Investigating the Effective Factors for Enhancing the Optimization of Al۶۰۶۱/۸Al۲O۳-۳WC-۸SiC Composite Using the Friction Stir Process

Friction Stir Processing (FSP) is an advanced solid-state technique widely recognized for its ability to enhance the microstructural and mechanical properties of materials, particularly in the fabrication of surface composites. This study investigates the application of FSP to fabricate a surface composite based on Al۶۰۶۱ alloy, reinforced with ۸% Al₂O₃, ۳% WC, and ۸% SiC particles, aiming to improve its mechanical performance. A series of experiments was conducted to evaluate the effects of varying rotational and linear speeds on the processed samples. The results revealed an ۸۹% reduction in grain size within the stir zone, decreasing from ۹۲ ± ۸ µm to ۱۰ ± ۱ µm, accompanied by a significant increase in hardness from ۴۴ HV₅₀ to ۶۱ HV₅₀, representing a ۳۸.۶% improvement. Increasing the number of FSP passes further enhanced hardness, with values of ۵۳ HV₅₀, ۶۰ HV₅₀, and ۶۱ HV₅₀ for one, two, and four passes, respectively, indicating a ۱۵.۱% increase. A consistent ratio of ۲۵ between rotational and traverse speeds was identified for aluminum alloy ۶۰۶۱, emphasizing the importance of precise parameter control. The optimum processing parameters were determined to be a rotational speed of ۱۰۰۰ rpm, a traverse speed of ۴۰ mm/min, and four passes. Moreover, the incorporation of reinforcing particles significantly improved hardness, increasing from ۵۰ HV₅₀ to ۶۱ HV₅₀, a ۲۲% enhancement, highlighting their critical role in strengthening the material. These findings demonstrate the potential of FSP as a highly effective method for optimizing material performance, offering valuable insights for applications in industries such as automotive, medical, and railway transportation.

کلیدواژه ها:

Friction stir processing ، ۶۰۶۱ aluminum alloy ، Hardness test ، Composite