In this work, functionally graded AZ91/WC nanocomposites were produced by a
novel multi-stage reduction of chamber diameter method. The WC nanoparticles
were packed in chambers having graduated diameters and friction stir
processing was applied using tool with four-sided fluted probe. The
functionally graded nanocomposites were obtained using different tool
rotational speeds (830, 960 and 1160 rpm) with a constant traverse speed and
plunge depth of 40 mm/min and 0.1 mm, respectively. The characteristics of
the functionally graded samples and AZ91 Mg alloy were evaluated utilizing
optical and scanning electron microscopes, and energy dispersive
spectroscopy as well as other tests such as hardness, pin on disc wear and
potentiodynamic polarization tests. The results showed that ?-Mg refining
and graded distribution of WC nanoparticles were enhanced with augmenting
tool rotational speed. The hardness increased slightly with augmenting tool
rotational speed. The results also revealed that the wear rate was decreased
and corrosion resistance was improved by adding WC nanoparticles. Abrasive
wear mode was the main mode of material removal during dry sliding while
cracks and pits were the main features of corroded surface.