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<p>The objective of this study is to enhance the microstructure, mechanical properties, and tribological performance of a 6&#xa0;mm-thick AA2024 alloy through the incorporation of B<sub>4</sub>C and Al<sub>2</sub>O<sub>3</sub> nanoparticles using multi-pass friction stir processing (MPFSP). The hybrid composites are fabricated using six FSP passes at a constant spindle speed of 800&#xa0;rpm and a traverse speed of 35&#xa0;mm/min. The research assessed composite performance using metallography, tensile testing, hardness evaluation, wear analysis, and fractographic studies. The microstructural findings indicated that MPFSP facilitated a consistent reduction in the mean grain size, decreasing from 7.18 ± 0.26&#xa0;μm after the initial pass to 2.82 ± 0.06&#xa0;μm following six passes. Electron backscatter diffraction results indicated that the fraction of high-angle grain boundaries rose from 76.49 to 95.21% after one to six passes. The ultimate tensile strength of the composite rises from 469 to 507&#xa0;MPa, while the yield strength increases from 327 to 360&#xa0;MPa. However, the elongation decreases from 6.4 to 3.1% when subjected to one pass to six passes. The hardness of the composite increases from 155 to 189 HV, while the wear depth decreases from 83 to 59&#xa0;µm when subjected to one pass to six passes. The enhanced mechanical and tribological performance of the composite is linked to grain refinement, consistent reinforcement distribution, and improved grain boundary transformations following six passes of FSP. The tensile fractured surfaces exhibited dominant ductile mode failure and the worn surface morphology showed abrasive wear, oxidation, and delamination as the primary wear mechanism caused due to thermal effects and repeated sliding cycles.</p>

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Evolution of Microstructure, Mechanical Properties, and Tribological Behavior of AA2024/B4C/Al2O3 Nanocomposites Fabricated by Multi-pass FSP

  • 期刊论文

  • 发表日期：

    2025年4月21日

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  • Md Saquib Bin Reyaz,
  • Joginder Singh,
  • Shallender Singh Bhati,
  • Husain Mehdi,
  • Subhash Mishra

摘要

The objective of this study is to enhance the microstructure, mechanical properties, and tribological performance of a 6 mm-thick AA2024 alloy through the incorporation of B4C and Al2O3 nanoparticles using multi-pass friction stir processing (MPFSP). The hybrid composites are fabricated using six FSP passes at a constant spindle speed of 800 rpm and a traverse speed of 35 mm/min. The research assessed composite performance using metallography, tensile testing, hardness evaluation, wear analysis, and fractographic studies. The microstructural findings indicated that MPFSP facilitated a consistent reduction in the mean grain size, decreasing from 7.18 ± 0.26 μm after the initial pass to 2.82 ± 0.06 μm following six passes. Electron backscatter diffraction results indicated that the fraction of high-angle grain boundaries rose from 76.49 to 95.21% after one to six passes. The ultimate tensile strength of the composite rises from 469 to 507 MPa, while the yield strength increases from 327 to 360 MPa. However, the elongation decreases from 6.4 to 3.1% when subjected to one pass to six passes. The hardness of the composite increases from 155 to 189 HV, while the wear depth decreases from 83 to 59 µm when subjected to one pass to six passes. The enhanced mechanical and tribological performance of the composite is linked to grain refinement, consistent reinforcement distribution, and improved grain boundary transformations following six passes of FSP. The tensile fractured surfaces exhibited dominant ductile mode failure and the worn surface morphology showed abrasive wear, oxidation, and delamination as the primary wear mechanism caused due to thermal effects and repeated sliding cycles.