Microstructural and Fractographic Investigation of Three-Layer Laminated AA 6061/TiC/GS Composite Produced by Friction Stir Additive Manufacturing Process

This experimental research utilizes TiC and grinding sludge (GS) an industrial waste, obtained from iron forging industry as reinforcements in AA 6061 alloy to enhance the physical and mechanical properties of the developed material. Friction stir additive manufacturing technique using stepped pin cylindrical HSS tool was used to develop three-layer laminated composite material. TiC and GS weight percentage were varied in developing the composite. Scanning electronic microscope was used to observe the microstructure. Mechanical properties such as hardness, tensile strength, corrosion and wear were investigated. Fractography analysis and EDS was conducted for the developed material. Experiment result revealed that AA6061/5%TiC/5%GS composite had achieved maximum hardness and tensile strength of 144.6 VHN and 386.3 MPa. Corrosion and wear properties of the developed material was enhanced. Fractographic results confirms that tensile test specimens were perfectly prepared. EDS mapping and spectrum confirms the existence of elements in the developed material.