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<p>We demonstrate a shear-deformation-driven, solid-state phase transformation pathway for the formation of an ultrafine-grained Al/Al<InlineEquation ID="IEq4"> <EquationSource Format="TEX">\(_2\)</EquationSource> <EquationSource Format="MATHML"><math> <mmultiscripts> <mrow /> <mn>2</mn> <mrow /> </mmultiscripts> </math></EquationSource> </InlineEquation>Cu composite via friction stir processing of a Cu cold-sprayed coating on an AA6061 aluminum substrate. This approach leverages the severe plastic deformation and high strain-rate environment inherent to friction stir processing to drive localized interdiffusion and solid-state reactions between the Cu coating and the Al alloy substrate. The processed surface exhibits a significant increase in hardness (<InlineEquation ID="IEq5"> <EquationSource Format="TEX">\(\approx \)</EquationSource> <EquationSource Format="MATHML"><math> <mo>≈</mo> </math></EquationSource> </InlineEquation>250 HV), compared to both the AA6061 substrate (<InlineEquation ID="IEq6"> <EquationSource Format="TEX">\(\approx \)</EquationSource> <EquationSource Format="MATHML"><math> <mo>≈</mo> </math></EquationSource> </InlineEquation>100 HV) and the as-deposited Cu coating (<InlineEquation ID="IEq7"> <EquationSource Format="TEX">\(\approx \)</EquationSource> <EquationSource Format="MATHML"><math> <mo>≈</mo> </math></EquationSource> </InlineEquation>132 HV); these measured hardness values represent an increase of 1.8-times and 2.4-times relative to the Cu CS coating and AA6061 substrate, respectively. This hardness enhancement is attributed to the uniform distribution of fine-grained Al<InlineEquation ID="IEq8"> <EquationSource Format="TEX">\(_2\)</EquationSource> <EquationSource Format="MATHML"><math> <mmultiscripts> <mrow /> <mn>2</mn> <mrow /> </mmultiscripts> </math></EquationSource> </InlineEquation>Cu reinforcement within an Al(Cu) matrix, as confirmed by transmission electron microscopy and atom probe tomography. Unlike conventional precipitation hardening, here, discrete Al<InlineEquation ID="IEq9"> <EquationSource Format="TEX">\(_2\)</EquationSource> <EquationSource Format="MATHML"><math> <mmultiscripts> <mrow /> <mn>2</mn> <mrow /> </mmultiscripts> </math></EquationSource> </InlineEquation>Cu grains are directly formed and dispersed among Al grains, resulting in a hetero-grained microstructure that transitions into a single-phase matrix below the processed zone. Our results demonstrate the potential of integrating solid-state deposition with high-speed mechanical mixing to generate unique, non-equilibrium microstructures that bypass equilibrium melting constraints and exceed the performance of conventional thermomechanical processing routes.</p>

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Ultrafine-Grained Al/Al2Cu Composite Formation via Friction Stir Processing of Cold-Sprayed Coatings

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2025年9月30日

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  • Syed Muhammad Mujtaba Rizvi,
  • Md Jasim Uddin,
  • Chris McRobie,
  • Josephine Hartmann,
  • Aniruddha Malakar,
  • Kayla Yano,
  • Dallin Barton,
  • Fu-Yun Tsai,
  • Florian Laggner,
  • Bharat Gwalani,
  • Elizabeth Kautz

摘要

We demonstrate a shear-deformation-driven, solid-state phase transformation pathway for the formation of an ultrafine-grained Al/Al \(_2\) 2 Cu composite via friction stir processing of a Cu cold-sprayed coating on an AA6061 aluminum substrate. This approach leverages the severe plastic deformation and high strain-rate environment inherent to friction stir processing to drive localized interdiffusion and solid-state reactions between the Cu coating and the Al alloy substrate. The processed surface exhibits a significant increase in hardness ( \(\approx \) ≈ 250 HV), compared to both the AA6061 substrate ( \(\approx \) ≈ 100 HV) and the as-deposited Cu coating ( \(\approx \) ≈ 132 HV); these measured hardness values represent an increase of 1.8-times and 2.4-times relative to the Cu CS coating and AA6061 substrate, respectively. This hardness enhancement is attributed to the uniform distribution of fine-grained Al \(_2\) 2 Cu reinforcement within an Al(Cu) matrix, as confirmed by transmission electron microscopy and atom probe tomography. Unlike conventional precipitation hardening, here, discrete Al \(_2\) 2 Cu grains are directly formed and dispersed among Al grains, resulting in a hetero-grained microstructure that transitions into a single-phase matrix below the processed zone. Our results demonstrate the potential of integrating solid-state deposition with high-speed mechanical mixing to generate unique, non-equilibrium microstructures that bypass equilibrium melting constraints and exceed the performance of conventional thermomechanical processing routes.