Influence of tungsten disulfide particles (WS2) on the friction and wear behavior of Mg-AZ91 forms the objective of this work. Friction stir processing (FSP) has been used to fabricate FSP AZ91/WS2 composite with various FSP passess. The microstructures were studied using a scanning optical microscope (OM), Electron Backscatter Diffraction (EBSD), and electron microscope (SEM). Hardness is measured using Vickers's microhardness tester. The impact of WS2 on the friction and wear resistance of Mg-AZ91 were evaluated using a pin on disc apparatus under dry sliding conditions. The microstructure showed the grain refinement of FSP AZ91/WS2 composite, due to severe plastic deformation and dynamic recrystallization. An increase in the FSP passess has transformed the grain size from micron to nano level. The hardness of FSP AZ91/WS2 composite is increased to 122 HV, from 62.2 HV0.3 of Mg-AZ91. The improvement in the hardness is due to reinforcement of WS2 and grain refinement. A significant improvement in the friction and wear resistance was achieved for Mg-AZ91 composites in contrast to FSP AZ91 and AZ91. SEM micro images showed the transfer of wear mechanism from severe adhesive wear to mild adhesive wear.
The present research work demonstrates the effect of friction stir process (FSP) and its process parameters (rotation speed and travel speed) on the microstructure evaluation, microhardness and wear behaviour of FSPed AA6082. The microstructure characterization of the processed samples was examined using the Optical Microscope (OM). Dry sliding wear test was carried out by varying the sliding velocity (0.5, 0.75 and 1.0 m s−1) and applied load (5, 10 and 15N) using the pin on disc apparatus. Wear mechanisms experienced by the FSPed AA6082 were mapped, and the optimal FSP and wear parameters have been determined using Taguchi analysis. The results showed that there is a significant improvement in the microhardness (92 HV
0.3) and wear resistance for RS 1250 rpm & TS 40 mm min−1 due to the grain strengthening mechanism and microstructure modification. Formation of oxide layer played a crucial role on the wear resistance of the FSPed AA6082 and its significance has been discussed elaborately using the Scanning Electron Microscope (SEM) and Energy Dispersive Spectroscopy (EDS).
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