Distribution of reinforcement particles in surface composite fabrication via friction stir processing: Suitable strategy

Fabrication of metal matrix surface composites (SCs) is an emerging trend of friction stir processing applications. Key factors affecting the properties of SCs are process parameters, tool geometry, tool dimensions and reinforcement strategies. In this research, effects of different reinforcement strategies and varying tool offset positions on dispersion of reinforcement particles in the base matrix are investigated. The experiments were performed in two phases using AA6063 as base metal at constant process parameters of 1120 rpm rotational speed, 40 mm/min traverse speed and 2.5 degrees tilt angle. In the first phase, effect of six different reinforcement strategies on the reinforcement particles distribution and defect formation was studied. It was found that groove method with tool offset in retreating side (RS) exhibited better homogeneity in reinforcement distribution out of the six reinforcement strategies considered. In the second phase, effect of variation of tool offset in RS was investigated. Results from second phase of experimentation reflected that the best dispersion of reinforcement powder with larger stir zone area was found with 1.5 mm tool offset which is numerically half of the tool pin radius. The results were supported by macro and microstructural images obtained from the optical microscope and scanning electron microscope.