No abstract

No abstract

No abstract

No abstract

Due to the limited solid-solubility of Fe and Ni in Al, coarse brittle intermetallics rich in Fe and/or Ni are inevitably formed in the as-cast microstructure of Al-Fe-Ni alloys. Upon formation, Fe(Ni)-rich intermetallics significantly deteriorate the properties and restrict the application of alloy in as-cast condition. The purpose of this study was to investigate the effect of friction stir processing (FSP) on microstructure and tribological properties of cast Al-7Fe-5Ni alloy. The dry sliding wear tests were done by using a pin-on-disk type machine under the applied pressures of 1, 2, and 3 MPa, sliding distance of 1000 m, at room temperature. According to the results, FSP (1250 rpm and 8 mm/min) effectively refined the microstructure, especially the coarse primary Al9FeNi intermetallics and eliminated the alloy casting-related defects. FSP also converted the large columnar grains of the cast alloys to the ultrafine equiaxed grains. These microstructural changes enhanced the substrate mechanical properties thereby increased its resistance against sliding-induced plastic flow, leading to the higher tribolayer stability on the surface, and accordingly, higher wear resistance. The results showed that applying 1-pass FSP reduced the wear by 13% and 53% under applied pressures of 1 and 3 MPa, respectively. The friction results also revealed that, compared with the as-cast sample, FSPed samples exhibited lower friction coefficient and friction coefficient fluctuations.

The effect of post-process aging on the microstructure and mechanical properties of multi-pass friction stir processed (FSPed) Al-4.5Cu alloy containing Si (1, 3, and 5 wt.%) was studied. According to the results, adding Si improved the fluidity and decreased the porosity content of the alloy. The addition of Si up to 3 wt.% also enhanced the mechanical properties. However, further addition of Si up to 5 wt.% impaired the tensile properties. Applying the first pass of FSP improved the tensile strength and fracture strain of the alloy containing 3 wt.% Si by 25 and 125%, respectively. However, the second and fourth pass of FSP substantially improved the fracture strain, but deteriorated the hardness and tensile strength of the alloy containing 3 wt.% Si. Post-FSP aging at 180 °C for 8 h significantly improved the mechanical properties. For instance, compared to the as-cast condition, the hardness, tensile strength, fracture strain, and toughness of post-aged four-pass FSPed Al-4.5Cu-3Si alloy increased by 107, 108, 175, and 310%, respectively. According to the fractography results, the fracture surface morphology of Al-4.5Cu-3Si alloy changed from a quasi-cleavage mode in as-cast condition to a ductile-dimple fracture mode after post-FSP aging.

No abstract

No abstract