al matrix. The improved mechanical action of the tool aided particle fragmentation as the average 316 stainless steel particle sizes decreased from 41.88 to 26.89 μm. As a result of the dynamic recrystallization and particle-assisted pinning effects, the mean grain sizes of the composite decreased from 7.48 to 4.31 μm when the tool rotational speed was raised. An increment in the tool rotational speed (800–1200 rpm) triggered a rise in the maximum shear force (1198–1562 N), tensile strength (200.09–279.98 MPa), and maximum hardness value (121–139 HV) of the composite while a favorable decrease in the composite's wear rate (0.63–0.20 mg/m) and the friction coefficient (0.38 ± 0.01–0.21 ± 0.01) ensued. The composite's improvement is attributable to the homogeneous spread of dislocation.

Study on microstructure and mechanical properties of hybrid aluminium matrix composite with ZrO2 and Ni particle as reinforcement fabricated through FSP route

An attempt was made to develop AA6063matrix composites (AMCs) using ZrO2 and nickel particles (with different wt.%) as reinforcement through the friction stir processing (FSP) route. Microstructural features of AMCs revealed equiaxed refined grains due to dynamic recrystallization and pinning effect. Phase analysis revealed absence of deleterious intermetallics. Maximum improvement in microhardness and ultimate tensile strength was 58.1% and 80% respectively in AMCs made with 12% ZrO2 while ductility was decreased by 60% compared to the base material. Ductility of AMCs was improved as the percentage of Nickel increased, while tensile strength decreased by small value. AMCs with 6 % ZrO2 + 6 % Ni were found to bring balance in tensile strength and ductility with percentage improvement of 59 and 15%, respectively compared to the base material. It also showed an increment in density by 20%.

Impact of multiple FSP passes on structure, mechanical, tribological and corrosion behaviors of AA6061/316 stainless-steel reinforced Al matrix composites

Stainless steel particulates were chosen as alternatives to ceramic particles to improve particle-matrix bonding, toughness, and performance of aluminum metal matrix composites. A multi-pass friction stir processing route was utilized for the development of AA6061/316 stainless steel reinforced composites by varying the number of tool passes (1–4). Detailed microstructure analysis, corrosion, hardness, wear, tensile, and impact toughness behaviors of the developed composites were studied. An increment in the number of tool passes (1–4) did not cause a particle-matrix reaction or alter the presence of inherent Mg2Si, Al, and ferrous phases in the composites. The progressive increment in the tool passes significantly enhanced the dislocation density, grain refinement, particle refinement (36.4–22.4 μm), and dispersion within the composite's structure due to the successive rotating tool-induced high straining and plastic deformation, dynamic recrystallization, and Zener pinning phenomena. The successive tool pass-induced microstructure improved the microhardness value (129–146 HV), tensile strength (163–241 MPa), impact toughness (5.7 ± 0.1–11.35 ± 0.1 J/cm3), and corrosion resistance of the composite while the wear rate (0.37–0.11 mm3/Nm) and the mean friction coefficient (0.37 ± 0.1–0.21 ± 0.1) of the composite were significantly reduced as the number of the tool passes was increased. The 4-pass friction stir processing technique is thus recommended for the development of AA6061/316 stainless steel reinforced composites.

Effect of processing parameters and heat treatment techniques on foaming properties of aluminium foam developed by friction stir processing route

In the present research friction stir processing has been used to make the precursors. The substrate contains the foamable mixture in a pre-drilled hole and the processing has been done in the centre line of the hole. The developed precursors are then treated by two heating methods, i.e. furnace and microwave heating to produce foam. The effect of different process parameters like the number of friction stir processing passes, volume and composition of foamable mixture, and heat treatment techniques have been investigated. The porous aluminium foam has been found with pore size in the range of 0.24–1.35 mm with a proportion of pores between 41% and 56% with microwave heating, while in case of furnace heating, the pore size is in the range of 0.22–1.49 mm with proportion of pores in between 41% and 61%. Also, the results show that the foam developed in microwave heating is much faster than that of furnace heating.

Applications of reinforcement particles in the fabrication of Aluminium Metal Matrix Composites by Friction Stir Processing - A Review

Composite materials possess advantages like high strength and stiffness with low density and prove their essentiality in the aviation sector. Aluminium metal matrix composites (AMMC) find applications in automotive, aircraft, and marine industries due to their high specific strength, superior wear resistance, and lower thermal expansion. The fabrication of composites using the liquid phase at high temperature leads to the formation of intermetallics and unwanted phases. Friction Stir Processing (FSP) is a novel technique of composite fabrication, with temperature below the melting point of the matrix, achieving good grain refinement. Many researchers reported enhancement of mechanical, microstructure, and tribological properties of AMMC produced by the FSP route. The FSP parameters such as tool rotational speed, tool traverse speeds are found to be having greater impact on uniform dispersion of particles. It is observed that the properties such as tensile strength, hardness, wear and corrosion resistance, are altered by the FSP processes, and the scale of the alterations is influenced significantly by the processing and tool parameters. The strengthening mechanisms responsible for such alterations are discussed in this paper. Advanced engineering materials like shape memory alloys, high entropy alloys, MAX phase materials and intermetallics as reinforcement material are also discussed. Challenges and opportunities in FSP to manufacture AMMC are summarized, providing great benefit to researchers working on FSP technique.

Influence of reinforcement on weld bead characteristics of friction stir processed Al5083/NFA composite

Aluminum 5083 alloy has been reinforced with nano fly ash (NFA) through the friction stir processing (FSP) route to fabricate the Al5083/NFA composite. Grooves are machined with different dimensions on the Al5083 alloy plates to incorporate nano fly ash and fabricate composites carried by one pass FSP. Composites with 1, 2 and 3% wt. of NFA as reinforcement material are fabricated and the weld joints of the composites are obtained by friction stir welding (FSW). Tool rotational speeds of 1200 rpm, 1400 rpm, and 50 mm/min traverse speed are considered as FSW process parameters. The increased addition of NFA influences the mechanical properties of weld joints, and increased tensile strength and hardness were observed. It was concluded that NFA particles were most effective for improving the mechanical properties of the AMC weld beads.

Predicting the ultimate tensile strength and wear rate of aluminium hybrid surface composites fabricated via friction stir processing using computational methods

In the present study, aluminium hybrid surface composites were prepared by incorporating boron carbide (B4C) and Aluminium oxide (Al2O3) ceramic particles via the Friction Stir Processing (FSP) route. Tool rotational speed, Tool traverse speed, Axial force, and Reinforcement ratio were the chosen process parameters. Response Surface Method (RSM) based Central Composite Design (CCD) was used to conduct the experimental trials. A second-order regression equation was developed for the responses, ultimate tensile strength (UTS), and wear rate (WR). Statistical tests were performed to check the adequacy of the regression models. The effect of process parameters on the responses was studied. It was found that tool traverse speed was the most dominant process parameter, followed by tool rotational speed, axial force, and reinforcement ratio. The optimal process parameters for the responses were found using a genetic algorithm, where the regression equations from RSM were used as the objective function.

Significance of Al2O3 addition in the aluminum 6063 metal foam formation through friction stir processing route – A comprehensive study

Closed-cell porous aluminum is expected to be a prominent material in near future because of its light weight, high specific modulus of elasticity, high energy absorption efficiency and high sound-insulating capacity in the automotive and aerospace industries. Recently, a new method of foaming has been developed in which a precursor is formed using friction stir processing. In the friction stir processing route, a precursor is fabricated by embedding a mixture of blowing agent powder and stabilization agent powder into aluminum alloy plates by the significant stirring action of friction stir processing. By applying the friction stir processing route precursor method, the cost-effective Al-foam formation along with high productivity can be accomplished. In this study, titanium hydride powder has been used as the blowing agent as it is reported to be most compatible with aluminum matrix. The effect of percentage of stabilization agent, i.e. alumina powder on porosity of aluminum foams formed using friction stir processing route is analyzed. The porous aluminum formed with three different percentages of alumina is observed and their porosity is calculated. Also, the compressive performance of the obtained samples is observed in order to examine the alumina powder addition on mechanical properties of the obtained metal foam. This study aims at analyzing the significance of addition of the alumina into the blowing agent while developing the metal foam through friction stir processing route.

Improvements in mechanical properties of aluminium alloy-titanium di boride and boron carbide hybrid composite produced through friction stir processing route

Aluminium alloys finds many applications in automotive, aerospace and ship building industries. Among all series AA 5083 alloys are commonly used in ship building industry but possess inferior mechanical properties which are replaced with aluminium alloy composites due to high strength to weight ratio. The present work is focussed to produce aluminium alloy composites with hybrid reinforcement Particles using friction stir processing route. The different proportions of boron carbide and titanium di boride particles are used as hybrid reinforcement particles. The aluminium alloy composites are fabricated by different proportions of reinforcement particles. The properties of fabricated composites such as ultimate tensile strength, micro Vickers hardness and impact strength are evaluated. The mechanical properties are improved and found that highest values of mechanical properties are obtained for 75% TiB2 + 25% B4C hybrid reinforced composite. The microstructural evaluations of composites are analysed using optical and scanning electron microscopy. It is found that hybrid reinforcement particles are uniformly distributed in the stirring zone without any micro defects.

Metallurgical assessment of AA7075 – T6 with x wt% tungsten carbide nanoparticle surface composites processed by FSP route

Our proposed research works the ideal way was to improve the aluminum alloy material lifetime by incorporating nanoparticle via friction stir processing (FSP) and it was evident from augmenting metallurgical view. The experimental work was carried out by varying tungsten carbide (WC) nanoparticles of 0, 3, 6 and 9 wt% with heat treated aluminium alloy (AA7075-T6) as a matrix through FSP route. The prepared samples were further assessing the metallurgical assessment through microstructure, scanning electron microscope, x-ray diffraction, energy dispersive spectroscopy and electron back-scattered diffraction analysis. The obtained results revealed that the homogeneous distribution of WC nanoparticles in the matrix stir zone having the absence of intermetallic reactions was observed in the microstructure and x-ray diffraction test. The significant degree of grain refinement was observed in the scanning electron microscopy in which composites due to dynamic recrystallization and pinning effect of tungsten carbide particles in the matrix has occurred. Energy dispersive x-ray spectroscopy analysis and scanning electron microscope analysis indicated the presence of tungsten carbide nanoparticles along the processed region in well-defined grain boundaries and its fine spread of grains across the stir zone by dynamic recrystallization. Also, the electron backscatter diffraction study indicated the good distribution of ceramic particles spread across the stir zone. On the whole, a great significance improvement was achieved in metallurgical behavior during the 9 wt% of WC nanoparticles addition in the matrix during the FSP route. These processed surface composites were suggested for automobile and marine components processed in the future.

Influence of Silica Rich CRT and BN on Mechanical, Wear and Corrosion Characteristics of Copper- Surface Composite Processed Through Friction Stir Processing

The center of attention of current research lies on utilizing E-waste cathode ray tube (CRT) glass as reinforcement to develop copper hybrid surface composites through friction stir processing route. Pure copper is taken as base material which is reinforced with different volume % of CRT glass (5, 10 & 15) and fixed amount (2%) of BN. The particle size of the reinforced CRT and BN particles are 30 µm and 10 µm respectively. The developed surface composite was characterized for microstructure through optical microscope and scanning electron microscope, density, micro hardness, tensile properties and wears behavior. The analysis confirms the presence of reinforcements in the matrix and also evidence for recrystallization. Density of the MMC is found decreasing while the hardness increases with addition of CRT & BN. The tensile and yield strength of unprocessed Cu is superior to that of MMC whereas it enhanced with raise in reinforcement content. Wear resistance of Cu depicts incremental trend with respect to reinforcement’s addition. Scanning electron microscope was used to understand the worn out surface morphology and wear mechanism. Corrosion results depict that increase in CRT addition decrease the corrosion current density of surface composite.

Mechanical properties and microstructural analysis of friction stir processed AA6056-zirconium dioxide (ZrO2)

In this experimental investigation intended on to fabricate the aluminium alloy AA6056 with adding together of Zirconium dioxide through Friction stir processing route. The Friction stir processing is a similar way of friction stir welding process, it is forced out to mixing the Zirconium dioxide into AA6056 while in FSP. The parameters of FSP are tool speed (800, 1000, 1200 and 1400 rpm), transverse speed (60 mm/min) and tool axial force (5 kN). The mechanical properties of tensile strength are measured for the four different specimens, produced with different rotational speed. The micro hardness is measured repeatedly on the joint area and base material zone with the help of Vickers hardness tester machine. Excellent hardness values are observed in the FSP zone compare to other zones; it tells about the FSP was carried out effectively. The SEM image of the tensile specimens for it in broken area was analyzed by the way of 3D profilometry images.

Role of tool rotational speed on the tribological characteristics of magnesium based AZ61A/TiC composite developed via friction stir processing route

Purpose: A new composite material was prepared and Different properties such as hardness and tribological behaviour of the fabricated metal matrix composite (MMC) was investigated and compared with the base AZ61A magnesium alloy. Design/methodology/approach: For the current research work, state-of-the-art technology, Friction stir processing (FSP) was performed to develop magnesium based AZ61A/TiC composite at optimized set of machine parameters. Findings: Increasing tool rotational speed ultimately leads in enhanced hardness, which further gives superior tribological properties as compared to base AZ61A alloy. Wear observations suggests a combination of abrasive and adhesive wear mechanism. Research limitations/implications: More microstructural and mechanical properties can be examined. Practical implications: The idea behind selecting AZ61A is mainly due to its increasing use in bicycle pedals and military equipment’s where at certain places it needs to encounter friction. In this current work, microhardness study and wear behaviour of AZ61A/TiC composite processed via FSP were examined. Originality/value: Paper is completely new and no work has been done till date considering this material and preparing composite with nanoparticles TiC.

Characterisation of floor tiles reinforced aluminium surface composite synthesized by friction stir processing

The present work employed Friction Stir Processing route for fabricating Aluminium Surface Composite. The fine ceramic particles obtained from floor tiles were selected as the reinforcement while Al6061 alloy as the matrix material. The fabricated surface composite was further investigated for microstructure and wear characterisation. Microstructural features depicted the successful incorporation and homogeneous dispersion of floor tile particles in the aluminium matrix. The reinforced particles enhanced the microhardness value to 92 HV which was about three times more than base metal. Higher wear resistance and lower friction coefficient exhibited on addition of floor tile particles in the matrix. The least wear rate of 4.9×10−3 mg/m and friction coefficient value of 0.30 was obtained in aluminium surface composite compared to 36.21×0−3 mg/m and 0.43 respectively.

Microstructural, mechanical and wear characteristics of aluminum matrix composites fabricated by friction stir processing

Aluminum matrix composites are widely used in aerospace, automotive industry and defense sector owing to its excellent weight-to-strength ratio. Friction stir processing has emerged as an excellent technique to produce particle reinforced as well as fiber reinforced aluminum matrix composites. This article is a state of the art of aluminum matrix composite fabrication by friction stir processing route. The fabrication procedure has been discussed with carefully mentioning the parameters associated with the process. Microstructures and consequent mechanical properties of the composites have been evaluated. Particular attention is given on the microstructural modification and strengthening mechanism. Also the wear and corrosion behavior of the composites has been discussed thoroughly. Finally, the article has been concluded with some suggestions toward future work.