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Friction stir processing (FSP) is an emerging novel, green and energy efficient processing technique to fabricate surface composites which is based on the basic principles of friction stir welding. The distinct advantages of friction stir processing are microstructural refinement, densification, homogeneity, accurate control and variable depth of t...
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The effect of deformation twinning on microstructure refinement was investigated for Fe-38Mn alloy during friction stir processing. It was proved that the friction stir processing microstructure of Fe-38Mn alloy was gradient distribution. The stir zone contained both recrystallized grains and fine deformed grains with average grain size of about 15...
The effect of friction stir processing (FSP) on the structural quality was tested in two A356 alloy ingots: conventional and continuously cast. Reduced pressure tests and microstructural analysis showed that the initial quality and microstructure in the two ingots were significantly different. The structural quality, as measured by the quality inde...
![Fig. 2. Dimensions of tensile specimen [6].](publication/335027554/figure/fig2/AS:789430289838081@1565226256736/Dimensions-of-tensile-specimen-6_Q320.jpg)
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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... this technique does not require any filer material hence it is easy to welding aluminum alloy and property of base material can be improved [5]. Ramesh and Murugun, [6] obtained FSW joints of Al 7075 with mechanical strength 62% higher than that of base metal. Chandrasekhar Sannapu and Murahari kolli [7] found that that the pin profile and rotational velocity influenced the material flow in FSW joints. ...
Joining of metal is very important operation in every manufacturing activity. Conventional welding of Al alloys by Tungsten inert gas welding, Metal inert gas welding and Resistance spot welding was reported to produce poor quality weld joints, as the inherent characteristics of the base metal affected the weld properties. Friction stir welding, identified as one of the best alternative is employed to join Al 5083 and Al 6061 in this study. Aluminum alloys, Al 5083 and Al 6061 are welded in lap joint configuration, with SiC nano particles interlayer. The process parameters such as welding speed tool, rotational speed and volume percentage of Nano-powder were optimized by utilizing Response surface methodology, RSM. The joints welded without the SiC nano particle interlayer were observed to possess low mechanical strength at the best welding conditions determined by the RSM.
... The microhardness value showed a fall in value an increment in rotational speed while an increase in hardness of Al-SiC/Al 2 O 3 prepared specimen was an outcome of pinning effect of a hard SiC and Al 2 O 3 particles. Ramesh et al [21], investigated a method to increase the surface hardness of a surface composite using FSP. The matrix material was AA7075-T651 and the reinforcement used was B 4 C. ...
In the present research study, Friction stir processing (FSP) has been utilized to prepare nano surface composites, AA7075 based matrix was reinforced with B 4 C nanoparticles (size <30 nm). The aim of this study is to form a thin layer of B 4 C over the surface of AA7075 based matrix material through Self-Assembled Monolayer (SAM) technique followed by Friction stir processing. The major advantage of SAM is to minimize the quantity of B 4 C nanoparticles used in the preparation of nano surface composites. Additionally, this research also investigates the effect of tool rotation speed of Friction stir processing on mechanical and wear properties of processed nano surface composite. The results observed a uniform dispersion of nanoparticles in the processed nano surface composite and an improved value of microhardness with maximum value was found to be 185 Hv of the sample processed at 1200 rpm, compared to base metal. For the constant load, as FSP tool rotation speed increases, wear resistance increases from 1000 to 1200 rpm and decreases slightly for 1400 rpm. Scanning Electron Microscope (SEM) micrograph, tensile test and Field Emission Scanning-Electron Microscope (FESEM) fractography image used to study microstructure and the mechanical properties of processed nano surface composite. The x-ray Diffraction (XRD) showed the presence of B 4 C nanoparticles. Processed nano surface composites can be used for aircraft and automobile industry applications.
... Optical Microscope (OM) and SEM was used to investigate the distribution of Al2O3 particles and precipitate alloys in nugget zone (NZ), heat affected zone (HAZ), thermomechanically affected zone (TMAZ) and base alloys. Vickers microhardness test was done to evaluate surface hardness with 500 g load and 15 sec dwell time, [14]. Eleven readings (one in the center and five from each side using step of 2 mm) and the average values were considered for further analysis and discussion. ...
Friction Stir Processing (FSP) technology was wielded to output the Al7075/ Al2O3 surface composite. The effects parameters of processing method on particle distribution have been studied. The microstructure and mechanical characteristics of the samples were examined using the optical microscope, SEM and hardness examination. Acquired consequences, showed that Al2O3 particles were in a good interior distribution inside the basement. This technique produced excellent bonding between the surface composite and the base material. On other hand the surface hardness was increased about 25% as compared with the substrate. In addition, grain matrix refinement and enhanced particle distribution were obtained after each FSP pass. Also the dispersion of Al2O3 particles in the stirred area became more homogeneous and the average hardness improved by increasing the number of passes.
... 17,18 Therefore, it is expected that aluminum surface composite containing B 4 C particles provide more hardness compared with others. Ramesh and Murugan 19 showed that fabricating Al7075/B 4 C surface composite via FSP enhanced hardness by 62%. Ranna et al. 20 demonstrated the effect of travel speed on the microstructure and abrasive properties of Al7075/B 4 C surface composites. ...
Al7075/B 4 C surface composites were fabricated by friction stir processing using four passes. The B 4 C powders were added into the prepared grooves with 1 and 2 mm width at the surface of Al7075 alloy in two different manners. In the first one, the B 4 C powders were added prior to the four consecutive passes in one stage. In the second manner, the powders were added in two stages, prior to the first pass and following the second one. The microstructural evaluations showed that the increase in the volume fraction of reinforcement significantly reduced the matrix grain size. Meanwhile, the reinforcement had a more homogeneous and uniform distribution in the samples processed through four consecutive passes. The maximum hardness and wear resistance was achieved in the one-stage powder-added samples, containing higher volume fraction of the reinforcement. A direct relationship was observed between the wear resistance and the composite layer hardness. The wear mechanism in the Al7075 substrate and the non-reinforced friction stir processed sample was the delamination of unstable aluminum oxide tribolayer. However, in the composite samples, a mechanically mixed layer, containing aluminum, chromium, and iron mixed oxides was formed along with B 4 C on the worn surface. In the two-stage powder-added samples, containing lower amounts of reinforcement, the detachment of mechanically mixed layer resulted in three-body abrasive wear condition and high friction coefficient. However, the most stable mechanically mixed layer was formed on the surface of the one-stage powder-added sample containing higher amounts of B 4 C.
... 17,18 Therefore, it is expected that aluminum surface composite containing B 4 C particles provide more hardness compared with others. Ramesh and Murugan 19 showed that fabricating Al7075/B 4 C surface composite via FSP enhanced hardness by 62%. Ranna et al. 20 demonstrated the effect of travel speed on the microstructure and abrasive properties of Al7075/B 4 C surface composites. ...
... Authors were observed that the Compressive strength improved from 330 N/mm2 to 355 N/mm2 for 7 wt% and 9 wt% of B 4 C particles respectively. It has been studied for Al6061 alloy after addition of B4C [23]. The comparative studies have been done for Al7075 and Al6061 alloy matrix hybrid composite. ...
Present study emphasizes the recent developments in aluminium metal matrix hybrid composites which is used widely in aerospace and automobile engineering due to low wear rate, low thermal expansion, high hardness and strength properties. Present review paper discuss over mechanical as well as tribological properties of Al-B4C composites fabricated through stir casting route. Aluminium metal matrix composites (AMMCs) are establishing extensive thought for realistic as well as essential reasons for tribological importance. Moreover, for superior properties in AMMCs, very limited experimental data is available because of the difficulties in the homogeneous mixing of reinforcements in composite. In this study, effect of B4C on Aluminium/aluminium alloy matrix has been reviewed and the future scope has been presented.
... Properties of B 4 C ceramic particles[15] ...
In the present investigation, rice husk waste from rice mill was utilized in the development of aluminum based green metal matrix composite. Response surface methodology (RSM) was employed to develop green metal matrix composite by considering tensile strength as a response. Rice husk ash (RHA) was used as primary reinforcement material and B 4 C was used as a secondary reinforcement material in the development of composite. Microstructure results showed a uniform distribution of RHA and B 4 C in aluminum based matrix material. The optimum combination of reinforcement parameters was found to be RHA weight percentage of 7.8%, RHA preheats temperature of 231.12 ∘ C, B 4 C preheats temperature of 435.24 ∘ C and B 4 C wt.% of 6.67% respectively to achieve a tensile strength of 249.867 MPa.
... Metal Matrix Composites (MMC), especially aluminum based Metal Matrix Composites, strengthened with ceramics particles production were created as another option to materials with better quality, a good weight proportion and quality to cost proportion, high firmness, and great solidness, which impact on enhancing wear resistance, hardness and erosion resistance. Be that as it may, these composites likewise experience the poor effects of toughness and low ductility because of the ceramics reinforcement [ 1]. ...
... FSP forms a region termed the Stirred zone, where the refinement of microstructure takes place making equiaxed fine grains with high grain boundaries. Figure 2.2 shows the step by step technique of Friction Stir Processing [1]. ...
... In study of Sert and Celik [17] they uses groove to insert SiC size (1)(2)(3)(4)(5) µm into Al7075-T651 matrix according the four step procedure, the results shows composite surface has microhardness values less than the base metal hardness. The SiC particles aggregated in the groove region at the stirred zone. ...
FRICTION STIR PROCESSING (FSP) IS A DEVELOPING NEW, VITALITY PROFICIENT AND GREEN PROCESSING METHOD TO CREATE COMPOSITES SURFACE, WHICH DEPENDS ON THE ADDITIVE AND BASE MATERIALS AND ITS CONTACT MIX BONDING. APPLICATION OF ALUMINUM ALLOYS IN MARINE, AEROSPACE FRAMES, STRUCTURES, TRANSPORTATION, AND EXTREMELY STRESSED PARTS.
IN THIS BOOK , COMPOSITE SURFACE IS FABRICATED SUCCESSFULLY BY DIRECT FRICTION STIR PROCESSING (DFSP).
... In these situations, it is desirable that only the surface layer of components is reinforced by ceramic phases while the bulk of components retain the original composition and structure with higher toughness. Friction stir processing (FSP) has evolved as a novel solid state, low-energy consumption route to prepare surface composites [30][31]. FSP has been used in various types of particle (SiC, B 4 C, TiC, WC and Al 2 O 3 ) reinforced copper composite materials. ...
... Nevertheless, the reinforcing particles deposition method is relevant in terms of structural and chemical homogeneity, agglomeration free and depth of the modified layer which influence the final surface performance [41]. Different methods for depositing reinforced particles have been reported such as (i) mixing reinforcing particles or powders with a volatile solvent such as methanol or a lacquer, in order to form a thin reinforcement layer, preventing reinforcing powders to escape [30,42] (ii) machining grooves of required depth and width in the substrate, compact with reinforcing particles and process the zone with a non consumable FSP tool in a single pass or in multiple passes along the groove [32][33][34][35][36][37][38][39][40] ,(iii) mixing reinforcing particles with substrate powders and coated on the substrate surface using thermal spray system and process the coated zone [43,44] and (iv) designing a net of blind holes of required diameter and depth in the substrate, compact with reinforcement particles, plunge the tool and traverse along the FSP direction [57,58]. [45][46][47][48][49] have successfully applied the FSP technique to fabricate copper based surface metal matrix composites (SMMC) in recent times. ...
Friction stir processing (FSP) is a green, energy efficient, one-step, solid-state surface modification technique. FSP is an emerging metal working technique and an effective method for producing fine-grained structure and surface composite, modifying the microstructure of materials, and synthesizing the composite. The objective of this review article is to provide the current state of understanding and development of friction stir processing technology on copper. This paper also presents the critical reviews on copper based particulates reinforced surface composites using friction stir processing route by various researchers in recent years. The researcher's findings with influencing parameters for obtaining successful copper based surface composites are given and discussed.
... They have compared the hardness of composite with the base metal Al 7075, which was atleast 1.5 times higher. R. Ramesh et al. [4] has studied the hardness and thereby wear resistance at various combination of rotational speed, travel speed and no. of passes for Al 7075/B4C surface composite fabricated using FSP. They found that the average hardness of friction stir processed surface composite was 1.5 higher than that of the base metal aluminium 7075 -T651. ...
Friction stir processing (FSP) is an emerging novel, green and energy efficient processing technique to fabricate surface. The working principle of process is based on friction stir welding. In the present work, FSP technique were used for fabrication of Aluminium 7075 based surface composites, reinforced with Boron Carbide (B4C) particles. 7xxx Al alloy matrix composites, which show the highest strength of all commercial Al alloys and widely used for automotive and aerospace applications. This paper provides the details about the fabrication of Al 7075-T651-B4C surface composite for various combination of tool rotation, tool travel speed and number of passes, which were intended to improve hardness and thereby wear resistance. A tungsten carbide tool having conical profile was used. The fabricated surface composites were examined using image analyzer and found defect free friction stir processed zone. It was also observed that B4C particles were uniformly distributed and well bonded with the matrix alloy. It was observed that the average hardness of friction stir processed surface composite was 1.4 – 1.6 times higher than that of base metal. The increase in hardness was attributed to B4C particles dispersed in aluminium matrix. From the various combination of tool travel, tool rotation and number of passes, an optimized condition has been derived for maximum hardness.
