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<p>This study investigates the effects of 2&#xa0;wt.% B<sub>4</sub>C content with multiple friction stir processing (FSP) passes on the microstructural, mechanical, and tribological properties of Al 6063-B<sub>4</sub>C surface composite. Optical microstructure analysis revealed that adding B<sub>4</sub>C content reduced grain size to (4.41&#xa0;µm), achieving fine grains but showing particle clustering in single-pass FSP. Optimal particle distribution and mechanical performance were observed at the second pass FSP by adding B<sub>4</sub>C. SEM and EDS analysis identified intermetallic phases such as AlB<sub>2</sub> and Al<sub>4</sub>C<sub>3</sub>, improving composite hardness and wear resistance, while excessive intermetallic at third pass reduced ductility. Tensile testing showed that 2&#xa0;wt% B<sub>4</sub>C at the second pass provided the best balance between strength (225&#xa0;MPa) and ductility, while the third pass led to brittleness and fracture. Wear rate analysis demonstrated that increasing no of pass content improved wear resistance, with the lowest wear rates at the second pass, though particle agglomeration presented localized weaknesses. Overall, the second pass FSP provided optimal particle dispersion, mechanical properties, and wear resistance, while further passes led to over-processing effects. </p>

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Friction Stir Processing of Al 6063-B4C Composites: Enhancing Mechanical and Wear Properties

  • 期刊论文

  • 发表日期：

    2025年5月7日

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  • Srinivas Banothu,
  • Banoth Mohan,
  • Mukuloth Srinivasnaik

摘要

This study investigates the effects of 2 wt.% B4C content with multiple friction stir processing (FSP) passes on the microstructural, mechanical, and tribological properties of Al 6063-B4C surface composite. Optical microstructure analysis revealed that adding B4C content reduced grain size to (4.41 µm), achieving fine grains but showing particle clustering in single-pass FSP. Optimal particle distribution and mechanical performance were observed at the second pass FSP by adding B4C. SEM and EDS analysis identified intermetallic phases such as AlB2 and Al4C3, improving composite hardness and wear resistance, while excessive intermetallic at third pass reduced ductility. Tensile testing showed that 2 wt% B4C at the second pass provided the best balance between strength (225 MPa) and ductility, while the third pass led to brittleness and fracture. Wear rate analysis demonstrated that increasing no of pass content improved wear resistance, with the lowest wear rates at the second pass, though particle agglomeration presented localized weaknesses. Overall, the second pass FSP provided optimal particle dispersion, mechanical properties, and wear resistance, while further passes led to over-processing effects.