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Microstructure and Tribological Performance of Aluminum Alloy Based Hybrid Composites Produced by Friction Stir Processing

Charan G.M., Sridhar B.S.


In this study, friction stir processing (FSP) was utilized to incorporate SiC and graphite particles into the matrix of Al-2024 alloy to form surface hybrid composite. A constant tool rotation rate of 1200 rpm and travel speed of 50 mm/min has been used. The wear resistance of the processed samples improved significantly. The coefficient of friction for different speed and at a constant load shows a steady response. But by increasing the normal load, the coefficient of friction values decreased. As increasing the sliding speed, the wear volume decreased. Microstructural analyses showed a uniform distribution of reinforcement particles inside the nugget zone, and a graphite rich mechanically mixed layer on the top of worn surface. This graphite layer is considered to stifle plastic deformation and thus to improve the tribological properties. The hardness at the boundary region is low compared to the nugget zone, and it is constant; this is due to the microstructural modification in the nugget zone.

Keywords: AA-2024, friction stir processing, graphite, SiC, tribology

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