Mechanical and Tribological Behaviour of Friction-Stir-Processed Al 6061 Aluminium Sheet Metal Reinforced with Hybrid Surface Nanocomposite

Friction stir processing (FSP) is a new and unique thermo-mechanical processing technique that alters the micro-structural, mechanical and tribological properties of the material in a single pass to achieve maximum performance with low production cost in less time. In this study, the influence of the FSP on the tribological and mechanical properties in terms of hardness for commercially available Al6061 Al sheet metal reinforced with aluminium oxide -graphite (Gr) hybrid surface nanocomposite was studied and investigated. FSP was carried out at various percentages (0, 2, 4, 6, 8 and 10 wt% of , with 0.5 wt% Gr) and using process parameters such as traverse speed 60 mm/min, rotational speed 700 rpm and axial force as 7 KN by high-carbon high-chromium tool. The samples were characterized using X-ray diffraction and scanning electron microscope. The mechanical properties in terms of hardness and wear tests were carried out on the modified surfaces. It was observed that Al6061-6 Gr hybrid surface composite exhibited high hardness value of 165 BHN and low wear rate of 0.81 g/s. This was due to refined grain structure and uniform distribution reinforcement than others.