Optimized process parameters for fabricating metal particles reinforced 5083 Al composite by friction stir processing

Area of Science:

• Materials Science and Engineering
• Metallurgy
• Composite Materials

Background:

• Metal matrix composites (MMCs) offer enhanced strength but typically exhibit reduced ductility.
• Metal particle reinforcement presents a viable strategy to improve ductility in MMCs.
• Conventional processing methods for metal particle-reinforced MMCs are often challenging.

Purpose of the Study:

• To investigate the application of friction stir processing (FSP) for fabricating metal particle-reinforced aluminum matrix composites.
• To optimize FSP parameters for effective incorporation of nickel (Ni) particles into an aluminum (Al) matrix.
• To achieve a defect-free stir zone with uniform particle distribution.

Main Methods:

• Friction stir processing (FSP) was employed to consolidate Ni particles within an Al matrix.
• A systematic exploration of processing parameters, including tool rotation speeds (1000–1800 rpm) and traverse speeds (6–24 mm/min), was conducted.
• Both as-received coarse (70 μm) and ball-milled finer (10 μm) Ni particles were incorporated.

Main Results:

• Optimized combinations of rotation and traverse speeds were identified for successful Ni particle incorporation.
• The study demonstrated the feasibility of using FSP to create defect-free aluminum-nickel composites.
• Uniform distribution of Ni particles within the Al matrix was achieved under optimized conditions.

Conclusions:

• Friction stir processing is an effective technique for producing metal particle-reinforced aluminum matrix composites.
• Optimized FSP parameters enable the successful incorporation of both coarse and fine Ni particles.
• This approach offers a pathway to enhance MMC properties, balancing strength and ductility.