Enhancing Aluminum-Based Composite Manufacturing: Leveraging Si3N4 Reinforcement via Friction Stir Process

Abstract

In the realm of composite manufacturing, this study delves into the innovative approach of enhancing Aluminum-Based Composite Manufacturing through Si3N4 Reinforcement leveraged via Friction Stir Process (FSP). The FSP technique, executed with precision using a vertical milling machine, intricately fabricates composite materials with unparalleled properties. Meticulously chosen parameters including pin diameter, tool tilt angle, and tool profile, coupled with precise tool traversal and rotation, define the operation. The composite substrate, composed of AA 2024, undergoes stringent cleanliness protocols before Si3N4 powders are strategically placed into a designated groove on the titanium surface for processing. Microscopic examination reveals the uniform dispersion of Si3N4 particles within the aluminum matrix, profoundly enhancing mechanical properties. The tensile strength experiences a remarkable 21.45% improvement, while hardness witnesses a significant enhancement of 36.9%. Additionally, fatigue strength is notably improved by 24.12%, and wear resistance sees a substantial boost of 30.44% following Si3N4 nanoparticle integration via FSP.