Fabrication of Aluminum Surface Composites through Friction Stir Deposition

Abstract

Aluminum composites are commonly used in industries such as the aircraft industry, the automotive industry the defense industry, the marine industry, and the automobile industry. Friction deposition was used to successfully create a composite of ceramic reinforcement particles. Layers were well-bounded, and extremely small in size grain, and the deposits were equally distributed and consisted of multiple layers of composite material. In this study, we use the friction stir deposition (FSD) approach to create an Al composite with the help of [Titanium diboride (TiB₂) & yttrium oxide (Y₂O₃)] Pure aluminum powder is deposited onto a mild steel substrate utilizing an AA6063 consumable rod. AA6063 consumable rods were drilled with a variety of hole designs around their periphery. In this hole, we took 3 sample rods and drilled them with Ø2.5, Ø4, and Ø5.5-millimeter diameters for (TiB₂) as well as 3 sample rods for (Y₂O₃) ceramic particles. AFS-D deposits are investigated in terms of their macrostructure, microstructure, and mechanical properties, as well as their relationship to various process parameters. Analyses using a scanning electron microscope (SEM) showed that composite material was distributed more uniformly when 4 configuration consumable rods, such as TiB₂ and Y₂O₃, were used. Equiaxed tiny grains were found throughout the composite's microstructure, indicating the existence of dynamic recrystallization during deposition. This treatment improves the material's base characteristics. Composites made from Ø4 of 4 holes of TiB₂ and Ø4 of 4-hole Y₂O₃ configurations were shown to have a longer plateau stress, which was a notable finding. Due to the material's uniform pore size, stress is gradually dispersed, increasing the material's toughness. Hardness was shown to have a non-linear relationship with TiB₂ and Y₂O₃ content at 4, thus, hardness rose up to a certain concentration but thereafter dropped. Thus, it is clear that precise modifications in TiB₂ and Y₂O₃ concentrations are required to produce optimal material characteristics, underscoring the significance of accuracy in composite formation.