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Research Programs

Surface Composite Fabrication via Friction Stir Processing in Aluminum Cast Alloys

 

Introduction

Friction Stir Processing (FSP) is a recent outgrowth of the Friction Stir Welding (FSW) process and relies on solid-state deformation to modify the surface of the working surface/materials. FSP has been shown to locally eliminate casting defects and to refine the microstructure of alloys to improve their mechanical properties and enhance corrosion resistance. Such improvements have important implications for manufactured components for a variety of automotive and other industrial applications.

In Friction Stir Processing a rapidly rotating pin tool is plunged into the surface of the component and is traversed across the surface to carry out the needed deformation. Frictional heating and extensive plastic deformation occur in the material causing considerable changes in the traversed area. Friction stir processed zones can be produced in metallic components to depths of about 50mm below the surface with a gradual transition from a heavily worked material at the surface to the underlying original material.

OBJECTIVES

1. Confirm and evaluate microstructure evolution during friction stir processing of aluminum alloys

2. Investigate the potential of friction stir processing to form a particle-reinforced zone in standard Al cast components.

Methodology

1. Carry out critical literature review. Learn the principles of friction stir processing, the tool geometries, and the multi-applications.

2. Conduct friction stir processing experiments following two paths. First, to confirm microstructure evolution during friction stir processing, and secondly to investigate surface composite fabrication via friction stir processing.

3. Examine and evaluate microstructure and mechanical properties subsequent to friction stir processing.

4. Establish optimum parameters for both microstructure evolution and surface composites fabrication.

5. Develop predictive models for microstructure evolution during friction stir processing.

WORK PLAN

Phase I

• Establish working principles of FSP tool
• Select aluminum alloys A365, A380, 206 as experimental alloys.
• Carry out friction stir processing (FSP) experiments using selected alloys, and alternate processing parameters.
• Microstructure examination of the FSPed alloys.
• Analysis and synthesis of results.

Phase II

• Carry out surface modification experiments via a particle reinforced zone on the component surface. 
• Create particle-reinforced zone by mixing-in strengthening particles by various different routes (in-situ chemical reactions, etc.)
• Microstructure examination of FSPed alloys.
• Evaluation of mechanical properties.
• Analysis and synthesis of results.
• Establish optimum parameters for surface composite fabrication.

 

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Last modified: March 01, 2008 14:33:22