Prediction of friction stir process parameters on microhardness and wear resistance characteristics of AA 6061-T6/(B4C+BN) hybrid surface composite
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Aluminium matrix composites are increasingly valued for their exceptional mechanical properties, making them vitalin automotive and aerospace industries that demand enhanced wear resistance and hardness. This study focuses on thefabrication of hybrid aluminium matrix composites reinforced with Boron Carbide (B4C) and Boron Nitride (BN) particles viaa novel method called friction-stir processing. The influences of the key process parameters, tool rotational speed, tool traversespeed, axial force, and powder ratio on the mechanical properties of the composites were investigated. The experiments wereconducted according to the Central Composite Design and empirical models were developed to predict the microhardness andspecific wear rate. The results were validated through Analysis of Variance and Response Surface Methodology. The optimalFSP conditions were identified as a rotational speed of 1300 rpm, transverse speed of 15 mm/min, axial force of 8 kN, andpowder ratio of 50% B4C + 50% BN. The maximum microhardness observed was 135 HV, indicating a 26% enhancementrelative to the Al Alloy. Additionally, the specific wear rate was minimized to 0.15 × 10-6 mm³/Nm. The incorporation oflubricant BN particles in equal weight percentages with B4C particles resulted in a notable enhancement in wear resistance.
Abstract
Aluminium matrix composites are increasingly valued for their exceptional mechanical properties, making them vitalin automotive and aerospace industries that demand enhanced wear resistance and hardness. This study focuses on thefabrication of hybrid aluminium matrix composites reinforced with Boron Carbide (B4C) and Boron Nitride (BN) particles viaa novel method called friction-stir processing. The influences of the key process parameters, tool rotational speed, tool traversespeed, axial force, and powder ratio on the mechanical properties of the composites were investigated. The experiments wereconducted according to the Central Composite Design and empirical models were developed to predict the microhardness andspecific wear rate. The results were validated through Analysis of Variance and Response Surface Methodology. The optimalFSP conditions were identified as a rotational speed of 1300 rpm, transverse speed of 15 mm/min, axial force of 8 kN, andpowder ratio of 50% B4C + 50% BN. The maximum microhardness observed was 135 HV, indicating a 26% enhancementrelative to the Al Alloy. Additionally, the specific wear rate was minimized to 0.15 × 10-6 mm³/Nm. The incorporation oflubricant BN particles in equal weight percentages with B4C particles resulted in a notable enhancement in wear resistance.