Fabrication of 5052Al/Al2O3 nanoceramic particle reinforced composite via friction stir processing route

In this research, microstructure and mechanical properties of 5052Al/Al2O3 surface composite fabricated by friction stir processing (FSP) and effect of different FSP pass on these properties were investigated. Two series of samples with and without powder were friction stir processed by one to four passes. Tensile test was used to evaluate mechanical properties of the composites and FSP zones. Also, microstructural observations were carried out using optical and scanning electron microscopes. Results showed that grain size of the stir zone decreased with increasing of FSP pass and the composite fabricated by four passes had submicron mean grain size. Also, increase in the FSP pass caused uniform distribution of Al2O3 particles in the matrix and fabrication of nano-composite after four passes with mean cluster size of 70 nm. Tensile test results indicated that tensile and yield strengths were higher and elongation was lower for composites fabricated by three and four passes in comparison to the friction stir processed materials produced without powder in the similar conditions and all FSP samples had higher elongation than base metal. In the best conditions, tensile strength and elongation of base material improved to 118% and 165% in composite fabricated by four passes respectively.

► Introducing optimum FSP conditions for fabrication of a defect free SZ.
► Fabrication of Al/Al2O3 nano-composite on surface of 5052 aluminum alloy.
► Evaluation of microstructure and tensile properties of the composite and FSP zones.