In this current investigation, Taguchi method is employed for the improvement of hardness and tensile strength of Friction Stir Processed (FSP) AA7075 with TiO2 reinforcement, which is potentially suited for manufacturing of components in automotive and aerospace applications. Controllable FSP process parameters like Rotational Speed (RS), Traverse Speed (TS), Tool Tilt Angle (TA) and number of passes (No. of pass) are taken into consideration. From Taguchi results, it is identified that No of pass as two, RS as 1400 rpm, TS as 28 mm min−1 and TA as 2° serves the most influencing statistical effect for yielding the hardness. Similarly for Ultimate Strength (UTS), it is identified that No of pass as one, RS as 1400 rpm, TS as 28 mm min−1 and TA of 3° are the influencing parameters. No defect like structure is apparent in the optimized specimens owing to the sufficient heat generation and stirring phenomenon. Besides, sufficient interaction between the plasticized AA7075 matrix and packed TiO2 particles in the SC eliminates the defect formation. Micrographs of the optimized specimens revealed that TiO2 particles are dispersed uniformly in AA7075 matrix with clear interface. Moreover, there is an increase in microhardness for optimized specimen compared to base specimen due to reduced grain size value and homogenous dispersion strengthening mechanism. Meanwhile, the load bearing capacity and work hardening action of TiO2 dispersoids enhances the UTS behavior of the optimized specimen.
In this work, aluminum/titanium carbide (Al/TiC) surface composite has been fabricated by friction stir processing using a novel modular Direct Particle Injection Tool (DPI–FSP). The tool has a unique feature wherein the TiC particles have been transferred from the tool itself by spring adjusted plunger movement into the matrix. The microstructural observations from optical and scanning electron microscope (SEM)-EDS results revealed the homogeneous distribution of particles in the stirred zone (SZ) and the thickness of the formed surface composite layer (SCL) is approximately 0.34[Formula: see text]mm. X-ray diffraction results confirmed that the particles are reinforced in the aluminum matrix, and no intermetallics have been formed in the composite. The microhardness of composite was increased from 68 to 135[Formula: see text]Hv, and the impact test results showed that the toughness was almost comparable to that of the base metal.
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