Effect of Tool Pin Shape on Defect-Free FSP and Particles Distribution in SiC/Al6061 Composites

Subject Areas : Composite materials

Morteza  Ezzati ¹ (Student, Department of Mechanical Engineering, Faculty of Engineering, Imam Khomeini International University, Qazvin, Iran.)
Parviz  Asadi ² (Assistant professor, Department of Mechanical Engineering, Faculty of Engineering, Imam Khomeini International University, Qazvin, Iran)
Mostafa  Akbari ³ (Assistant professor, Department of Mechanical Engineering, Technical and Vocational University (TVU), Tehran, Iran)

Received: 2020-07-23 Accepted : 2020-08-11 Published : 2021-01-01

Keywords: Material Flow, FSP, Pin Shape, Defect formation, Reinforcing particles distribution,

Abstract :

In this research, Al-SiC composites were produced using FSP tools with different pin shapes to investigate the distribution of reinforcing particles in the base metal. First, to obtain the optimal rotational and traverse speed and tilt angle, several tests were performed on different parameters. The results showed that the rotational speed of 1250 rpm and the traverse speed of 100 mm/min in all tools produced flawless samples. Then, tools with different tool pin profiles of triflate, cylindrical, threaded, triangular, square, and hexagonal were utilized in this study. The distribution of reinforcing particles in the base metal was studied using a light microscope. The results showed that the cylindrical tool was not able to distribute particles in the base metal even after four passes of the process and was not a suitable tool for composite production. Tools with flat surfaces, such as square and triangular tools, have performed better in distributing reinforcing particles in the base metal. The results showed that the presence of a kind of eccentricity and pulse production in these tools had improved the distribution of particles. Threaded and hexagonal tools have the best performance in the distribution of reinforcing particles in the base metal and can be introduced as a suitable tool for composite products in the FSP process. The results of this study also showed that the change in the direction of tool rotation improved the distribution of reinforcing particles in all tools.

References:

[1] N. Kumar Maurya, M. Maurya, A.K. Srivastava, S.P. Dwivedi, A. kumar, S. Chauhan, "Investigation of mechanical properties of al 6061/sic composite prepared through stir casting technique", Materials Today: Proceedings, Vol. 25, No.  2020, pp. 755-758.

[2] N.K. Chandla, Yashpal, S. Kant, M.M. Goud, C.S. Jawalkar, "Experimental analysis and mechanical characterization of al 6061/alumina/bagasse ash hybrid reinforced metal matrix composite using vacuum-assisted stir casting method", Journal of Composite Materials, Vol. 54, No. 27, 2020, pp. 4283-4297.

[3] Z.Y.M. R.S. Mishra , I. Charit, "Friction stir processing: A novel technique for fabrication of surface composite", Materials Science and Engineering, Vol. A341, No.  2003, pp. 307-310.

[4] R.S. Mishra, Z.Y. Ma, "Friction stir welding and processing", Materials Science and Engineering: R: Reports, Vol. 50, No. 1–2, 2005, pp. 1-78.

[5] M. Akbari, P. Asadi, R.A. Behnagh, "Modeling of material flow in dissimilar friction stir lap welding of aluminum and brass using coupled eulerian and lagrangian method", The International Journal of Advanced Manufacturing Technology, Vol. 113, No. 3, 2021, pp. 721-734.

[6] M.H. Shojaeefard, M. Akbari, P. Asadi, A. Khalkhali, "The effect of reinforcement type on the microstructure, mechanical properties, and wear resistance of a356 matrix composites produced by fsp", The International Journal of Advanced Manufacturing Technology, Vol. No.  2016, pp. 1-17.

[7] K. Elangovan, V. Balasubramanian, "Influences of tool pin profile and tool shoulder diameter on the formation of friction stir processing zone in aa6061 aluminium alloy", Materials & Design, Vol. 29, No. 2, 2008, pp. 362-373.

[8] H. Khodaverdizadeh, A. Heidarzadeh, T. Saeid, "Effect of tool pin profile on microstructure and mechanical properties of friction stir welded pure copper joints", Materials & Design, Vol. 45, No. 0, 2013, pp. 265-270.

[9] G. Faraji, O. Dastani, S.A. Mousavi, "Effect of process parameters on microstructure and micro-hardness of az91/al2o3 surface composite produced by fsp", J. of Materi Eng and Perform, Vol. 20, No. 9, 2011, pp. 1583-1590.

[10] M. Azizieh, A.H. Kokabi, P. Abachi, "Effect of rotational speed and probe profile on microstructure and hardness of az31/al2o3 nanocomposites fabricated by friction stir processing", Materials & Design, Vol. 32, No. 4, 2011, pp. 2034-2041.

[11] Y.-h. Zhao, S.-b. Lin, L. Wu, F.-x. Qu, "The influence of pin geometry on bonding and mechanical properties in friction stir weld 2014 al alloy", Materials Letters, Vol. 59, No. 23, 2005, pp. 2948-2952.

[12] V.M. Khojastehnezhad, H.H. Pourasl, A. Bahrami, "Estimation of mechanical properties of friction stir processed al 6061/al2o3-tib2 hybrid metal matrix composite layer via artificial neural network and response surface methodology", Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications, Vol. No.  2021, pp. 14644207211034527.

[13] M. Akbari, M.H. Shojaeefard, P. Asadi, A. Khalkhali, "Wear performance of a356 matrix composites reinforced with different types of reinforcing particles", J. of Materi Eng and Perform, Vol. 26, No. 9, 2017, pp. 4297-4310.

[14] M. Akbari, P. Asadi, "Dissimilar friction stir lap welding of aluminum to brass: Modeling of material mixing using coupled eulerian–lagrangian method with experimental verifications", Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications, Vol. 234, No. 8, 2020, pp. 1117-1128.

[15] G. Buffa, J. Hua, R. Shivpuri, L. Fratini, "A continuum based fem model for friction stir welding—model development", Materials Science and Engineering: A, Vol. 419, No. 1–2, 2006, pp. 389-396.

[16] G. Buffa, J. Hua, R. Shivpuri, L. Fratini, "Design of the friction stir welding tool using the continuum based fem model", Materials Science and Engineering: A, Vol. 419, No. 1–2, 2006, pp. 381-388.

[17] P. Chauhan, R. Jain, S.K. Pal, S.B. Singh, "Modeling of defects in friction stir welding using coupled eulerian and lagrangian method", Journal of Manufacturing Processes, Vol. 34, No.  2018, pp. 158-166.

[18] N. Dialami, M. Cervera, M. Chiumenti, Effect of the tool tilt angle on the heat generation and the material flow in friction stir welding, ed., 2019,

[19] M. Akbari, M.H. Shojaeefard, P. Asadi, A. Khalkhali, "Hybrid multi-objective optimization of microstructural and mechanical properties of b4c/a356 composites fabricated by fsp using topsis and modified nsga-ii", Transactions of Nonferrous Metals Society of China, Vol. 27, No. 11, 2017, pp. 2317-2333.

[20] M. Akbari, M.H. Shojaeefard, P. Asadi, A. Khalkhali, "Wear and mechanical properties of surface hybrid metal matrix composites on al–si aluminum alloys fabricated by friction stir processing", Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications, Vol. 233, No. 5, 2017, pp. 790-799.