Research Papers: Other (Seals, Manufacturing)

Fabrication of Hybrid Surface Composites AA6061/(B4C + MoS2) via Friction Stir Processing

[+] Author and Article Information
Daulat Kumar Sharma

Department of Metallurgy,
Gujarat Technological University,
Ahmedabad 382424, Gujarat, India
e-mail: dgsharma@gecg28.ac.in

Vivek Patel

School of Materials Science and Engineering,
Northwestern Polytechnical University,
Shaanxi, China;
Department of Mechanical Engineering,
School of Technology,
Pandit Deendayal Petroleum University,
Gandhinagar 382007, Gujarat, India
e-mail: vivek.patel@sot.pdpu.ac.in

Vishvesh Badheka

Department of Mechanical Engineering,
School of Technology,
Pandit Deendayal Petroleum University,
Gandhinagar 382007, Gujarat, India
e-mail: vishvesh.badheka@spt.pdpu.ac.in

Krunal Mehta

Department of Mechanical Engineering,
School of Technology,
Pandit Deendayal Petroleum University,
Gandhinagar 382007, Gujarat, India
e-mail: krunal.mehta@sot.pdpu.ac.in

Gautam Upadhyay

Department of Metallurgy,
Gujarat Technological University,
Ahmedabad 382424, Gujarat, India

1Corresponding author.

Contributed by the Tribology Division of ASME for publication in the Journal of Tribology. Manuscript received December 23, 2018; final manuscript received March 2, 2019; published online March 25, 2019. Assoc. Editor: Longqiu Li.

J. Tribol 141(5), 052201 (Mar 25, 2019) (10 pages) Paper No: TRIB-18-1521; doi: 10.1115/1.4043067 History: Received December 23, 2018; Accepted March 02, 2019

Poor tribological properties restrict structural applications of aluminum alloys and surface composites of aluminum alloys have gained more attention in material processing. The addition of solid lubricant reinforcement particles along with abrasive ceramics contributes to the enhancement of tribological performance of surface composites. In the present study, the solid-state technique, friction stir processing (FSP) was used to develop mono (B4C) and hybrid (B4C + MoS2) surface composites in the AA6061-T651 aluminum alloy. The hybrid surface composites were produced by varying an amount of MoS2. Multipass FSP with different direction strategies was adopted for achieving uniform distribution of reinforcement powders in the aluminum matrix. Microstructure analysis showed a uniform dispersal of reinforcement particles without any clustering or agglomeration in the processing zone. Microhardness and wear performance of mono and hybrid composites improved in comparison with the base metal. The mono surface composite exhibited the highest hardness while the hybrid surface composite (75%B4C + 25%MoS2) achieved the highest wear resistance. This was attributed to the solid lubricant nature of MoS2. Furthermore, dissolution of the strengthening precipitate condition during multipass FSP without reinforcement particles resulted in the reduction of hardness and wear resistance.

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Fig. 1

Schematic representation of composite fabrication by (a) the holes filling method and (b) the holes filling and closing method [17]

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Fig. 2

SEM micrographs of as-received: (a) B4C and (b) MoS2 particles

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Fig. 3

(a) Tool steel pin-less tool for capping pass and (b) WC tool for stirring pass. Note: all dimensions are in millimeters.

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Fig. 4

(a) Blind-holes pattern in Al 6061 for inserting reinforcement particles before FSP and (b) the specimen cut for microstructure and mechanical properties examination after FSP

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Fig. 5

Surface morphology of FSPed samples: (a) 100%B4C, (b) 75%B4C + 25%MoS2, (c) 50%B4C + 50%MoS2, (d) 25%B4C + 75%MoS2, (e) 100%MoS2, and (f) without reinforcement particles

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Fig. 6

Macrographs of surface composites: (a) 100%B4C, (b) 75%B4C + 25%MoS2, (c) 50%B4C + 50%MoS2, and (d) without reinforcement particles

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Fig. 7

Optical microstructure of the SZ: (a) 100%B4C, (b) 75%B4C + 25%MoS2, (c) 50%B4C + 50%MoS2, and (d) without reinforcement particles

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Fig. 8

SEM micrograph showing dispersal of reinforcement particles within the matrix of the SZ: (a) 100%B4C, (b) 75%B4C + 25%MoS2, (c) 50%B4C + 50%MoS2, and (d) showing a breakdown of B4C particle in SZ of the mono surface composite

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Fig. 9

EDX elemental analysis of (a) 100%B4C, (b) 75%B4C + 25%MoS2, and (c) 50%B4C + 50%MoS2

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Fig. 10

SEM micrograph of the BM/SZ interface of (a) 100%B4C, (b) 75%B4C + 25%MoS2, (c) 50%B4C + 50%MoS2, and (d) optical microstructure of the BM/SZ interface of 75%B4C + 25%MoS2

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Fig. 11

Microhardness profile along the cross-section of FSPed samples

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Fig. 12

Microhardness distribution from the top surface of FSPed samples

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Fig. 13

Variation of material loss comparison with the sliding distance: (a) 100%B4C, (b) 75%B4C + 25%MoS2, (c) 50%B4C + 50%MoS2, (d) without reinforcement particles, (e) BM, and (f) comparison of average of three test data among the all samples

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Fig. 14

Variation of wear rate with the sliding distance

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Fig. 15

Variations of friction coefficient with sliding distance



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