Applications of reinforcement particles in the fabrication of Aluminium Metal Matrix Composites by Friction Stir Processing - A Review

Open Access

Table 3

Work reported on composite fabrication via FSP.

Base material	Tool design parameters	Operating parameters	Reinforcement	Reinforcement technique	Remarks	Reference
AA5083	SD-16 mm PD-6 mm PL-3 mm	TR-800 rpm TS-50 mm/min	Al-Co-Cr-Fe-Ni series HEA powders	Blind holes	56% increase in hardness 42% increase in yield strength, 22%increase in UTS than FSPed base alloy	[101]
AA6061	SD-14 mm PD-5 mm,PL-2.7 mm	TR-1200 rpm WS-100 mm/min	B₄C 5-7 μm	Groove	Improver wear resistance and microhardness	[31]
A356	SD-18 mm,PD-6 mm,PL=3.5 mm	TR-800,1200,1600 rpm WS-8,32,80 mm/min	B₄C −10 μm	Groove	Higher rotational to traverse speeds ratio gives optimal properties.	[39]
Al5083	SD-18 mm,PD-6 mm,PL-4.5 mm	TR-800 rpm WS-35 mm/min	CeO₂ 50 nm, SiC 80 nm	Groove	The maximum hardness and tensile strength were obtained for the composite containing 100%SiC reinforcement	[59]
AA6063	SD-18 mm,PD-6 mm,PL-5.8 mm	TR-1000 rpm WS-30 mm/min	SiC	Groove	The high value of hardness	[112]
Al7075	SD-18 mm,PD 6-8 mm,PL-5.4 mm	TR-1200,1400 rpm WS-30,40 mm/min	SiC 30-40 μm	Groove	1.65-2.15 times increase in Hardness	[113]
AA6082	SD-16 mm,PD-5 mm,PL-4 mm	TR-1250 rpm, WS-135 mm/min	Al₂O₃ 50 nm	Groove	An increase in FSP passes enhances hardness, wear resistance	[48]
AA6061	SD-27 mm,PD-10 mm,PL-3 mm	TR-480 rpm WS-203.2 mm/min	Al₂ O₃ 50 nm	Hole	The distribution of ceramic particles is more homogeneous as FSP passes increases.	[114]
AA2024	SD-25 mm PD-8 mm PL-2.5 mm	TR-900,1120,1400,1800 rpm TS-10,15,20 mm/min	Al₂O₃ 30 nm	Groove	A finer grain in second and third passes FSPed specimen, increase in ultimate tensile strength, hardness	[115]
AA6061	SD-12.5 mm,PD-5 mm,PL-2 mm	TR-1200 rpm WS-3 mm/s	Al₂O₃ 320 nm, CNT 10-20 nm	Cylindrical holes	The presence of nano-sized reinforcement led to more pronounced grain refinement.	[50]
AA8026	SD-18 mm,PD-5 mm,PL-5 mm	TR-800,1200,1600 rpm WS-40,80 mm/min	TiB₂5 μm Al₂O₃ 70 nm	Groove	Type and size of reinforcement have an impact on mechanical properties	[116]
AA6082	SD-18 mm,PD-6 mm,PL-5.5 mm	TR-1600 rpm WS-60 mm/min	TiB₂ 20 μm BN- 200 nm	Groove	The addition of reinforcement enhances wear resistance.	[47]
Al7075	SD-24 mm,PD 6-8 mm	TR-1200 rpm WS-30 mm/min	TiC 3.5 μm	Groove	Increased hardness and corrosion resistance	[117]
AA1050	SD-15 mm,PD-3 mm,PL-3 mm	TR- 1000 rpm WS-20 mm/min	TiC 10 μm	Hole	Substantial improvement in microhardness, friction factor, wears resistance.	[118]
AA5052	SD-18 mm,PD-6 mm,PL-4.5 mm	TR-700,1000,1300 rpm WS-50,65,80 mm/min	TiO₂ 2 μm	Groove	Optimal process parameter for enhancement in mechanical properties.	[66]
Al3003	SD-18 mm,PD-3 mm,PL-4.3 mm	TR-1200 rpm WS-50 mm/min	TiO₂	Groove	Grain refinement and 70% reduction in grain size	[69]
AA5083	SD-20 mm,PD-6 mm,PL-4.5 mm	TR-1600 rpm WS-60 mm/min	WC	Blind holes	Accelerated dynamic recrystallization on increasing vol. fraction and also enhanced strength and ductility	[25]
AA7075-T6	SD-18 mm PD-4 mm	TR-1200 rpm TS-20 mm/min	WC	Groove	9 wt% of WC nanoparticle addition improves metallurgical behavior in the matrix.	[119]
Al6061	SD-15 mm,PD-5 mm,PL-5.5 mm	TR-1200 rpm WS-50 mm/min	ZrB₂	Direct melt reaction	Four pass FSP improves microstructural homogeneity	[64]
Al2024-T3	SD-20.32 mm,PD-9.53 mm,PL-8.89 mm	TR-400 rpm Ws-355.6 mm/min	CNT and Al mixture	Groove	Unique dispersion of CNTs in four zones	[120]
Al5083	SD-16 mm, PD-4 mm	TR-880 rpm WS-25 mm/min	MWCNTs 150 nm	Side face groove	No agglomeration, grain size refined in composites, increase in tensile strength	[121]
AA6061	SD-18 mm, PD-6 mm,PL-5.7 mm	TR-1200 rpm TS-50 mm/min	Al₃Fe (0-15 wt%)	Addition of iron powder into molten aluminium	Elimination of casting defects, improved tensile strength, removal of the sharp edge of Al₃Fe particle	[122]

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