Investigating effects of process parameters on microstructural and mechanical properties of Al5052/SiC metal matrix composite fabricated via friction stir processing

Friction stir processing (FSP) is a novel process for refinement of microstructure, improvement of material’s mechanical properties and production of surface layer composites. In this investigation via friction stir processing, metal matrix composite (MMC) was fabricated on surface of 5052 aluminum sheets by means of 5 μm and 50 nm SiC particles. Influence of tool rotational speed, traverse speed, number of FSP passes, shift of rotational direction between passes and particle size was studied on distribution of SiC particles in metal matrix, microstructure, microhardness and wear properties of specimens. Optimum of tool rotational and traverse speed for achieving desired powder dispersion in MMC was found. Results show that change of tool rotational direction between FSP passes, increase in number of passes and decrease of SiC particles size enhance hardness and wear properties.

► Al5052/SiC surface composite layer was successfully fabricated via FSP.
► FSP with nano-sized SiC particles generated an ultrafine microstructure.
► Hardness was significantly enhanced with addition of SiC powder.
► In comparison with base material, nano composite layer had nine times lower wear rate.