Different reinforcement strategies of hybrid surface composite AA6061/(B₄C+MoS₂) produced by friction stir processing

Abstract

Aluminum surface composites have gained huge importance in material processing due to their noble tribological characteristics. The reinforcement of solid lubricant particles with hard ceramics further enriches the tribological characteristics of surface composites. In the current study, friction stir processing was chosen to synthesize hybrid surface composites of aluminum containing B 4 C and MoS 2 particles with anticipated improved tribological behavior. B 4 C and MoS 2 powder particles in 87.5: 12.5 ratio were reinforced into the AA6061 by hole and groove method. Microstructural observations indicated that reinforcement particles are well distributed in the matrix. The hardness and wear resistance of hybrid surface composites improved as compared to the base material, due to well distributed abrasive B 4 C and solid lubricant MoS 2 particles in AA6061. The hybrid surface composites achieved~32 % increased average hardness as compared to the base material. Hole method revealed~13 % better wear resistance compared to the groove method for friction stir processed hybrid surface composite, attributing to an improved homogeneity of particle distribution shown by zigzag hole pattern. Moreover, friction stir processed AA6061 without reinforcement particles exhibited reduced hardness and wear resistance due to loss of strengthening precipitates during multi-pass friction stir processing.

Understanding the effect of particle reinforcement on friction stir weldment: A review

“…It is worth noting that reinforcement done with a zigzag pattern has exhibited homogenized particle distribution more than the groove depositing type. 101 Moreover, a relatively minor groove increased tensile and bending strength. It is because when the groove is small, the availability of base material for interaction may be more, due to which sufficient plasticization occurs for material flow that causes good material mixing.…”

Experimental investigation on microstructure, mechanical and machining properties of Al‐4032/granite marble powder (GMP) composite produced through stir casting

“…In machining, a significant quantity of energy is spent to accomplish the cutting operation that is greater than other industrial practices [3,4]. Still, it is likely to cut the energy consumption in end milling operation with optimization of machining parameters [5,6].…”

Characterization of novel molybdenum disulfide and cerium dioxide reinforced hybrid aluminum matrix composites fabricated by friction stir processing

“…Friction stir processing was initially developed for grain refinement in alloys. The intensity of grain refinement is controlled by the degree of recrystallization which depends upon the amount of heat generation and cooling rate of the processed specimens [9][10][11]. However, recently this process has proven to be an excellent technique for both surface and bulk composite fabrication [12][13][14][15][16].…”