Studies on secondary processing of In situ aluminum matrix composites Reinforced with intermetallic phases Via friction stir processing for Enhancement of microstructure and Tensile behavior

Abstract

Researchers have initiated several investigations on weight reduction and developed new materials with Aluminum Matrix Composites (AMCs). The demand of modern industries have been contented with the enhanced properties of materials. Micro and nano size reinforcement particles were blended with Aluminum matrix to acquire varied properties. In recent years, vast exploration of AMCs were done by aerospace, tanker armors, electrical and automotive industries etc., Earlier SiC and Al2O3 were used as reinforcement whereas intermetallics such as Al3Ti, Al3Zr, Al3Ni, Al2Cu, Al3Fe and Al3C4 were used to overcome the drawbacks of ceramic particles. Intermetallics have high wettability, physical and thermal properties closer to aluminum which provides a better interfacial bonding. newlineIn the current investigation In-situ method is employed for casting AA6061-T6 intermetallic composites. Al3Fe, Al3Zr, Al3Ni and Al2Cu intermetallics were produced with varied content of Fe, Ni, Zr and Cu (0, 5, 10 and 15 wt.%) powders. Agitated aluminum melt was poured in a preheated permanent mould after holding for 40 minutes. As a secondary approach, multi pass friction stir processing (FSP) was performed in the casted composite. Specimens were sliced from cast and friction stir processed plate with a wire cut EDM. Mechanical and metallurgical properties were compared from both cast and FSP plates. newlineThe chemical composition of the intermetallic composites were analyzed using X-Ray diffraction (XRD) analysis. Metallurgical characterization was done using Optical Microscope (OM), Field Emission Scanning Electron Microscope (FESEM). Advanced characterization studies like Electron Backscatter Diffraction (EBSD newline