Friction stir processing (FSP) was applied to graphene nanoplatelets (GNPs) physically compacted on the surface of squeeze cast A356 alloy to incorporate GNPs within the matrix and to improve its mechanical properties. Squeeze casting resulted in finer size silicon and intermetallic compounds in cast microstructure, and subsequently FSP further refined the microstructure of squeeze cast A356 alloy, and GNP reinforced A356 alloy. The finer Si particles, intermetallics and graphene dispersed in the matrix increased the yield and ultimate tensile strength of FSP squeeze cast A356 alloy compared to the results reported in prior literature for FSP A356 alloy. Eutectic Si needles have been converted to fine spherical particles during FSP and were uniformly distributed within the nugget zone. The crystallite size of GNPs which were physically adhered to the surface of squeeze cast alloy prior to FSP decreased after FSP as a result of deformation. Thus, a combination of squeeze casting, and friction stir processing and incorporation of GNPs reinforcement in the A356 matrix is a promising route to further improve its mechanical properties.
Al alloys, despite their excellent strength-to-weight ratio, cannot be used at elevated temperatures because of microstructural instability owing to grain growth and precipitate coarsening, thus, leading to a drastic loss in their strength. In this work, we have attempted to address the issue of grain growth by introducing in-situ formed polymer derived ceramics in an Al-Mg alloy. A stable grain structure with minimal loss in hardness when exposed to 450 °C and 550 °C for 1 hour was obtained due to the particle pinning of the grain boundaries by the Zener mechanism. Table 1 Chemical composition of the as-received Al 5052 alloy.
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