Fabrication of Surface-Hybrid-MMCs Layer on Aluminum Plate by Friction Stir Processing and Its Wear Characteristics

Abstract

Aluminum-base hybrid composites reinforced with mixtures of SiC and Al 2 O 3 particles 1.25 mm in average size have been fabricated on an A 1050-H24 aluminum plate by friction stir processing (FSP) and their wear resistance has been investigated as a function of the relative weight ratios of the particles. A mixture of SiC and Al 2 O 3 powders of different weight ratios was packed into a groove of 3 mm width and 1.5 mm depth cut on the aluminum plate, and covered with an aluminum sheet 2 mm thick. A FSP tool of square probe shape, rotated at a speed of 1500 rpm, was plunged into the plate through the cover sheet and the groove, and moved along the groove at a travelling speed of 1.66 mm/s. After the hybrid composite was fabricated on the Al plate, the homogeneity of the particles distribution inside the Al matrix has been evaluated from the macro/microstructure and hardness distribution. Moreover, the wear characteristics of the resulted hybrid composites were evaluated using a ball-on-disc wear tester at room temperatures at normal loads of 2 and 5 N. As a result, it was found that the reinforcement particles were distributed homogenously inside the nugget zone without any defects except some voids that appeared around the Al 2 O 3 particles. The average hardness decreased with increasing the relative content of Al 2 O 3 particles. Regarding the wear characteristics, the wear volume losses of the hybrid composites depended on the applied load and the relative ratio of SiC and Al 2 O 3 particles. The hybrid composite of 80% SiC þ 20% Al 2 O 3 showed superior wear resistance to 100% SiC and Al 2 O 3 or any other hybrid ratios at a normal load of 5 N.

Wear properties of friction stir processed AISI D2 tool steel

“…Under dry sliding, all FSPed samples lowered friction coefficient compared to the BM. Same results of reducing the friction coefficient with FSP were reported by Aldajah et al [10] in FSP of 1080 carbon steel and by Mahmoud et al [11] for hybrid composite of Al 2 O 3 /SiO 2 -Al. It can also be observed that the friction coefficient of all FSPed samples exhibits fluctuations.…”

The effect of SiC particles on the microstructure and mechanical properties of friction stir welded pure copper joints

“…hardness than the base metal (BM) and much improved wearresistant properties [9,10]. Recently, it was found that the particles can also be used to refill the gap or pores in the workpiece by a novel technique called friction stir powder process (FSPP), which was developed based on the principle of FSW.…”

Surfacing – Technologies and Layer Properties (A Review)

“…The specific in this case is that no heating is required for the deposition of the bed, and the thermal treatment is at relatively low temperatures (2900C). Both in this case and in the friction stir surfacing (FSC) [43], [44], [45], [46], [47], the melting temperatures of the substrate are not reached. Therefore, diffusion processes have a significant effect on the final result.…”