Comparison studies on mechanical and wear behavior of fabricated aluminum surface nano composites by fusion and solid state processing
Introduction
Aluminum matrix composites are finding high technology applications owing to their excellent mechanical, wear and corrosion resistance properties [1], [2]. The useful service life of the components depends on the surface [3], [4], [5]. Ceramic particles were reinforced into the matrix by utilizing various techniques such as coating, hard surfacing, cladding, and electron beam irradiation [6], [7]. Choo et al. [8] have deposited TiC particles on the plain carbon steel plate using high energy electron beam irradiation technique for producing the surface composite. This composite exhibited 3 to 4 times higher hardness than the base alloy due to the presence of TiC hard particles. These processes create an excellent bond between the substrate and the composite. Dubourg et al. [9] have modified the surface by addition of copper and iron powders on the aluminum surface by laser cladding. The hardness of Al/38Cu-11Fe(wt%) hardness was 550 Hv0.2 whereas the hardness of the nontreated sample hardness was 20 Hv0.2. Presence of intermetallic compounds, grain refinement and hardened surface of the Al matrix improve the hardness of the composite. TIG arc surfacing is a cost effective process. It produces high thickness surface composite layer which comprises of intermetallic compounds. Metallurgical bonding nature is the specific advantage of TIG arc surfacing [10], [11].
Recently Gandra et al. [12] have fabricated SiC composite on the AA2024-T3 substrate by employing AA6082-T6 aluminum alloy consumable rods by friction surfacing process. Faying surface of the consumable aluminum rod has been provided with a 2 mm diameter hole to a depth of 20 mm. SiC particles were packed in the hole for reinforcement during frictional surfacing. The hardness of the composite coating was 110 Hv which is 30% higher than the base alloy. Friction surfacing leads to grain refinement due to continuous and discontinuous recrystallization process. The SiC particles strengthened the coating with improved hardness and reduced wear. Jiguo et al. [13] have used TIG arc source with Ni and Al powder preplaced on the Q235 steel plate to prepare the surface with Ni-Al intermetallics. Islak et al. [11] have fabricated AISI 1060 steel/B4C surface composite by TIG arc method. Microhardness of the composite was 4 to 5 times higher than the base material. Similarly TIG arc source was used with Ti & Al powder preplaced on the Titanium substrate to form the titanium aluminide intermetallic compounds [14]. The hardness and wear resistance of the coated surface was improved about 3 to 4 times than base material. In another study conducted on AISI 8620 steel, SiC/C particles diffused on the surface by TIG arc method. The hardness and wear behavior of the modified surface was significantly improved [15].
In order to fabricate surface composite by solid state processing method, recently well known Friction Stir Processing (FSP) technique is used [16]. The composite processed through FSP can have thickness in the range of microns to several millimeters. The reinforcement particles are incorporated in the matrix by mechanical mixing without melting the substrate. Several investigators have produced the surface composite by FSP. Compared to other surface modification techniques, FSP provides better grain refinement and uniform dispersion of reinforcement particles in the matrix [17]. The reinforcement particles are preplaced in the grooves/holes on the surface of the metallic substrate plate and then processed with the FSP tool to form the surface composite [18]. Various second phase hard particles such as SiC, ZrO2, CNT, TiC, Si3N4, TiO2, B4C and Al2O3 were used as a reinforcement in FSP [19], [20]. The thermal stability of the aluminum alloy was improved by the addition of SiC into matrix [21]. The hardness and corrosive behavior of Al5083 alloy were greatly improved by the addition of SiC/CNT and CeO2 particles. The higher percentage of cerium oxide improves the corrosive resistance of Aluminum alloy [22], [23]. Soleymani et al. [24] have reported that there is a significant effect on the wear properties of the Al5083 based MoS2 reinforced composites.
Increase in number of FSP passes increases the uniform distribution of particles in the matrix and reduces the clustering effect with enhanced mechanical and wear properties [25], [26]. The application of B4C is used in the surface modification processes extensively especially to develop Al based composites. B4C has its low density (2.52 g/cm3), high hardness and excellent thermal stability. Owing to its specific properties, it finds specific applications such as neutron absorption; high wear resistance, high impact resistance, etc. [27], [28]. The present work aims to fabricate the Al/B4C surface composite by TIG arc and FSP method. The microstructural characteristics, microhardness and wear properties of the fabricated surface composites were compared. The friction and wear behavior of the composite at different sliding loads (30 N, 60 N & 120 N) were investigated and the results were compared with the base material.
Section snippets
Materials and methods
Aluminum alloy of 5083-O plate with a thickness of 8 mm having chemical composition of 4.1%Mg, 0.06%Cr, 0.5%Mn, 0.19%Fe, 0.02%Zn, 0.2%Si, 0.04%Ti (all in weight %) was used. A groove size of 1 mm width and 3 mm depth was created in the middle of the aluminum plate for TIG arc surfacing. The same groove size was used for friction stir processing also to have a same volume fraction of particles. Prior to the process, the surfaces of the aluminum plate were cleaned with acetone. To prevent the
Results and discussion
Fig. 4 shows macro images of the composite surface specimens prepared by (a) TIG arc method and (b) FSP method respectively. After a number of preliminary trials, the TIG arc surfacing process parameters were fixed. In the FSP, the tool parameters such as tool traverse speed and rotational speed are the key parameters pertaining to the material flow [29]. Heat generation during FSP in the stir zone is directly related to rotational speed and inverse of traverse speed [30]. Tmax (maximum
Conclusions
The Al-B4C nano surface composites were successfully fabricated by using TIG arc and FSP methods. The hardness and wear related properties of the composites were evaluated.
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The metallographic evaluation revealed the uniform dispersion of nano B4C particles in the fabricated composites.
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The composites produced by FSP method is having larger thickness (wider and deeper composite) when compared to TIG arc method. FSPed composites exhibited higher hardness and wear resistance than TIG arc surface
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