The Additive Manufacturing of Aluminum Matrix Nano Al2O3 Composites Produced via Friction Stir Deposition Using Different Initial Material Conditions

Abstract

The current work investigates the viability of utilizing a friction stir deposition (FSD) technique to fabricate continuous multilayer high-performance, metal-based nanoceramic composites. For this purpose, AA2011/nano Al2O3 composites were successfully produced using AA2011 as a matrix in two temper conditions (i.e., AA2011-T6 and AA2011-O). The deposition of matrices without nano Al2O3 addition was also friction stir deposited for comparison purposes. The deposition process parameters were an 800 rpm rod rotation speed and a 5 mm/min feed rate. Relative density and mechanical properties (i.e., hardness, compressive strength, and wear resistance) were evaluated on the base materials, deposited matrices, and produced composites. The microstructural features of the base materials and the friction stir deposited materials were investigated using an optical microscope (OM) and a scanning electron microscope (SEM) equipped with an EDS analysis system. The worn surface was also examined using SEM. The suggested technique with the applied parameters succeeded in producing defect-free deposited continuous multilayer AA2011-T6/nano Al2O3 and AA2011-O/nano Al2O3 composites, revealing well-bonded layers, grain refined microstructures, and homogeneously distributed Al2O3 particles. The deposited composites showed higher hardness, compressive strengths, and wear resistance than the deposited AA2011 matrices at the two temper conditions. Using the AA2011-T6 temper condition as a matrix, the produced composite showed the highest wear resistance among all the deposited and base materials.

A Novel Friction Stir Deposition Technique to Refill Keyhole of Friction Stir Spot Welded AA6082-T6 Dissimilar Joints of Different Sheet Thicknesses

“…This reduction in thickness as a result of high accumulated plastic deformation promotes high internal strain, which increases the strength [ 48 ]. As reported in [ 28 , 29 ], the microstructure of the AA2011-T6 rod alloy shows coarse grains and the intermetallics of Al 7 Cu 2 Fe (rodlike shape) and Al 2 Cu (almost spherical or irregular shapes), as shown in Figure 11 c.…”

“…During the deposition process, the material of the rotating consumable rod is subjected to severe plastic deformation at high homologous temperatures. As a result, the material deposited by the friction stirring process undergoes dynamic recrystallization and develops a very fine grain size [ 28 , 29 ]. El-Sayed Seleman et al [ 28 ] studied utilizing the FSD process to manufacture continuous multilayer high-performance, metal-based AA2011/nano Al 2 O 3 composites using AA2011 in two temper conditions of AA2011-T6 and AA2011-O as a matrix.…”

“…As a result, the material deposited by the friction stirring process undergoes dynamic recrystallization and develops a very fine grain size [ 28 , 29 ]. El-Sayed Seleman et al [ 28 ] studied utilizing the FSD process to manufacture continuous multilayer high-performance, metal-based AA2011/nano Al 2 O 3 composites using AA2011 in two temper conditions of AA2011-T6 and AA2011-O as a matrix. The results showed that the microstructure of the starting, consumable rods, AA2011-T6 and AA2011-O, was changed from coarse grain to refined equiaxed grain throughout the deposited material.…”

“…Recently, friction stir deposition (FSD) as an additive manufacturing technology is recommended by many authors to build multilayers of different materials on various substrates [ 28 , 29 , 30 ]. This technology is a suitable technique to produce metallic parts for the automobile and aircraft industries.…”

“…This technology is a suitable technique to produce metallic parts for the automobile and aircraft industries. It is also a thermomechanical process based on the FSW principles, by adding a mechanism of material feeding to deposit alloys [ 29 , 30 , 31 ] and composites [ 28 ]. Perry et al [ 32 ] concluded that the FSD path of AA2024 Al alloy at a 300 rpm tool rotational speed, 2 mm/s travel speed, and 0.85 mm/s feed rate reveals an almost fully recrystallized microstructure.…”