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Friction stir processing (FSP) was developed based on the same principles of friction stir welding (FSW) mainly to enhance the surface properties of various materials and to produce surface composites. In this work surface composites of AA7075 as the metal matrix that reinforced with ultra-fine sized SiO 2 particles were developed using FSP. A groo...
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A 6061 Al coating for AZ31 Mg alloy was prepared by multi-pass friction stir welding (FSW) with different travel speeds. The microstructure, mechanical properties of the interfacial region and the corrosion behavior of the coating were investigated systematically. The results indicate that the interfacial intermetallic compounds formed in the stir...
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The unique combination of very large strains, high temperatures and high strain rates inherent to friction stir welding (FSW) and friction stir processing (FSP) and their dependency on the processing parameters provides an opportunity to tailor the microstructure, and hence the performance of welds and surfaces to an extent not possible with fusion...
The widely accepted casting routes to produce metal matrix composites (MMCs) presented lot of challenges and defects which include inhomogeneous dispersion, interfacial reaction, porosity and poor wettablily. Friction stir processing (FSP) has become a popular method to produce bulk and surface MMCs. FSP was developed based on the working principle...
The present work is focused on friction stir welding and friction stir processing of dissimilar alloys due to its emerging technique applied in the wide area of applications viz., aviation, ship building, defence industries etc. In recent years, the novel solid-state joining techniques viz., friction stir welding and friction stir processing are ap...
The joining of dissimilar materials is required in many engineering and defense applications, and the conventional fusion welding often results in defective welds. The friction stir welding has minimized the welding defects, but not completed. This work focuses on the effect of friction stir processing on TIG-welded joints with filler ER 5356 to im...
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... Nakata et al. 20 reported that due to the modification of the microstructure of aluminum die casting alloy by applying the multi-pass FSP, the hardness of the material increased by 20 Vickers compared to the original sample, and the tensile strength (MPa) also increased by 1.7 times versus that of the base metal. El-Aziz et al. 21 investigated the mechanical properties of AA1075/SiO 2 composite produced using FSP. They found that the hardness of composite was improved by 10%-30% compared to that of unreinforced alloy. ...
In this study, the friction stir extrusion process as a new method was used to produce AA 1050 aluminum composite wires reinforced with silicon carbide (SiC) powder. The effect of process parameters on temperature (T), porosity (P) and ultimate tensile strength (UTS) was evaluated using the response surface method based on the Box-Behnken design. The input parameters included rotational speed (RS), extrusion force (EF) and reinforcement weight percentage (RF). Moreover, the microstructural evaluation of composite samples was conducted using optical microscope and scanning electron microscope. Finally, analysis of variance and regression analysis were used to obtain an appropriate model and confirm the accuracy of the results. The results showed that the temperature was increased by increasing the rotational speed to 1000 r/min and decreasing the extrusion force to 5.5 kN. Moreover, the lowest porosity value (averaged = 0.5%), and the highest tensile strength value (averaged = 153 MPa) were obtained at RS = 750 r/min, EF = 10.5 kN and RF = 3%. This can be attributed to the uniform distribution of reinforcing particles and strong interfacial bonding between SiC particles and the aluminum matrix. Also, the most effective parameter in the process was rotational speed which exhibited the greatest influence on P (53%) and UTS (41%) of composite samples. However, reinforcement weight percentage had the least effect on P (14%) and UTS (28%).
... There were limited publications discussing the improvement of mechanical characteristics in metal matrix composites reinforced with SiO 2 . [42,43] The base sample has a higher % elongation, indicating that the material is more ductile. The ductility of this material is decreased after FSP by a factor of 6.34 times that of the base material. ...
... Abd El-Aziz et al. [34] fabricated AA7075 alloy reinforced with SiO 2 by FSP. The microstructure showed a uniform distribution of SiO 2 particles. ...
Friction stir processing (FSP) is an efficient solid-state process for the fabrication of surface composites. In the current research, FSP has been utilized to fabricate surface composite, which comprises AA7075 alloy as base material matrix and niobium carbide (NbC) as the reinforcement particles. The tensile strength, elongation, hardness, and wear rate of AA7075-NbC surface composite that is fabricated at various combinations of FSP process parameters (tool rotation speed, tool traverse speed, and groove width) are evaluated. Hybrid polynomial—radial basis function-based models are developed to correlate the relationship between the process parameters and the properties. Also, the optimum process parameters for maximizing hardness, strength, elongation, and wear resistance are deduced. The results indicate that the FSP process window for achieving the desirable properties in the AA7075-NbC surface composite is as follows: tool rotation speed between 860 and 900 rpm, tool traverse speed between 20 and 21.3 mm/min, and groove width of 1.1 mm and 1.18 mm for tensile strength, ductility; and tool rotation speed between 811 and 1043 rpm, tool traverse speed of 56 mm/min and 60 mm/min, and groove width of 1.4 mm for wear resistance. The betterment in mechanical and tribological properties is attributed to the homogeneous dispersion of reinforcement particles.
In this work, an armor grade AA7075-T6 matrix material plate was reinforced along the surface of the material with aluminosilicate (Al2SiO5) and multiwalled-carbon nanotubes (MWCNT) using friction stir processing method. The adoption of friction stir processing overcome the difficulties like inadequate bonding strength, development of agglomeration, interface reactivity among reinforcements and substrates when employing the casting approach to impart hard / soft reinforcement particles. The friction stir processed hybrid surface composite plate was developed to enhance the mechanical and tribological property of the matrix material used in structural plate and gun barrel in defense applications. Friction stir processed AA7075 hybrid surface composite plate was tested through pin-on-disc equipment to understand the property enhancement. The test results indicate that, wear rate and friction coefficient value of the friction stir processed samples was lesser than the base material and adhesive wear mechanism was dominant in the developed materials. The microhardness, wear and friction coefficient performance of the processed surface hybrid composite material was optimized using genetic algorithm based multi-objective optimization.
