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<p>In this study, in-situ AA2024–AlB₂ composites were fabricated via friction stir processing using boron powder precursors. Four tool rotational speeds (400, 800, 1200, and 1600&#xa0;rpm) were investigated at a constant traverse speed of 20&#xa0;mm/min to evaluate their influence on microstructure, particle distribution, and mechanical performance. X-ray diffraction confirmed complete transformation of boron into AlB₂ in all processed specimens. At 800&#xa0;rpm, optimal processing conditions were achieved, producing fine equiaxed grains (3.1 ± 0.1&#xa0;µm) with uniform AlB₂ dispersion, resulting in a hardness of 122.1 ± 3.3 HV₀.₁ and a 116% increase in ultimate tensile strength (456.2 ± 11.4&#xa0;MPa) compared to the base alloy (210.7 ± 10.2&#xa0;MPa). The corresponding yield strength and elongation were 83.89 ± 1.3&#xa0;MJ/m<sup>3</sup> toughness and 36.8 ± 1.1%, respectively. In contrast, higher rotational speeds (≥ 1200&#xa0;rpm) led to excessive heat input, grain coarsening (up to 5.9 ± 0.3&#xa0;µm), and AlB₂ particle agglomeration, reducing hardness to 93.6 ± 3.7 HV₀.₁ and deteriorating tensile properties.</p>

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Friction Stir Processed In Situ AA2024–AlB2 Composites: Microstructure and Mechanical Behavior

  • 期刊论文

  • 发表日期：

    2025年11月19日

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  • Mahna Nikzad-Dinan,
  • Roohollah Jamaati,
  • Hamed Jamshidi Aval

摘要

In this study, in-situ AA2024–AlB₂ composites were fabricated via friction stir processing using boron powder precursors. Four tool rotational speeds (400, 800, 1200, and 1600 rpm) were investigated at a constant traverse speed of 20 mm/min to evaluate their influence on microstructure, particle distribution, and mechanical performance. X-ray diffraction confirmed complete transformation of boron into AlB₂ in all processed specimens. At 800 rpm, optimal processing conditions were achieved, producing fine equiaxed grains (3.1 ± 0.1 µm) with uniform AlB₂ dispersion, resulting in a hardness of 122.1 ± 3.3 HV₀.₁ and a 116% increase in ultimate tensile strength (456.2 ± 11.4 MPa) compared to the base alloy (210.7 ± 10.2 MPa). The corresponding yield strength and elongation were 83.89 ± 1.3 MJ/m3 toughness and 36.8 ± 1.1%, respectively. In contrast, higher rotational speeds (≥ 1200 rpm) led to excessive heat input, grain coarsening (up to 5.9 ± 0.3 µm), and AlB₂ particle agglomeration, reducing hardness to 93.6 ± 3.7 HV₀.₁ and deteriorating tensile properties.