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Synthesis of Surface Composites Using Friction Stir Processing Scholars' Mine Masters Theses Student Theses and Dissertations Summer 2009 Synthesis of surface composites using friction stir processing Bharat Gattu Follow this and additional works at: https://scholarsmine.mst.edu/masters_theses Part of the Materials Science and Engineering Commons Department: Recommended Citation Gattu, Bharat, "Synthesis of surface composites using friction stir processing" (2009). Masters Theses. 4489. https://scholarsmine.mst.edu/masters_theses/4489 This thesis is brought to you by Scholars' Mine, a service of the Missouri S&T Library and Learning Resources. This work is protected by U. S. Copyright Law. Unauthorized use including reproduction for redistribution requires the permission of the copyright holder. For more information, please contact [email protected]. SYNTHESIS OF SURF ACE COMPOSITES USING FRICTION STIR PROCESSING by BHARAT GATTU A THESIS Presented to the Faculty of the Graduate School of the MISSOURI UNIVERSITY OF SCIENCE AND TECHNOLOGY In Partial Fulfillment of the Requirements for the Degree MASTER OF SCIENCE IN MATERIALS SCIENCE AND ENGINEERING 2009 Approved by Rajiv S. Mishra, Advisor F. Scott Miller Lokesh R. Dharani lll PUBLICATION THESIS OPTION This thesis consists of the following two articles that have been prepared for submission for publications as follows: Page 18-34 are intended for submission to the MATERIALS SCIENCE AND ENGINEERING A. Page 35-50 are intended for submission to the MATERIALS SCIENCE AND ENGINEERING A. IV ABSTRACT Composite materials have an edge over monolithic materials due to higher strength/stiffness - to - density ratios, improved fatigue and wear resistance and better high temperature properties. Surface composites provide improved tribological properties such as wear resistance, friction coefficient and corrosion resistance. Friction stir processing (FSP) which originated from friction stir welding (FSW - a method for joining aluminum alloys) is a solid state technique to modify the microstructure of the alloys. During FSP the frictional heat generated at the tool - work piece interface plasticizes the material allowing it to flow around the pin. The combined effect of the plastic deformation and the generated heat leads to grain refinement in the alloys. In the present work, effort has been made to expand the scope of FSP as a novel method for the synthesis of surface composites. Different ways for incorporation of SiC particles into AlllOO alloy were explored and compared with each other. The response of the flow of the powder in the substrate during FSP has been studied for different processing features. The effects of various parameters and methodology on the incorporation and distribution of SiC particles in the nugget, the microstructure and mechanical properties of the composite layer were studied. v ACKNOWLEDGMENTS I would like to thank my advisor, Dr. Rajiv S. Mishra, for giving me a great opportunity to work in this innovative research area. I am grateful to him for giving me continuous support, guidance and encouragement in this endeavor. His knowledge and patience encouraged me through the journey of my research. I would also like to acknowledge the NSF IIUCRC program for providing the funding and the additional support of Boeing, PNNL, GM and Friction Stir Link. I am grateful to my committee members, Dr. F. Scott Miller and Dr. Lokesh R. Dharani for their valuable suggestions and input for this work. I would also like to take this opportunity to extend my sincere thanks to all my present and former colleagues. I am especially grateful to Kumar and Nilesh Kumar for their valuable suggestions and assistance. I am also grateful to Dr. Wang, Dr. Dutta, Saumydeep Jana, Partha De, Jeff Rodelas, Gaurav Bhargava, Yuan Wei, Arun Mohan, Jiye Wang, Gaurav Argade, Neal Ross, Prabhanjana Kalya, Nagarajan Balasubramanian, Marco Garcia and Steve Webb. This thesis is dedicated to my dearest parents, my brother and my friends (Abhi, Argha, Sagnik and Shashwat) who stood by me, encouraged me to pursue my dreams and expected great things for me. VI TABLE OF CONTENTS Page PUBLICATION THESIS OPTION .............................................................. .iii ABSTRACT ....................................................................................................................... iv ACKNOWLEDGMENTS ................................................................................................... v LIST OF ILLUSTRATIONS ....................................................................... ix LIST OF TABLES ............................................................................................................... x SECTION 1. INTRODUCTION ...................................................................................................... 1 1.1 COMPOSITE MATERIALS .............................................................................. ! 1.1.1 Geometry of Reinforcement ....................................................................... 1 1.1.2. Type of Matrix .......................................................................................... 3 1.1.2.1. Polymer matrix composite (PM C) ..................................................... 3 1.1.2.2. Metal matrix composite (MMC) ....................................................... .4 1.1.2.3. Ceramic matrix composite (CMC) ..................................................... 5 1.2. SURFACE COMPOSITES .................................................................................. 5 1.3. CONVENTIONAL MANUFACTURING OF SURFACE COMPOSITES ....... ? 1.4. FRICTION STIR WELDING (FSW) .................................................................. 9 1.5 FRICTION STIR PROCESSING (FSP) ............................................................. 11 1.6 TOOL DESIGN FOR FSP .................................................................................. 11 1. 7 HEAT AND MATERIAL FLOW ...................................................................... 13 1.8 FSP VS. CONVENTIONAL TECHNIQUES .................................................... 13 1.9 OBJECTIVES AND JUSTIFICATION OF PROBLEM ................................... 14 1.10 BIBLIOGRAPHY ............................................................................................. 15 PAPER I. STUDY OF VARIOUS PROCESS FEATURES FOR THE FABRICATION OF SURF ACE COMPOSITES USING FRICTION STIR PROCESSING .................... 18 ABSTRACT ................................................................................................................ 18 1.1 INTRODUCTION .............................................................................................. 18 1.2 EXPERIMENTAL PROCEDURE ..................................................................... 19 Vll 1.2.1 Effect of Pattern Geometry ........................................................................... 22 1.2.2 Effect of Offset and Thin Sheet Cover ......................................................... 24 1.2.3 Direction vs. Offset of Multiple Pass and Linear Hole vs. Staggered Pattem ............................................................................................................ 25 1.3 RESULTS AND DISCUSSION ......................................................................... 26 1.3.1 Effect of Pattern Geometry ........................................................................... 26 1.3.2 Effect of Offset and Thin Sheet Cover ......................................................... 28 1.3.3 Direction vs. Offset of Multiple Pass and Linear Hole vs. Staggered Pattem ........................................................................................................... 30 1.4 CONCLUSIONS ................................................................................................. 32 1.5 ACKNOWLEDGMENTS .................................................................................. 33 1.6 REFERENCES ................................................................................................... 33 II. FABRICATION OF AlllOO-SiCp SURFACE COMPOSITES USING FRICTION STIR PROCESS AND STUDY OF THEIR MECHANICAL PROPERTIES .......................................................................................................... 35 ABSTRACT .............................................................................................................. 35 2.1. INTRODUCTION ............................................................................................. 35 2.2. EXPERIMENTAL PROCEDURES .................................................................. 36 2.3. RESULTS AND DISCUSSION ........................................................................ 41 2.3.1 Effect of multiple pass with 100% overlap ................................................... 41 2.3.2 Mechanical Properties .................................................................................. .44 2.3.3 Microstructural analysis of surface composite ............................................ .46 2.4. CONCLUSIONS ................................................................................................ 48 2.5. ACKNOWLEDGMENTS ................................................................................. 49 2.6 REFERENCES ................................................................................................... 49 SECTION 2. CONCLUSIONS AND RECOMMENDATIONS .................................................... 51 2.1. CONCLUSIONS ...............................................................................................
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