Fabrication Of Surface Composites Research Articles

Development of Machine Learning Regression Models for the Prediction of Tensile Strength of Friction Stir Processed AA8090/SiC Surface Composites

Abstract Friction Stir Processing is a state-of-the-art technology for microstructure refinement, material property enhancement, and fabrication of surface composites. Machine learning approaches have garnered significantinterest as prospective models for modeling various production systems. The present work aims to develop fourmachine learning models, namely linear regression, support vector regression, artificial neural network andextreme gradient boosting to predict the influence of FSP parameters such as tool rotational speed, tool traversespeed and groove width on ultimate tensile strength of friction stir processed AA8090/SiC surface composites.These models were developed through Python programming and the original dataset was divided into 80% for the training phase and 20% for the testing phase. The performance of the models was evaluated by root mean squared error, mean absolute error and R2. Based on the results and graphical visualization, it was observed that the XGBoost model outperformed other models with high accuracy in predicting UTS of AA8090/SiC surface composites.

SURFACE MODIFICATION AND SURFACE COMPOSITES DEVELOPMENT TECHNIQUES FOR BIOCOMPATIBLE AND BIODEGRADABLE ALLOYS

The degradation control of implants has now become a most critical factor for investigation. The rapid degradation or uncontrolled degradation of metals causes allergic reaction and implants failure. The biocompatibility and biodegradability of biometals are essential properties for the development of bioimplants. The biodegradation is the chemical reaction of implants metal with the surrounding body fluids. The gradual dilution of metal oxide with the body fluid is considered as a degradation. Magnesium, zinc, and iron metals are biodegradable metals. The biodegradability of as-cast metals is not capable of fulfilling the need of patients, therefore, degradation of implants is required to be in control. Many more research articles have been published on improvement of corrosion resistive implant surface by coating, passivation oxide layer, plasma spraying, electropolishing, blasting, chemical etching, laser treatment, heat treatment, severe plastic deformation (SPD), alloying, and development of surface composites. This paper critically reviewed the surface modification and surface composite fabrication techniques to improve the biodegradability, biocompatibility, and strength of implants.

A Review of Magnesium Based MMC Fabrication Techniques for Biomedical Applications

The magnesium is selected for the future implants material due to its excellent biocompatibility behavior. The biodegradable and biocompatible nature of Mg and its alloy make it prime choice for the development of bio-implants. The mechanical properties of Mg are similar to natural human bone therefore it can be used for temporary implantation for supporting a fracture bone. The rapid biodegradation of pure Mg before the healing time, raise the requirement to develop a metal matrix composites of Mg. The prominent technique of MMC fabrication is friction stir processing (FSP). The FSP is widely used for fabrication of surface composites and also used for grain structure refining and strengthening. The current article reviewed the various surface composites of Mg developed by FSP for alteration of biodegradation and mechanical properties. .

Fabrication of Surface Metal Matrix composite of AA7075 using Friction Stir Processing

Friction stir processing (FSP), a process, derived from the friction stir welding (FSW) process, is an emerging novel, green and energy efficient processing technique to fabricate surface composite. In the present investigation, the FSP technique has been used for the fabrication of surface composites, usingAluminium Alloy 7075 as parent metal and Titanium Dioxide and Silicon Carbide powder particles as reinforcement. Aluminium Alloy 7075 has been selected as the matrix phase, as being widely used by the automotive and aerospace application and has the highest strength among all commercial Al alloys. In present work details about the fabrication of surface composites using various reinforcement combinations like AA7075-TiO2, AA7075-andAA7075-SiC,TiO2+SiC at constant tool rotation, tool travel speed and number of passes have been discussed. The same being intended to improve hardness. It is observed that the average hardness of friction stir processed surface composite was 4 higher than that of parent metal.

Fabrication of Surface Metal Matrix Composite of AA7075 using Friction Stir Processing

Friction stir processing (FSP), derived from the friction stir welding (FSW) process, is an emerging novel, green and energy-efficient processing technique to fabricate surface composite. The FSP technique has been used in the present investigation to fabricate surface composites, using Aluminium Alloy 7075 as parent metal and Titanium Dioxide and Silicon Carbide powder particles as reinforcement. Aluminium Alloy 7075 has been selected as the matrix phase, as being widely used by the automotive and aerospace application and has the highest strength among all commercial Al alloys. The present work details the fabrication of surface composites using various reinforcement combinations like AA7075- TiO2, AA7075- and AA7075- SiC, TiO2+SiC at constant tool rotation, tool travel speed and the number of passes have been discussed. The same being intended to improve hardness and thereby wear resistance. The fabricated surface composites are examined for microstructure using an image analyzer and found friction stir processed zone with fine microstructure than the base material. It is also observed that the average hardness of friction stir processed surface composite was higher than that of parent metal. Wear Resistance is found to be improved compared to the parent metal. It is found that Tensile strength is also enhanced than the base material.

Effect of process parameters on surface composite fabrication of newly commercialized Mg-ZE41 alloy by friction stir processing (FSP): microstructural development and microhardness

PurposeAltering the microstructure and developing the surface metal matrix composites (MMCs) in a solid-state by friction stir processing (FSP) has been on trend for the past decade. The microstructural modification increases the material properties, which are structure sensitive. The microstructural evolution is highly influenced by the selection of process parameters in FSP. In this study, the effect of process parameters on the microstructure evolution and microhardness of the fabrication of surface MMCs of newly commercialized Mg-ZE41 alloy by the incorporation of different reinforcement particles such as ZrO2, CeO2 and Al2O3 is investigated.Design/methodology/approachBy making use of Taguchi’s design of experimentation, which recognizes the crucial factors and ascertain their effect on the properties of the material, the optimization of process parameters for this study was done using MATLAB-14 software. The parameters were adopted along with the levels throughout the FSP for the fabrication of different surface MMCs. For each reinforcement particle, two factors at three levels each had L9 factorial design were used to analyse the effect of these factors on the processing result (microstructure, grain refinement and hardness). The two different factors used in this study are tool rotational speed (TRS) and tool traverse speed (TTS) as a part of the full factorial design matrix for different surface MMCs.FindingsAmong all combinations, TRS of 1500 rpm and TTS of 20 mm/min. for ZE41-ZrO2 MMCs and ZE41-CeO2 MMCs were observed as optimum to produce defect-free processed zone along with the high level of grain refinement and hardness, whereas for ZE41-Al2O3 the same was obtained at 1500 rpm TRS and 10 mm/min TTS.Originality/valueIn this paper, the role of process parameters in the development of surface MMCs on newly commercialized Mg-ZE41 alloy by FSP is investigated. The effect of TRS and TTS on microstructure evolution, grain refinement and microhardness is analysed. Hence, in this study, the optimum parameters for the fabrication of surface MMCs of Mg-ZE41 alloy have thus been established.

Fabrication of surface composites on different aluminium alloys via friction stir process - A review report

ABSTRACT Friction stir processing (FSP) is used to enhancing the hardness, tensile strength, corrosion and wear resistance of the substrate by changing the microstructure and through reinforcing the surface with hard-particles. In this paper, the available literatures have been carefully scrutinised and systematically categorised into FSP process and its resulting effects on the different grades of aluminium-based metal matrix composites (AMMCs). The effect of various reinforcements on AMMCs is also discussed. The objective of this paper is to review the various FSPed AMMCs fabricate at different operating conditions under various FSP parameters and summarise their effects on the microstructure and final properties of surface composites. Improvement in mechanical properties, corrosion resistance and wear resistance were observed. Fine grains of 100 nm to 400 nm in size were obtained in AA7075-T6 matrix after multi-pass FSP with rapid cooling. In AA7075/9 wt% TiB2 SCs, the grain size reduces from 335 µm (cast AA7075) to 6.3 µm, UTS increased to ~237%, hardness increased to ~246% and wear rate reduced to ~47% as compared to cast AA7075. This review paper will be helpful to new researchers working in the field of FSP, as it comprises significant knowledge related to AMMCs through FSP.

A review of recent progress in the fabrication of surface composites through friction stir processing

The development of surface composites is an effective tool to encounter surface-related issues, and during the recent past, friction stir processing has been developed as an energy-efficient process to fabricate surface composites effectively. FSP is an evolving thermo-mechanical surface modification technology that removes casting defects locally, refines micro-structures, improves various mechanical properties like hardness, wear resistance, strength, etc., without affecting the bulk properties. Nowadays, besides low strength metal systems, i.e., aluminum and magnesium-based alloys, FSP has been reported for making surface composites of high strength alloys like steel and titanium-based alloys. The effect of process variables and tool geometry on surface composites of different alloys have been reviewed largely, but presently we are away from obtaining desired composites. For the whole understanding of FSPed surface composites, this review consolidates different aspects of fabricated surface composites, effects of process parameters, different reinforced particles, number of passes during fabrication of surface composites, tool wear and tool materials, strengthening mechanisms for of FSPed surface composite including gaps in recent works and possible suggestions for obtaining cost-effective and defect-free FSPed composites.

Influence of process parameters of friction stir processing on the fabrication of metal foam

Friction stir processing is one of the most effective technique for the fabrication of surface composites by the insertion of reinforced particles on various materials such as aluminium, copper, magnesium etc. Being a green manufacturing technique, it is extensively explored for surface and microstructural modification as well as for the enhancement of mechanical and tribological properties of the material. Nowadays this technique is found very promising for fabrication of metal foam. In friction stir processing, a specially designed non-consumable tool is used for the stirring action over the base material under the appropriate conditions and generate sufficient pressure and temperature through the friction. Current study is focused about the influence of process parameters of FSP/W on the microstructural behaviour and mechanical properties such as hardness, wear, compressive and tensile strength of the fabricated metal foam. Metal foams are light in weight with very high value of compressive strength and hardness. Wide application of metal foams can be seen in the automobile and aerospace industries. In the given review some future aspects of the FSP are also discussed.

The study of mechanical and metallographic properties of friction stir processed AMMCs using different reinforcement

Friction Stir Processing (FSP) is a novel solid-state process that is used to fabricate the surface composites using various types of reinforcement materials like Al2O3, BN, CNT and many more. The inclusion of reinforcement can play important role while deciding hardness, tensile strength, wear resistance and other properties. The reinforcement reduces the grain growth of base metal, which also improves the hardness. Reinforcements like graphite acts like self-lubricating agent which affect wear resistance properties drastically. The microstructure of the fabricated composite gets more homogeneous by varying process parameters which improves the mechanical, corrosion and other properties of the base metal. The proposed work focused upon the critical review of the work done in the field of surface composite fabrication done on base metal of aluminium with Al2O3, SiC, fly ash, CNT etc. as the reinforcement material. The formation of intermetallic like Al2Cu, Al3V, Mg2Cu etc. during the FSP also affects the mechanical as well as the electrical properties of the fabricated AMMCs. So, the nature of reinforcement particles influenced the microstructural, micro-hardness and tribological characteristics of the fabricated composite.

Investigating the effects of tool offset distance and SiC particles on microstructural and mechanical properties of AA6082/SiC composites via friction stir processing

Fabrication of surface composites (SC) is an emerging trend in friction stir processing. The several factors that influence the properties of SC are reinforcement approaches, tool dimensions, process parameters and tool geometry. In this study, the effects of reinforcement approaches and tool offset positions on the distribution of reinforcing particles in the base alloy matrix were examined. The experiments were conducted in 2 batches using AA6082-T6 (base material). They were carried out at constant process conditions of 920 rpm tool rotation and 20 mm/min transverse speed. In the first batch, the effect of the hole reinforcement approach with tool offset on the distribution of reinforcement particles and the formation of defects were investigated. In the second batch, the effect of groove reinforcement with tool offset was studied. The groove method with a tool offset distance of 0.75 mm in the retreating side (RS) showed better homogeneity in the distribution of reinforcement particles without defects. The observed mechanical properties were corroborated with macro and microstructural characterization obtained from optical microscopy and scanning electron microscopy.

Fabrication and multi-objective optimization of friction stir processed aluminium based surface composites using Taguchi approach

Friction stir processing is a technique for the modification and fabrication of surface composites. Surface composites of aluminium have a diverse application in industries like aerospace and automobile. Here, B4C nano-particles (< 30 nm) have been employed as the reinforcement on AA7075 based substrate alloy and surface composites have been constructed at varying Tool rotation and Tool traverse speeds. The influence of these varying factors on the ultimate tensile strength (UTS), microhardness (Hv) and residual stress (RS) have been studied. Taguchi L9 orthogonal array was used for the DOE and the changes in the mechanical properties of these nine samples with regards to the tool rotation speeds of 800 rpm, 1000 rpm and 1200 rpm and the tool traverse speeds of 40 mm min−1, 50 mm min−1 and 60 mm min−1 were investigated. It was found that between the two processing variables, Tool traverse speed was the more significant variable. 800 rpm and 60 mm min−1 were determined to be the optimum parameters for Friction stir processing and the predicted values of microhardness (Hv) through Taguchi analysis were the most accurate.

Investigation on the microstructure, microhardness, and tribological behavior of AA1100-hBN surface composite

Abstract Aluminum alloy AA1100 has less wear resistance and mechanical properties than that of other aluminum alloys. This research work is on the fabrication of surface composites of AA1100 alloy by friction stir processing (FSP). The surface composites are fabricated by reinforcing hBN (hexagonal Boron Nitride) in AA1100 alloy to improve the mechanical and tribological properties. The influence of process parameters, rotational speed (rpm), and transverse speed (mm/min) on the microstructural evolution and properties of the fabricated surface composites is investigated.

Al-Based Surface Composites and Strengthening Of Welded Joints Through Multi-Pass FSP Technique: A Review

Friction stir processing (FSP) is a microstructural modifying technique that uses the same principles as the friction stir welding technique. FSP technique can be employed on the same surface repeatedly as desiredand this repetition is called multi-pass friction stir processing (MFSP). The recent developments have shown that MFSP technique is very useful towards uniform dispersion of reinforcement particles during fabrication of surface composites. Some studies have also demonstrated that MFSP technique can be employed on welded joints as a way of improving the mechanical properties of the welded joints. This paper reports on the progress made in using the multi-pass friction stir processing (MFSP) technique in producing aluminium-based surface composites. It further looks at the progress made in using the MFSP on aluminium-based welded joints. An effort is made to identify the gap that requires some exploration for the better utilization and understanding of this technique

Crack Repairing of Aluminum Alloy 6061 by Reinforcement of Al&lt;sub&gt;2&lt;/sub&gt;O&lt;sub&gt;3&lt;/sub&gt; and B&lt;sub&gt;4&lt;/sub&gt;C Particles Using Friction Stir Processing

Crack repairing of aluminum alloys is done using conventional welding techniques or mechanical methods, which results in the redundancy of mechanical properties due to defects formation. Friction Stir Welding/Processing (FSW/FSP) is a solid-state joining technique which is used to join various different similar and dissimilar metals, along with the fabrication of surface composites to cater the mentioned problem. The objective of this study is to repair the crack produced in 6061 aluminum alloy by the reinforcement of ceramic particles, Al2O3 and B4C, to further increase the efficiency of the joint along the crack line. Weld parameters, equipment used and the processing conditions are emphasized. The mechanical testing and the characterization of the weld as well as base metal was done and compared using tensile testing, micro hardness test and microstructural analysis. X-Ray Diffraction (XRD) was performed for crystallinity and intermetallic study. The dispersion of the particles was investigated using Field Emission Scanning Electron Microscope (FESEM). The crack in the Al-6061 was effectively repaired using FSP. The reinforced samples showed improved mechanical properties as compared to non-reinforced ones.

Surface Composite Fabrication by Friction Stir Processing: A Review

Newer materials with unique properties are needed to cater the ever-increasing industrial demands to meet new challenges concerning technological advancements. Quest for special materials and processes is prevalent as conventional materials fail to level up. Composite materials promisingly bridge this gap by providing controllable properties at reasonable costs. Their scope of application can further be drastically enhanced by subjecting them to special surface processing treatments. Friction stir processing (FSP) is one such promising process that can meet the stringent applicational demands. Composites are increasingly being used in industries for properties like high strength to weight ratio, increased hardness, stiffness, ductility, corrosion resistance, etc. FSP, a solid-state material modification technique, has proved its caliber in surface composite fabrication. Some attention-seeking advantages of FSP include peerless efficiency, less tool wear rate, and ability to modify material locally are some of many attention-seeking advantages. Despite being cost-effective FSP also manages to eliminate the drawbacks of the conventional manufacturing process. FSP reinforces a special material into the parent material surface to attain specific properties. Properties so developed depend on parameters like: tool geometry, traverse speed, rotation speed, number of passes etc. The present paper aims to review comprehensive information on fabrication of surface composites by FSP, process parameters, properties, industrial applications, and future scope. Key Words: Friction stir processing surface processing treatments surface composites material modification process parameters.

Characterization of A356/(fly ash + red mud) surface hybrid composite fabricated by friction stir processing

Friction stir processing (FSP) is considered as a potential technique for fabrication of surface composites due to its solid-state nature along with its capability to modify microstructural features. In the present investigation, emphasis was on utilization of wastes (fly ash and red mud) as reinforcements instead of costly ceramics for surface composite fabrication in order to reduce overall cost along with environmental threats. Equal proportions of fly ash and red mud particles were reinforced on the surface of as cast A356 alloy to fabricate A356/(red mud + fly ash) hybrid surface composite via FSP. Microstructural features revealed evenly dispersed particles throughout the stir zone with an excellent bonding. Defects such as clustering, segregation along grain boundaries and pores at the interface were not observed. Compositional analysis indicated peaks related to matrix and reinforced particles only. Hardness and tensile strength in the stir zone improved significantly in comparison of as cast A356 alloy. This may be ascribed to grain refinement, uniform distribution of particles in the matrix and good interfacial strength between matrix and particulates.

An experimental and simulation validation of residual stress measurement for manufacturing of friction stir processing tool

Residual stresses have been considered to be an important parameter when friction stir processing (FSP) tool is to be manufactured. FSP has often been used for surface modification and fabrication of surface composites. Involuntary residual stress in a designed tool may cause it to fail before due time. Because of this, the knowledge about the stresses on the tool probe after its machining has been considered to be desirable. The present research has focused on the analysis of the residual stresses on the tip and periphery of the FSP tool probe which has been manufactured using H13 tool steel material during the turning processes on a CNC lathe machine. The experiments have been performed on two different types of tool probes, namely circular, tapered circular probes. ABAQUS/CAE simulation has been performed for circular and tapered circular probe, as the provision of a sustainable, simple and reasonable model to analyze the machining processes (using ABAQUS/CAE software) has been the primary objective of this research. The results have been found to be within a close range of the experimental observations. The same model can thus be applied to other geometries.

Optimization of coating thickness and coating width for friction surfaced Al6061-B4C over Al6061

Friction surfacing is a surface composite fabrication method performed by coating a layer of mechatrode on the substrate. It is a solid-state coating processes used mainly for protecting the surface from wear, corrosion and also to repair the damaged surfaces or worn-out parts. In this investigation Al 6061-B4C composite consumable tool was coated over the Al 6061 substrate. The composite consumable tool was fabricated by stir casting process with Al6061 reinforced with weight percentage of B4C 0, 3, 6, 9 and 12. Based on the Taguchi method a 25-run was experiments performed. Four parameters and 3 levels were considered for investigation. The parameters considered for investigation are weight % of B4C, rotational speed, traverse speed and axial load. The output parameters measured are coating thickness and coating width. Uncertainty analysis (standard JCGM 100:2008 (Type ‘A’)) was performed for the measured value to ensure precision. And in addition, grey relational analysis was used to optimize coating thickness and coating width with the condition smaller the better. From the uncertainty error analysis, it was observed that the precision of both coating thickness and coating width was less than 5%. It can be observed from the results that for process parameters weight % of B4C, rotational speed, traverse speed and axial load both coating thickness and coating width were predicted to be 2.7 mm and 19.05 mm.

Surface integrity of metal matrix nanocomposite produced by friction stir processing (FSP)

Friction-stir processing is considered a green manufacturing process of surface composite fabrication and surface modification. Surface integrity includes different parameters such as roughness, topography, microhardness, and chemical analysis, which is one of the primary features of FSP. The goal of this research is to evaluate the surface integrity of FSP on aluminum matrix nanocomposite. The main parameter effects, including rotational speed, pass number, and the traverse speed on the surface roughness, surface topography, microhardness, and chemical analysis, were studied compressively. The obtained result revealed that the model of the quadratic polynomial is fitted to predict surface integrity. Furthermore, the results showed that the pass number and rotation speed 45.7% and 21.2%, respectively, have the most impact on surface roughness. The most impact on hardness belonged to traversing speed with 55%. Such a way, energy-dispersive spectroscopy analysis revealed that in the traverse speed 50 mm/min the microhardness achieve 127.24 Vickers.