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<p>Friction stir additive manufacturing (FSAM) utilizes friction stir welding (FSW) and friction stir processing (FSP) method to develop three-layer laminated friction stir additive manufactured composite. FSAM process depends upon the tool pin profile and the selected process parameters. Thus, tapered square pin, tapered octagonal scrolled pin, and tapered hexagonal pin tool were selected for the stirring purpose. Tool rotational speed (1200&#xa0;rpm), transverse speed (55&#xa0;mm/min) and tool tilt angle (1˚) were the selected FSAM process parameters for the preparation of Al 6061/TiC/GS composite. Experimental results revealed that tapered octagonal scrolled pin tool gives better result in comparison with other two tools. Microscopy and SEM results confirm uniform dispersal of the reinforcements. The maximum hardness (148.25 VHN), tensile strength (387.8&#xa0;MPa), and compressive strength (138.3&#xa0;MPa) were achieved by using TOSP tool. The thermal conductivity was enhanced by 23% and was found to be 188.19 W/m-K. TOSP tool shows minimum wear loss ranging from was 4.2&#xa0;mg/m to 10.8&#xa0;mg/m. Reduction in corrosion rate was noticed for the developed material. Through EDS analysis, it was observed that Cu, Mg, Mn, and Al, etc., were found in the upper surface of developed composite.</p>

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Analysis of Tool Pin Profile Shape for Three-Layer Laminated AA 6061/TiC/GS Composite Developed by Friction Stir Additive Manufacturing Process

  • 期刊论文

  • 发表日期：

    2025年9月29日

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  • Manish Maurya,
  • Ambrish Maurya,
  • Sudhir Kumar

摘要

Friction stir additive manufacturing (FSAM) utilizes friction stir welding (FSW) and friction stir processing (FSP) method to develop three-layer laminated friction stir additive manufactured composite. FSAM process depends upon the tool pin profile and the selected process parameters. Thus, tapered square pin, tapered octagonal scrolled pin, and tapered hexagonal pin tool were selected for the stirring purpose. Tool rotational speed (1200 rpm), transverse speed (55 mm/min) and tool tilt angle (1˚) were the selected FSAM process parameters for the preparation of Al 6061/TiC/GS composite. Experimental results revealed that tapered octagonal scrolled pin tool gives better result in comparison with other two tools. Microscopy and SEM results confirm uniform dispersal of the reinforcements. The maximum hardness (148.25 VHN), tensile strength (387.8 MPa), and compressive strength (138.3 MPa) were achieved by using TOSP tool. The thermal conductivity was enhanced by 23% and was found to be 188.19 W/m-K. TOSP tool shows minimum wear loss ranging from was 4.2 mg/m to 10.8 mg/m. Reduction in corrosion rate was noticed for the developed material. Through EDS analysis, it was observed that Cu, Mg, Mn, and Al, etc., were found in the upper surface of developed composite.