International Journal of Research in Engineering, Science and Management 103 Volume-3, Issue-4, April-2020 www.ijresm.com | ISSN (Online): 2581-5792

A Review On Friction Stir Processing of Aluminium Alloy Surface Composite

S. Divya1, D. Elavarasan2, M. Kishor3, K. Manisekar4, R. Manikandan5 1Assistant Professor, Dept. Mechanical Engineering, Sri Eshwar College of Engineering, Coimbatore, India 2,3,4,5Student, Dept. Mechanical Engineering, Sri Eshwar College of Engineering, Coimbatore, India

Abstract: This paper mainly focuses on the improvement of microstructure of the material. It also explains about the hardness of aluminium 6061 alloy by using the most common process. The tool and the work piece come into contact, at that technique ‘Friction Stir Processing (FSP)’. Friction Stir time friction is developed between the surfaces which in turn Processing (FSP), a strong state materials handling procedure is essentially used to switch the microstructure and properties of causes the plastic deformation of the material and because of its surface which chips away at the standards of Friction Stir Welding thermal properties, tensile strength the microstructure gets (FSW). FSP is one in all the foremost promising techniques that reinforced. produces surface composites. FSP enhances the mechanical R. Abrahams, et al. (2019) discuss the improvement study of properties like lastingness, hardness, ductility and fatigue and also FSP process parameters and tool design, especially the tool tribological properties like wear resistance. It also eliminates the rotational and transverse speeds. It also focuses to show the defects that are produced within the matrix alloy during casting process and reduces distortion. The vast majority of the Severe correlation between the mechanical properties and the resulting Plastic Deformation (SPD) methods changes the greater part microstructure using different FSP parameters. It is awaited that properties of the texture yet FSP doesn't change the lion's share FSP will improve the mechanical properties of aluminium alloy properties, rather, grain size refinement might be accomplished in which can lead to many industrial applications. light of information heat that rises up out of erosion. This paper S. Bharti et al. (2019) talks about the process of FSP done in investigates the hardness of aluminium 6061 alloy after the aluminium 6000 series alloys. In this experiment, reinforcement of properties after the application of Friction Stir Processing (FSP). microstructural examination is done for aluminium 6000 series alloys. Vickers Micro Hardness test is done for the polished Keywords: Hardness, Ballistic Performance, Aluminium Alloy, work piece and the tensile test is carried out for the same. It is Friction Stir Processing. also confirmed that if the number of passes is increased, the hardness of the material is also increased. FSP has the ability to 1. Introduction increase the hardness of the material. Friction stir processing originally depends on the principle of S. Chainarong et al. (2014) said that the surface of the skin is Friction Stir Welding invented in 1991 by Wayne Thomas at smooth and mixed uniformly after the FSP process. It is also the Welding Institute (TWI) of United Kingdom that is used for found that the stirred area has uniform pattern and there are no microstructural modification. FSP is merely same when cracks found in the particular zone. The heat generated from compared with friction stir welding process, the difference is Friction Stir Processing is mainly due to rotation speed and that in FSW process, two plates are fabricated for joining travel speed which results in the reduction of internal resistance purpose whereas FSP is employed to change the surface and surface roughness. properties of the fabric. In FSP, a solid tool with a shoulder and I. Sudhakar et al. (2015) mainly discuss the ballistic a pin is used and is rotated at high speed, the pin of the tool resistance for the aluminium alloys. The industrial applications plunges within the material and because of friction between the of aluminium and its alloys is limited because of its poor surface of work piece and power shoulder, heat is generated tribological properties. But the surface matrix composites of which ends in plastic deformation zone of the material due to aluminium shows better ballistic resistance. There are some recrystallization. When certain reinforcements like Al2O3 or Si improvements in wear resistance found in the friction processed carbide powders are used in this process, the properties of work areas. The wear resistance is improved with the help of boron piece are found to be increased when compared with without using composites as reinforcements. carbide powder in friction stir processing. H.G. Rana et al. (2016) mainly investigates about a green and 2. Literature review energy efficient technique called Friction Stir Processing (FSP). In this work, the aluminium 7075 alloy is mainly used and R. Arun Kumar et al. (2019) investigates the friction stir boron carbide powder is used for improvement. It found that there are some defects in the processed area but the hardness is processing technique which involves in the modification of increased 40-70% higher than that of the initial one. The wear International Journal of Research in Engineering, Science and Management 104 Volume-3, Issue-4, April-2020 www.ijresm.com | ISSN (Online): 2581-5792 resistance also increased up to 100%. technique. M. M. El-Rayes, et al. (2012) mainly investigates the multi- M. Sharifitabar et al. (2011) investigates the microstructure pass friction stir processing technique and inspect the and mechanical properties of alloy 5052 Al/Al2O3surface microstructure of aluminium 6082 alloy. In this work, three composite. Two series of samples are tested with and without passes are done for the inspection. One unchanged rotational powder were done FSP by one to four passes. Tensile test is speed and three changeable traverse speeds. The done to calculate the mechanical properties of the material. It is microstructure, mechanical properties such as hardness and proved that grain size in the stirred zone gets decreased with the tensile strength which are to be addressed with respect to the increase in the number of FSP passes. Then, the increase in the number of passes and traverse speeds. The hardness and tensile FSP passes causes the uniform distribution of Al2O3alloy. The test done in the processed zone were good when the number of tensile strength and elongation is improved to 118% and 165% passes increased which causes softening and reduce the in composite by four FSP passes. ultimate tensile strength. At the same time, increasing the N. Netto et al. (2019) proposes a failure analysis study on the traverse speed increases the strength and hardness. tool degradation during Friction Stir Processing (FSP) of 6061- P. Nelaturu et al. (2018) investigates about the initiation of T6 aluminium alloy. It explains about the process of FSP that fatigue crack and growth mechanisms in cast and friction stir the tool consists of a pin and a shoulder which is plunged into processed A356 aluminium alloy. FSP is an emerging the material until the shoulder comes in contact with the top technology which is used over a decade. From the work, it is layer of the workpiece. The pin of the tool forces the work observed that crack initiation mainly occur at microstructural material to undergo plastic deformation resulted in a defect sites and it is the main reason for the low fatigue life. homogeneous and recrystallized structure. The tool degradation FSP has given great improvement in fatigue life in order of found in three phases. magnitude. Aruri Devaraju et al. (2017) prepared the nano composite V. V. Patel et al. (2017) discuss the experimental surface layer by reinforcing TiB2 on 6061-T6 aluminium alloy investigation on hybrid friction stir processing using with Friction Stir Processing. The composites are examined by compressed air in aluminium 7075 alloy. It is found that in optical microscope and scanning electron microscope for the hybrid FSP with compressed air cooling has produced fine equi- dispersion of reinforcement particles. It is found that increase axed grain microstructure. The hybrid sample generated less in the volume percentage of TiB2 particle, the micro hardness heat input which resulted in the inhibition of grain growth was increased up to 132 HV and the specified value is higher during the process. The micro hardness gets improved by than the received aluminium alloy’s micro hardness. It also hybrid FSP process. proved that the tensile properties of Al surface nano composites V. Sharma et al. (2015) gives a review of surface composites were decreased as compared with the initial one. by friction stir processing. He also proposes that FSP is a A. Devaraju et al. (2013) fabricated the aluminium 6061-T6 promising technique for making surface composites. It can alloy incorporated with mixture of (SiC+Gr) and (SiC+Al2O3) improve the wear resistance, hardness, strength, ductility, particles. A technique called Friction Stir Processing is corrosion resistance, fatigue life and formability. It is mainly employed to improve the tribological properties and to refine used for making the composites of aluminium and magnesium the microstructure and to improve the mechanical properties on alloys. The paper explains about the FSP technique and the aluminium 6061-T6 alloy. As a result, reinforcement particles fabrication of surface composites by FSP. It also discusses the of (SiC+Gr) and (SiC+Al2O3) were uniformly distributed along merits and demerits of using FSP. One of the most the nugget zone without any imperfections. Both of the disadvantages is the tool wear which restricts the use of FSP to composites’ hardness values are increased when compared with prepare hard surface composites. the initial one. J. Qu et al. (2011) mainly presents about the improvement of S. Rathee et al. (2016) adopted Taguchi’s experimental tribological characteristics of aluminium 6061 alloy with the design for the optimization of process parameters for enhanced help of friction stir processing. It is found that tribological and micro hardness of AA 6061/SiC surface composite. Three mechanical properties are enhanced after the Friction Stir process parameters such as rotational speed, tool traverse speed Processing (FSP). and tool tilt angle with three levels to maximize the micro K. Surekha et al. (2011) compares the behavior of friction stir hardness. The paper explains about the importance of FSP and processed and laser melted AA 2219 aluminium alloy. its process parameters. The paper resulted in the improvement Potentiodynamic and polarization and chemical impedance of micro hardness values due to combined effect of hard nature spectroscopy tests were done to compare the corrosion of reinforcement of particles, grain refinement and uniform behavior. The corrosion resistance is well achieved by FSP dispersion of reinforcement particles and pinning of grain rather than laser melted. The hardness values of Friction Stir boundaries. Processed material are higher than the laser melted material Abhishek SHARMA et al. (2019) done a comparative study which shows that the material done with FSP has better on the surface properties of AL-SiC-multi-walled carbon mechanical properties than the material done with LM nanotubes (CNT) and AL-SiC-graphene nano platelets (GNP) International Journal of Research in Engineering, Science and Management 105 Volume-3, Issue-4, April-2020 www.ijresm.com | ISSN (Online): 2581-5792 hybrid composites. Carbon nanotubes (CNT), graphite and some remedial measures. The usage of properly designed stirrer graphene are extra-ordinary reinforcements because of their and the parameters. Coating of CNTs with copper to increase high thermal conductivity, low coefficient of expansion and their densities. The usage of methanol and ethanol to prevent self-lubricating properties. Finally, the comparative study cold welding of aluminium particles. concluded that Al-SiC-GNP hybrid composite to be the best one A. Tajiri et al. (2015) studied the effect of friction stir among the carbonaceous compound family for increasing the processing conditions on the behavior of fatigue and texture surface hardness and wear resistance of aluminium alloys. development in A356-T6 cast aluminium alloy. FSP allows the R. Keshavamurthy et al. (2018) reports mainly on the alloy to modify its microstructure to eliminate casting defects mechanical behavior of friction stir processed aluminium 6061- under two different rotational speeds. To enhance the fatigue Boron Nitride surface composite. In this paper, the effect of strength, plane bending fatigue tests are carried out with low number of passes and the reinforcement in the microstructure rotational speeds which yield better results. The enhancement of the alloy. The hardness and tensile characteristics are also of fatigue strength eliminated the casting defects. The work examined. The microstructure resulted in the homogeneous resulted in the improvement of fatigue strength when compared distribution of boron nitride particles after friction stir with the cast specimen due to the elimination of casting defects. processing. SEM analysis confirmed the good relationship FSP done in lower speed yield better results rather than higher existing between aluminium alloy and boron nitride particles. speed. Boron Nitride reinforcement particles show improvement in J. Tang et al. (2019) presented how the multi-pin tool in ultimate tensile strength, yield strength and hardness values Friction Stir Processing influence the parameters on when compared with the unreinforced aluminium alloy. It also microstructure and mechanical properties of SiC/Al found that increasing the number of passes increases the composites. In this work, multi-pin tool and single pin tool to hardness, ultimate tensile and yield strength of both alloy and fabricate the aluminium matrix composites reinforced by SiC the boron nitride surface composite. particles. The multi-pin tool improved the refinement of M. AMRA et al. (2018) analyzes the microstructure and wear particles and increased the homogeneous distribution of SiC performance of AL5083/CeO2/SiC mono and hybrid surface particles when compared to the traditional single pin tool, composites done by friction stir processing (FSP). The mainly due to the increased effect of multi-pin tool on the stir observations of microstructure in friction stir processed regions and friction ability of the material. It also increased the micro and worn out surfaces were done by optical and scanning hardness and decreased the coefficient of friction. electron microscope. Among the samples, the hybrid composite S. Zhang et al. (2019) discuss the effect of energy input (AL5083/CeO2/SiC) revealed highest wear resistance and during FSP on microstructure and mechanical properties of lowest friction coefficient. All composite samples showed AL/CNT composites. In this work, Raman Spectroscopy, higher hardness value and wear resistance when compared with Scanning Electron Microscope and Transmission Electron the unreinforced alloy. Microscope are used to analyze the microstructure and M. Balakrishnan et al. (2019) analyzes the effect of friction mechanical properties of Al/CNT composites. The author also stir processing on microstructure and tensile properties and its found that grains of aluminium matrix in the nano composites behavior of aluminium 6061alloy / Al3Fe cast aluminium were coarsened slightly with increased energy input. The composites. In this paper, he proposed that FSP is an emerging carbon nanotubes dispersion and their mechanical technology for the improvement of microstructure and characteristics and behavior are different in various energy properties of aluminium matrix composites. He also stated that inputs. But, better carbon nanotubes dispersion and tensile Al3Fe aluminium matrix composites are formed by adding pure properties were exhibited in higher energy input. With the high iron powder to molten aluminium and subjected to the process energy input, the tensile strength of the composite was to be FSP. Then the study of microstructural changes is done before increased 53.8% when compared with the reinforced and after FSP with the help of OM, SEM, EBSD and TEM. FSP aluminium composite and elongation was to be increased process resulted in the total homogenous rearrangement of 31.2% which has extra-ordinary ductile property. Thus the particles due to the stirring action of the FSP tool. It also author came to know that the energy input plays a notable role eliminated the typical casting defects (pores) due to proper in the refinement of carbon nanotube dispersion and mechanical plasticization. It also improved the tensile strength and ductility characteristics of Al/CNT nanocomposites. of the material after Friction Stir Processing (FSP). K. J. Hodder et al. (2012) discuss the fabrication of Sunil kumar Tiwari et al. (2018) mainly investigates the aluminium-alumina metal matrix composites through cold gas fabrication of aluminium composites reinforced by carbon dynamic spraying followed by Friction Stir Processing. Cold nanotubes. There are many issues such as improper distribution dynamic spraying is used for surface modification on various of AL-CNT composites, agglomeration of CNTs in Aluminium structures mainly in aircraft and automobile industries. This composites and distortion in the structure on CNTs. In this method restricts the unnecessary phase transformations and paper, the author tried to discuss the remedial approaches for micro structural changes on substrate material. The results AL-CNT composites. To overcome these issues, he proposed obtained reveals that coupling cold spraying with Friction Stir International Journal of Research in Engineering, Science and Management 106 Volume-3, Issue-4, April-2020 www.ijresm.com | ISSN (Online): 2581-5792

Processing improves the hardness of Al-Al2O3 composites and alloy is tabulated in table 2. gives an appropriate method for the fabrication of dense MMC coatings with improved material properties when compared to 4. Method the initial one. A. Friction Stir Processing M. Sivanesh Prabhu et al. (2019) reports the friction and wear measurements of friction stir processed aluminium alloy Friction Stir Processing (FSP) is a solid-state emerging technique from the standards and principles of Friction Stir 6082/CaCO3 composite. It is found that there are some Welding (FSW) which is mainly used to change the properties improvements in microstructure of FSPed AA6082/CaCO3 composite. He also proposed that friction coefficient and wear of metal through plastic deformation. This is achieved by of the aluminium composites are mainly caused due to the forcibly inserting a non-consumable tool in to the workpiece. In applied load. The micro hardness of friction stir processed this process, a rotating tool with a pin and a shoulder is used to improve the toughness and flexibility. The friction between the AA6082/CaCO3 composite has increased to 82 HV from 64 HV by grain refinement. These results are gained by Scanning tool and workpiece creates a localized heating which softens Electron Microscope and the values are compared with the and plasticizes the workpiece. This method is used everywhere unreinforced one. where the mechanical properties of the material are to be improved. This technique can improve the wear resistance, 3. Material and its composition tensile strength, creep, fatigue etc. Aluminium 6061 alloy is used in this work. It is a B. Micro hardness (or Micro indentation) test precipitation-hardened aluminium alloy, majorly contains The term ‘micro hardness’ is often engaged in the literature magnesium and silicon. It was developed and started its usage to define the hardness testing of materials with low loads. A in 1935. It was originally called as “Alloy 61S” and now-a-days most accurate term for the test is “Micro indentation hardness it also referred as “Structural Aluminium”. It is used widely testing”. In this type of testing, a diamond indenter is impressed because of its better mechanical properties, weldability. It on the surface of the material with a known applied force. The exhibits better fatigue strength, good formability. It is not hardness number is calculated on the basis of the indent acceptable for very complex sections. It is one of the most impressed on the surface of the material. Micro hardness testing commonly used alloys of aluminium for general purpose. It is is used where the minute work pieces are to be tested or the mainly used in heavy structures such as rail coaches, truck specimen size is very low. Through this method, the hardness frames, yacht construction, flashlight, bridge construction, of thin samples can also be measured. It can also use where the aerospace applications, tower construction, automotive parts, small regions in a composite sample to be measured. It can motor boats etc. provide exact and specified information about the features of the surface material in terms of microstructure, non- Table 1 homogeneous or inclusive to cracking. Chemical composition of aluminium 6061 alloy Chemical Composition C. Scanning Electron Microscope (SEM) Element Wt% Aluminium 97.9% Scanning Electron Microscope (SEM) is a type of test Magnesium 0.972% process which scans a sample with the help of electron beam to Silicon 0.607% produce an enlarged image of the material for analysis purpose. Copper 0.183% It is also called SEM microscopy. It is used very effectually in Iron 0.120% Manganese 0.084% microanalysis and failure analysis. It is performed at high Chromium 0.077% enlarged and high resolution images and exactly measures very Titanium 0.029% minute features and defects. It is one of the most versatile Zinc 0.004% technique and it can be used to image the morphology of the given test samples. It is used to examine wet and dry samples Table 2 Physical and mechanical properties of aluminium 6061 alloy while viewing them. It can generate X-rays from samples for Physical& Mechanical Properties the purpose of microanalysis. It is very helpful to gather the Properties Values information about heterogeneity. Density (ρ) 2.70 g/cm3 Young’s Modulus (E) 68.9 GPa (9,990 ksi) D. Ballistic Test Tensile Strength (σt) 124-290 MPa (18.0-42.1 Ballistic Test is a standard-based process where products are ksi) Elongation (ε) at break 12-25% examined to check that they will meet the protection, safety and Poisson’s Ratio (υ) 0.33 performance. It is the study of motion, dynamics, angular movement and the effects of projectile motion of the body. The chemical composition of aluminium 6061 alloy is Most of this tests helps in commercial research and tabulated in table 1. development areas and military applications. It is used to The physical and mechanical properties of aluminium 6061 measure how hard the material is. The term used in ballistic International Journal of Research in Engineering, Science and Management 107 Volume-3, Issue-4, April-2020 www.ijresm.com | ISSN (Online): 2581-5792 testing is DOP which means Depth of Penetration. By using this [3] Shalok Bhartia, Varun Dutta, Sanjay Sharma, Rajiv Kumar, A study on value, the hardness of the material can be calculated under the the effect of Friction Stir Processing on the hardness of Aluminum 6000 series, Materials Today: Proceedings 18 (2019) 5185–5188. applied momentum. [4] S. Chainarong, P. Muang junburee, S. Suthummanon,Friction Stir E. 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