Effect of tool pin profile on the microstructure and mechanical properties of friction stir processed Al6061/Al₂O₃—TiB₂ surface hybrid composite layer

Abstract

The Al6061/Al2O3–TiB2 surface hybrid composites were produced using friction stir processing. The effect of the tool pin profile was investigated on the microstructure and mechanical properties including hardness and wear resistance. For this purpose, simple cylindrical, threaded cylindrical, taper, square, and triangular pin profiles were used. X-ray diffraction analysis and transmission electron microscopy were used to characterize the used powder. Light and scanning electron microscopes were utilized for the microstructural observations of the processed samples. The results showed that the distribution of Al2O3–TiB2 particles in the specimens produced using square and triangular tool pin profiles was more uniform due to their tool geometry, which results in better stirring of the material and good material flow. Consequently, a greater reduction of particle clustering was observed, and hence the mechanical properties were enhanced. Moreover, the samples produced using square and triangular pin profiles exhibited more grain refinement than the other samples. More uniform structure, less clustering, and finer grains produced by square and triangular pin profiles caused higher hardness and wear resistance of the samples.

Estimation of mechanical properties of friction stir processed Al 6061/Al2O3-Tib2 hybrid metal matrix composite layer via artificial neural network and response surface methodology

“…As shown in Figure 2(a) and (b), the macrostructure was composed of four diverse regions, including the base metal (BM), thermomechanically affected zone (TMAZ), heat-affected zone (HAZ), and SZ. 7 , 30 The average hardness of the processed samples was clearly higher than that of the base Al matrix. The highest hardness value for most samples was obtained in the SZ, and the average measured microhardness value of the samples was used as the output for the meta-modeling.…”

“…This study used a square pin tool, which has better performance in FSP than that of tool pins with other geometries. 7 The tool was made of H13 steel, and conventional turning and milling machines were employed to form it. The required hardness of the tool was 55 (HRC), which was achieved by performing a heat treatment process.…”

“…Khojastehnezhad et al. 7 investigated the influence of the tool pin geometry on the microstructure and mechanical properties of a friction-stir-processed Al 6061/Al 2 O 3 -TiB 2 surface hybrid composite layer. In this study, simple and threaded cylindrical, taper, square, and triangular pin geometries were employed.…”

Joining of aluminium matrix composites using friction stir welding: A review

“…Tool pin profile plays an important role during the FS processing/welding and as it greatly affects the microhardness as was reported by Khojastehnezhad et al 68 while studying the effect of tool pin profile on the microstructure and mechanical properties of FSPed Al6061/Al2O3-TiB2 surface hybrid composite layer and found tool pin with square profiles produced highest values of hardness (160 HV) and attributed this improvement to more uniform distribution of Al 2 O 3 -TiB 2 and finer grain sizes.…”

Studies on microstructural characteristics and mechanical properties of hybrid Al-4032 AMC reinforced with SiC and granite marble powder

“…Careful selection of process parameters (stirrer position, stirrer rotation, stirring duration, melt temperature, and reinforcement feeding technique) is essential for the fabrication of the AMCs. powder in polymer composites, [10][11][12][13] cement and concrete composites, [14][15][16] and dental composites. 17,18 However, the research is a continuous process, and more work is required to be carried out to plug the gaps.…”