Indian Journal of Engineering & Materials Sciences

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Experimental Investigation on the Synthesis of Al5086-GRN-ηSiC Hybrid Surface Composite Using Additive Powder Fed Friction Stir Processing


Affiliations
1 School of Mechanical Engineering, Lovely Professional University, Phagwara Punjab 144 411, India
2 Mechanical Engineering, University Institute of Engineering and Technology, Panjab University Chandigarh 160 014, India
 

In the current research work, graphene (GRN) and nano-silicon carbide (SiC) reinforced Al5086-alloy based hybrid surface composites has been developed using a unique surface engineering technique called additive-powder-fed friction stir processing (APF-FSP) process. Herein, the mechanical exfoliation of graphite into GRN has been carried out using APF-FSP process to improve the microstructural and mechanical properties. The microstructure, morphology, and mechanical properties of as-synthesized hybrid Al5086-GRN-ηSiC surface composite has been investigated. Microscopic analysis has been conducted to scientifically ascertain the grain size, crystal structure and surface morphology of APF-FSP zone. The mechanical properties such as hardness and elastic modulus have also been evaluated using nanoindentation and micro-hardness technique. Nano-indentation and micro-pillar testing techniques have been used to assess mechanical properties in terms of hardness, elastic modulus, and compressive strength of as-developed hybrid Al5086-GRN-ηSiC surface composite. The best optimal condition to obtain the defect free structure is 1800 RPM rotational speed and 40 mm/min transverse speed with trapezoidal shape tool pin geometry. The microstructure and morphological examination reveal that the grain size of Al-matrix gets refined from 30 µm to ~8 µm and reinforcements (GRN/ ηSiC) are uniformly distributed in the matrix, which is expected to improve the mechanical properties. The SEM and TEM morphology analysis show that the diphasic nano-mixture cluster of ηSiC and GRN in the range (100-200 nm) have been formed and GRP co-exist in multi-layer of atoms in Al-matrix owing to mechanical exfoliation of graphite. The highest hardness (145 HV0.3) and tensile strength (385±5 MPa) have been obtained. Overall, findings of this work conclude that APF-FSP offers up new possibilities for fabricating functionalized surface composites with improves mechanical properties for aerospace and automobile industries.

Keywords

Al5086 Alloy, Additive Powder Fed, Friction Stir Processing, Surfaces, Composite Materials, Hardness.
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  • Experimental Investigation on the Synthesis of Al5086-GRN-ηSiC Hybrid Surface Composite Using Additive Powder Fed Friction Stir Processing

Abstract Views: 101  |  PDF Views: 56

Authors

Gagandeep Singh Raheja
School of Mechanical Engineering, Lovely Professional University, Phagwara Punjab 144 411, India
Chander Prakash
School of Mechanical Engineering, Lovely Professional University, Phagwara Punjab 144 411, India
Shankar Sehgal
Mechanical Engineering, University Institute of Engineering and Technology, Panjab University Chandigarh 160 014, India

Abstract


In the current research work, graphene (GRN) and nano-silicon carbide (SiC) reinforced Al5086-alloy based hybrid surface composites has been developed using a unique surface engineering technique called additive-powder-fed friction stir processing (APF-FSP) process. Herein, the mechanical exfoliation of graphite into GRN has been carried out using APF-FSP process to improve the microstructural and mechanical properties. The microstructure, morphology, and mechanical properties of as-synthesized hybrid Al5086-GRN-ηSiC surface composite has been investigated. Microscopic analysis has been conducted to scientifically ascertain the grain size, crystal structure and surface morphology of APF-FSP zone. The mechanical properties such as hardness and elastic modulus have also been evaluated using nanoindentation and micro-hardness technique. Nano-indentation and micro-pillar testing techniques have been used to assess mechanical properties in terms of hardness, elastic modulus, and compressive strength of as-developed hybrid Al5086-GRN-ηSiC surface composite. The best optimal condition to obtain the defect free structure is 1800 RPM rotational speed and 40 mm/min transverse speed with trapezoidal shape tool pin geometry. The microstructure and morphological examination reveal that the grain size of Al-matrix gets refined from 30 µm to ~8 µm and reinforcements (GRN/ ηSiC) are uniformly distributed in the matrix, which is expected to improve the mechanical properties. The SEM and TEM morphology analysis show that the diphasic nano-mixture cluster of ηSiC and GRN in the range (100-200 nm) have been formed and GRP co-exist in multi-layer of atoms in Al-matrix owing to mechanical exfoliation of graphite. The highest hardness (145 HV0.3) and tensile strength (385±5 MPa) have been obtained. Overall, findings of this work conclude that APF-FSP offers up new possibilities for fabricating functionalized surface composites with improves mechanical properties for aerospace and automobile industries.

Keywords


Al5086 Alloy, Additive Powder Fed, Friction Stir Processing, Surfaces, Composite Materials, Hardness.

References