Investigation of microstructure and hardness of surface composite AA5086(H116)/ZrO2 and surface hybrid composite AA5086(H116)/ZrO2/Gr fabricated by friction stir processing

Authors

Abstract

      In this research friction stir processing (FSP) was used to produce surface composite layer with zirconia reinforcement particles on aluminum AA5086 alloy. The effect of the combination ratio of ZrO2/Graphite powders on microstructure and hardness of surface hybrid composite layer fabricated by friction stir processing on aluminum alloy was investigated. A H13 work steel tool with taper cylindrical  pin geometry was used to produce hybrid composite layer. The FSP parameters were 1250 RPM in rotational speed and 50 mm/min in traverse speed of tool. Microstructures of produced samples were evaluated by means of optical microscopy and distribution of particles was evaluated by scanning electron microscopy. The hardness of surface composite layer was characterized using vickers hardness test. The results revealed that FSP caused to grain refinement and by increasing the passes of process to three passes on fabricating surface composite, distribution of zirconia particles on matrix has improved. The maximum of hardness value was achieved by producing surface hybrid composite (15%ZrO2/15%Gr). X-ray diffraction studies were carried out in order to identify the phases present in the stir zone of the specimens. The results showed that no reaction occurred between the aluminum matrix and the reinforcement particles during three FSP passes.
 

Keywords


1-ف. عادل مهربان، ف. کریم زاده، م.ح. عباسی، "توسعه نانو کامپوزیت سطحی  Al/Ni–Alبر سطح آلیاژ Al6061 با استفاده از فرآیند اصطکاکی–اغتشاشی و بررسی خواص آن"،  ششمین همایش مشترک انجمن مهندسین متالورژی و انجمن علمی ریخته­گری ایران، 1391.
2-R.S. Mishra and Z.Y. Ma , "Friction stir welding and processing", Materials Science and Engineering R, Vol. 50, pp. 1– 78, 2005.         
3-N. Yuvaraj,  S. Aravinda and Vipin, "Fabrication of Al5083/B4C surface composite by friction stir processing and its tribological characterization", Journal of Materials Research and Technology, Vol. 4, pp. 398–410, 2015.
4-س. امامی، م. الوند، ت. سعید، ا. حیدر زاده، ب. اقبالی، "بررسی تاثیر سرعت چرخش و پیشروی ابزار در جوشکاری همزن اصطکاکی بر ریزساختار و سختی آلیاژ برنج تک­فازی"، ششمین همایش مشترک انجمن مهندسین متالورژی و انجمن علمی ریخته­گری ایران، 1391.
5-R.S. Mishra, Z.Y. Ma and I. Charit, "Friction stir processing: a novel technique for fabrication of surface composite", Materials Science and Engineering A, Vol. 341, pp. 307–310, 2003.
6-E.R.I. Mahmoud, M. Takahashi, T.

Shibayanagi and K. Ikeuchi, "Wear characteristics of surface–hybrid–MMCs layer fabricated on aluminum plate by friction stir processing", Wear, Vol. 268, pp. 1111–1121, 2010.
7-R. Taherzadeh Mousavian, R. Azari Khosroshahi, S. Yazdani, D. Brabazon and A.F. Boostani, "Fabrication of aluminum matrix composites reinforced with nano- to micrometer-sized SiC particles", Materials and Design, Vol. 89, pp. 58-70, 2016.
8-M.A. Baghchesara, H. Abdizadeh and H.R. Baharvandi, "Fractography of stircasted Al–ZrO2 composites", Iranian Journal of Science and Technology, Transaction B, Engineering,Vol. 33(B5), pp.453–462, 2009.
9-A.K. Bandyopadhyy, Nano Materials, New Age International Publishers, New Delhi, Second Edition, 2010.
10-S. Mitrovic, M. Babic, B. Stojanovic, N. Miloradovic, M. Pantic and D. Dzunic, "Tribological potential of hybrid composites based on zinc and aluminum alloys reinforced with SiC and graphite particles", Tribology in Industry, Vol. 34(4), pp. 177–185, 2012.
11-ش. ترابی، ح. دانش منش، م.م. مشکسار، "مقایسه خواص مکانیکی آلومینیوم خالص تجاری با کامپوزیت هیبریدی Al-1% Vol Mg-1% Vol SiC پس از فرآیند اتصال نوردی تجمعی (ARB) "، مجله مواد نوین، جلد 5، شماره2، ص21-32، 1393.
12-R.S. Mishra and M.W. Mahoney, Friction Stir Welding and Processing, ASM International, Materials Park, Ohio, 2007.
13-M. Zohoor, M.K. Beshrati Givi and P. Salami, "Effect of processing parameters on fabrication of Al–Mg/Cu composites via friction stir processing", Materials and Design, Vol. 39 , pp. 358–365, 2012.
14-A. Yazdipour,  M.A. Shafiei and K. Dehghani, "Modeling the microstructural evolution and effect of cooling rate on the nano grains formed during the friction stir processing of Al5083", Materials Science and Engineering A,Vol. 527, No. (1–2), pp. 192–197, 2009.
15-M. Peel, A. Steuwer, M. Preuss and P.J. Withers, "Microstructure, mechanical properties and residual stresses as a function of welding speed in aluminium AA5083 friction stir welds", Acta Materialia, Vol. 51, pp. 4791– 4801, 2003.
16-A. Shafiei Zarghani, S.F. Kashani Bozorg and A. Zarei Hanzaki, "Microstructures and mechanical properties of Al/Al2O3 surface nano-composite layer produced by friction stir processing", Materials Science and Engineering A, Vol. 500, pp. 84–91, 2009. 17-Z. Arifin Ahmad, M. Ambar Yarmo, F.H. Abdul Aziz, M.Y. Meor Sulaiman, B. Ahmad, K. Nizar Ismail and N. Akmar Rejab, "Formation of titanium carbide reinforced copper matrix composite by in situ processing", Advanced Materials Research,Vol. 173, pp. 111–117, 2010.
18-A. Mostafapour Asl and S.T. Khandani, "Some studies on hardness and tensile properties of surface hybrid nanocomposite of Al5083/Al2O3p/Graphitep fabricated via friction stir processing", 1st International and 6th National Joint Conference of Iranian Metallurgical Engineering Society and Iranian Foundrymen’s Society, 2012.
19-S. Shahraki, S. Khorasani, R.A. Behnagh, Y. Fotouhi and H. Bisadi, "Producing of AA5083/ZrO2 Nanocomposite by friction stir processing (FSP)", Metallurgical and Materials Transactions B, Vol. 44, pp. 1546–1553, 2013.
20-T.J. Minton, "Friction stir welding of commercially available superplastic aluminium", Ph.D. Thesis Submitted to Brunel University, Department of Engineering and Design, 2008.
21-م. مردعلی زاده، م.ع. صفرخانیان، م.ر. سلیمانی یزدی، "اثر پارامترهای سرعت پیشروی، سرعت دورانی و زاویه ابزار بر توزیع سختی در فرآیند جوشکاری اصطکاکی اختلاطی لبه روی هم آلیاژ آلومینیوم 5456"، سومین کنفرانس بین المللی مهندسی مواد و متالورژی و هشتمین همایش مشترک انجمن مهندسین متالورژی و انجمن علمی ریخته­گری ایران، 1393.
22-Y. Morisada, H. Fujii, T. Nagaoka and M. Fukusumi, "MWCNTs/AZ31 surface composites fabricated by friction stir processing", Materials Science and Engineering A, Vol. 419, pp. 344–348, 2006.
23-M. Azizieh, A.H. Kokabi and P. Abachi, "Effect of rotational speed and probe profile on microstructure and hardness of AZ31/Al2O3 nanocomposites fabricated by friction stir processing", Materials and Design, Vol. 32, pp. 2034–2041, 2011.
24-P. Asadi, G. Faraji and M.K. Besharati, "Producing of AZ91/Si composite by friction stir processing (FSP)", The International Journal of Advanced Manufacturing Technology, Vol. 51, pp. 247–260, 2010.
25-س.ه. عبداللهی، ف.ا. کریم زاده، م.ح. عنایتی، ا. تحویلیان،  "ایجاد نانو کامپوزیت سطحی Mg-Ni بر روی آلیاژ AZ31 طی فرآیند اصطکاکی اغتشاشی و ارزیابی خواص ایجاد شده "، ششمین همایش مشترک انجمن مهندسین متالورژی و انجمن علمی ریخته­گری ایران، 1391.
26-A. Mostafapour Asl and S.T. Khandani, "Role of hybrid ratio in microstructural, mechanical and sliding wear properties of the Al5083/Graphitep/Al2O3p a surface hybrid nanocomposite fabricated via friction stir processing method", Materials Science and Engineering A, Vol. 559, pp. 549–557, 2013.
27-A. Devaraju, A. Kumar, A. Kumaraswamy and B. Kotiveerachari, "Wear and mechanical properties of 6061–T6 aluminum alloy surface hybrid composites [(SiC + Gr) and (SiC + Al2O3)] fabricated by friction stir processing", Materials Research and Technology, Vol. 2(4), pp. 362–369, 2013.
28-R.W. Fonda, P.S. Pao, H.N. Jones, C.R. Feng, B.J. Connolly and A.J. Davenport, "Microstructure, mechanical properties and corrosion of friction stir welded Al 5456", Materials Science and Engineering A.Vol. 519 , pp. 1–8, 2009.