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DOI 10.1007/s00170-011-3758-8
ORIGINAL ARTICLE
Received: 7 March 2011 / Accepted: 7 November 2011 / Published online: 4 December 2011
# Springer-Verlag London Limited 2011
1 Introduction
The development of composite materials and the related
design and manufacturing technologies is one of the most
important advances in the history of materials. Composites
are multifunctional materials having unprecedented mechanical and physical properties that can be tailored to meet
the requirements of a particular application. The unique
characteristics of composites provide the engineer with
design opportunities not possible with conventional monolithic (unreinforced) materials. Many manufacturing proH. S. Arora (*) : H. Singh : B. K. Dhindaw
School of Mechanical, Material and Energy Engineering,
Indian Institute of Technology Ropar,
Rupnagar, Punjab 140001, India
e-mail: harpreetsa@iitrpr.ac.in
1044
2 Fabrication of composites
Metal matrix composites (MMCs) are an important class of
material for structural and electrical applications [19].
Particulate-reinforced MMCs are of particular interest
because of their easy fabrication, low cost, and isotropic
1045
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3 Fabrication of nanocomposites
In recent years, nanoparticles have been attracting increasing attention in the composite community because of their
capability of improving the mechanical and physical
properties of traditional fiber-reinforced composites [28
Material investigated
Characteristic studied
Prominent results
The SiCp could flow beyond the TMAZ under the tool
shoulder, and it covered the range of 1.5 mm apart
from the edge of the pin at the advancing side.
On the depth of 0.5 and 1.0 mm under surface, the
microhardness was steady, 10% higher than the base
metal, due to integral dispersed SiC
Lim et al. [22]
Aluminum alloys 6111 Effect of processing parameters
At a tool rotation speed of 1,500 rpm and a shoulder
T4 and 7075T6 and
on distribution of MWCNTs
penetration depth of 0.24 mm, the stir zone was free of
MWCNTs
in the composite formed
voids.
Increasing the tool rotation speed to 2,500 rpm and
the shoulder penetration depth to 0.24 mm reduced the
thickness of the lamellae.
It was suggested that multiple passes might be required to
further improve the dispersion of nanotubes in the matrix.
Ke et al. [23]
Pure aluminum plate
Microhardness and tensile strength After 3-pass FSP, the grain refinement and the
and pure nickel
precipitation hardening effect of the Al3Ni intermetallics
resulted in a significant increase in the microhardness
powder
and tensile strength of the Al Al3Ni composites.
Dixit et al. [24]
Aluminum alloy 1100
Mechanical properties of the
The embedded particles were uniformly distributed and
and NiTi powder
composite formed
had strong bonding with the matrix, and no interfacial
products were formed during the processing.
Both the experimental and the modeled values showed
improved mechanical properties in the prepared
composite in the form of enhanced modulus, yield
strength, and microhardness values
Asadi et al. [25]
Magnesium alloy AZ91 Microstructure evaluation of the
It was found that decreasing the rotational speed and
and SiC powder
FSPed zone and the distribution
increasing the linear speed led to a decrease in the grain
of the SiC particles in SZ
size.
PD was found to be an effective parameter to produce
sound surface layer.
PD value was found to be influenced by traverse and
rotational speeds and tilt angle.
Mahmoud et al. [26] Aluminum alloy 1050Wear behavior of SMMC
It was found that addition of reinforcement powder
H24 and SiC, Al2O3
(SiC, Al2O3, or mixture) was beneficial in reducing the
powders
wear volume loss, especially at relatively low loads.
Alidokht et al. [27] Aluminum alloy A356, Microstructure and tribological
FSPed A356 displayed higher hardness compared with
SiC and MoS2 powders performance using dry wear
the as-cast A356.
tests conducted on pin-on-disk It was found that both the extent of wear and wear rate
Tribometer
were significantly lower in the FSPed A356 and the
composite samples as compared with the as-cast A356.
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SiO2 in volume fraction after four FSP passes were 1.8 and
0.8 m, respectively. The resulting grain size was significantly refined from the initial grain size of 75 m for the
AZ61 billet. Improvement in mechanical properties was
also observed. The yield stress of the FSP composites was
improved to 214 MPa in the 1D (one groove) and to
225 MPa in the 2D (two groove) specimens, compared with
140 MPa of the as-received AZ61 billet and 147 MPa of the
FSPed AZ61 alloy without silica reinforcement. The
ultimate tensile strength (UTS) was also appreciably
improved in the composite specimens. The tensile elongation of the 2D and four-pass composites at 350C reached
350% at 1102 s1 and 420% at 1101 s1, clearly
exhibiting high strain rate super plasticity.
Microstructures and mechanical properties of the Al/
Al2O3 surface nanocomposite layer produced by FSP were
analyzed by Zarghani et al. [35]. Commercial 6082 Alextruded bar with a thickness of 7 mm and nanosized Al2O3
powder with an average diameter of 50 nm were used as
substrate and reinforcement particulates, respectively. The
hardened H-13 tool steel pin was 5 mm in diameter, and its
length was about 4 mm. The pin rotation was set to be
1,000 rpm, and its advancing speed was 135 mm/min. To
insert nanosized Al2O3 powder, a groove with a depth and
width of 4 and 1 mm, respectively, was machined in which
the desired amount of Al2O3 powder was filled in. To
prevent sputtering of powder and its ejection from groove
during the process, the groove's gap initially was closed by
means of a tool that only had shoulder and no pin. Samples
were subjected to various numbers of passes from one to
four, with and without Al2O3 powder. After each pass, an
ambient air cooling was applied. Optical micrograph of the
as-received 6082 Al is shown in Fig. 3a. The grain size of
the 6082 Al matrix was refined using the FSP, as shown in
Fig. 3b. In comparison with the surface composite layer
produced by one FSP pass, the surface composite layer
produced by three FSP passes showed a better dispersion of
Al2O3 particles. There were just a few regions that included
the aggregated nanosized Al2O3 particles. On the other
hand, a good dispersion of nanosized Al2O3 particles,
which were separated from each other, could be observed
for the surface composite layer produced by four FSP
passes, as shown in Fig. 3c. As reported by other
researchers [36, 37], it was suggested that the grain
refinement during FSP was caused by dynamic recrystallization. However, the FSP with the nanosized Al2O3
particles more effectively reduced the grain size of the
6082 Al matrix in which some grains were less than
300 nm, as shown in Fig. 3c and 3d. It was considered that
the pinning effect by the nanosized Al2O3 particles retarded
the grain growth of the 6082 Al matrix.
The typical microhardness readings observed by the
authors in the central cross-sectional zones of the friction
1049
1050
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Material investigated
Characteristic studied
Prominent results
Effect of processing parameters The addition of the MWCNTs promoted grain refinement
on microstructure, grain
by the FSP.
refinement, and
Good dispersion of the MWCNTs was obtained for the
microhardness
sample FSPed at 25 mm/min and 1,500 rpm.
The FSP with MWCNTs increased the microhardness
of the substrates
Microstructural observations of The yield stress of the FSP composites was improved
Lee et al. [34]
Magnesium alloy AZ61
the nanocomposite formed
and SiO2 nanoparticles
to 214 MPa in the 1D (one groove) and to 225 MPa
and
in the 2D (two groove) specimens, compared with
mechanical properties
140 MPa of the as-received AZ61 billet and 147 MPa
of the FSPed AZ61 alloy without silica reinforcement.
Grain refinement by multipass The surface composite layer produced by three FSP
Zarghani et al. [35]
Aluminum alloy 6082
FSP, microhardness, and wear passes showed a better dispersion of Al2O3 particles.
and Al2O3 powder
behavior of surface composite Almost a three-time increment of the hardness of the
formed
parent Al alloy was achieved.
It was observed that wear resistance against a steel disk
was significantly improved (two to three times) in the
Al/Al2O3 surface nanocomposite layer produced by four
FSP passes compared with the as-received Al.
Yang et al. [38]
Aluminum alloy 6061
Effect of axial force and
Larger axial force makes the expanded AMCZ and
and nano-Al2O3 particle
multipass, hardness values in
bonding of AMCZ increases with number of passes.
the composite zone formed
Pores became smaller and more distributed.
FSZ had higher hardness values than other zones due to
refined grain size via dynamic recrystallization.
Sharifitabar et al. [39] Aluminum alloy 5052Grain size refinement and
Multiple-pass FSP with the nanosized Al2O3 particles
H32, Al2O3 powder
elongation
more effectively reduced the grain size of the 5052Al
matrix, which ranged from 5.5 to 0.94 m.
It was observed that an increase in the FSP pass from one
to three caused improvement of elongation, especially for
stir zone produced without powder. However, elongation
decreased in both samples produced by four passes.
Microhardness of the composite It was found that with an increase in FSP passes, the
Asadi et al. [40]
Magnesium alloy AZ91,
formed
average grain size of the SZ decreased.
SiC and Al2O3 powders
The average hardness of as-cast AZ91 alloy was found to
be 63 HV, which increased to a range from 90 to115 HV
with SiC addition and about 105 HV with Al2O3 addition
after two passes.
Mazaheri et al. [41] Aluminum ally A356
Vickers microhardness
The average microhardness values for A356Al2O3 and
and Al2O3 powder
A356nAl2O3 surface composites were about 90 and
110 HV, respectively
Hsu et al. [42]
Aluminum and titanium
Microstructural observations
Very fine Al3Ti particles less than 100 nm in size were
powder
and mechanical properties
formed.
It was concluded that the Al3Ti particle size was
affected by both the Ti content and the FSP parameters.
The Youngs modulus of the AlAl3Ti composites
increased significantly with increasing volume fraction
of Al3Ti.
Hsu et al. [43]
Aluminum and copper
Microstructural observations
Particles less than 100 nm were formed.
powder
and mechanical properties
The composite possessed enhanced Youngs modulus
and good strength with reasonable good compressive
ductility.
Zhang et al. [44]
Commercial pure Al
YS, UTS, and uniform
FSP-water sample exhibited much higher YS and UTS
powder and TiO2
elongation
as compared with FSP-air sample due to finer grain size.
powder
Uniform elongation decreased to 6.8%.
Bauri et al. [45].
Commercially pure Al,
Microhardness and tensile tests Microhardness after second pass increased to 58 VHN
K2TiF6 salt and
of the composite formed
from 38 VHN.
1054
Table 2 (continued)
Investigator name
Material investigated
graphite powder
Characteristic studied
Prominent results
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