Microstructural and sensor data analysis of friction stir processing in fabricating Al6061 surface composites

Abstract

Aluminium alloys, having high strength, ductility, and toughness, are useful structural materials. Composites of these with ceramic reinforcements improve the hardness and wear resistance, making them suitable for use in the aerospace and automobile industries. Since surface properties play a crucial role for most applications, the manufacturing of surface composites of aluminium alloys is recommended. For this purpose, Friction stir processing
(FSP) is being utilized nowadays. It refines the microstructure with a homogeneous dispersion of reinforcements into the matrix and improves physical properties like surface hardness, wear resistance, strength, etc., while retaining the properties of remaining volume.
The study aims to investigate and compare the temperature and vibration sensor data while manufacturing Al6061 alloy-based surface hybrid composites by using two different FSP tools. The FSP method is used for the fabrication of Al6061 alloy based composites with the copper and graphite powders mixture (1:1), reinforced into the matrix surface by using two
H13 tools with two different pin profiles - threaded cylindrical and plain cylindrical. Holes of different diameters and depths are drilled on the Al6061 matrix for reinforcement addition.
This FSP process is investigated using a thermal gun and a Cross-Domain Development kit for temperature and vibration measurement. It is verified that both the temperature and vibration values are lower in the composites fabricated by FSP tool with threaded pin profile than that by FSP tool with plain pin profile. The processed samples are later investigated for the microstructure by Field Emission Scanning Electron Microscope and Energy-Dispersive
X-Ray Spectroscopy tests. The reinforcements are dispersed more uniformly by the FSP tool with threaded cylindrical profile. This research can be used to further monitor and control properties like temperature, vibration, force, current, etc., to obtain a uniform reinforcement dispersion with improved mechanical properties during the surface composite preparation by FSP.