The present research focuses on the tribological behavior of the AA5083 alloy-based hybrid surface composite using aluminosilicate and multi-walled-carbon nanotube through friction stir processing for automotive applications. The friction stir processing parameters (tool rotation and traverse speed) are varied based on full factorial design to understand their influence on the tribological characteristics of the developed hybrid composite. The surface morphology and composition of the worn hybrid composite are examined using a field-emission scanning electron microscope and an energy-dispersive x-ray spectroscope. No synergistic interaction is observed between the wear rate and friction coefficient of the hybrid composite plate. Also, adhesive wear is the major wear mechanism in both base material and hybrid composite. The influence of friction stir process parameters on wear rate and the friction coefficient is analyzed using the hybrid polynomial and multi-quadratic radial basis function. The models are utilized to optimize the friction stir processing parameters for reducing the rate of wear and friction coefficient using multi-quadratic RBF algorithm optimization.

The life span of many engineering components depends upon their surface properties. The improved surface properties of the materials are essential for enhancing the mechanical and tribological performance of the material. In many applications, the components required only improved surface properties without changing the entire volume properties of the material. The friction stir process (FSP) is a novel processing technique for the fabrication of such surface composites. In the present investigation, the surface composites were fabricated by incorporating molybdenum disulfide ( MoS2) and graphite (Gr) as reinforcement on the surface of aluminum alloy (Al 1120) through the friction stir process (FSP) at tool rotational speed of 1400 rpm and tool feed rate of 40 mm/min process parameters using square profile FSP tool. The tribological behaviors of fabricated surface composites were calculated by using a pin on disk tribometer. It was observed that the wear resistance of surface composites improved as compared to the matrix material.

This study was carried out to investigate the optimum condition of a friction stir welding process for a joint of AA2219-T87 and AA2195-T8 dissimilar aluminum alloys. These alloys are known to have good cryogenic properties, and as such to be suitable for use in fuel tanks of space vehicles. The welding parameters include the travelling speed, rotation speed and rotation direction of the tool. The experiment was conducted under conditions in which the travelling speed of the tool was 120-300 mm/min and the rotation speed of the tool was 400-800 rpm. To investigate the effect of the rotation direction of the tool, the joining was performed by switching the positions of the two dissimilar alloys. After welding, the microstructure was observed and the micro-hardness were measured; non-destructive evaluation was carried out to perform tensile tests on defect-free specimens. The result was that the microstructure of the weld joint underwent dynamic recrystallization due to sufficient deformation and frictional heat. The travelling speed of the tool had little effect on the properties of the joint, but the properties of the joint varied with the rotation speed of the tool. The conditions for the best joining properties were 600 rpm and 180-240 mm/min when the AA2219-T8 alloy was on the retreating side(RS).

In this study, to confirm the effect of alloying elements on the phase transformation and conditions of the friction stir process, we processed two materials, SS400 and SM45C steels, by a friction stir process (FSP) under various conditions. We analyzed the mechanical properties and microstructure of the friction stir processed zone of SS400 and SM45C steels processed under 400RPM - 100mm/min conditions. We detected no macro (tunnel defect) or micro (void, micro crack) defects in the specimens. The grain refinement in the specimens occurred by dynamic recrystallization and stirring. The microstructure at the friction stir processed zone of the SS400 specimen consisted of an α-phase. On the other hand, the microstructure at the friction stir processed zone of the SM45 specimen consisted of an α-phase, Fe3C and martensite due to a high cooling rate and high carbon content. Furthermore, the hardness and impact absorption energy of the friction stir processed zone were higher than those of base metals. The hardness and impact absorption energy of FSPed SM45C were higher than that of FSPed SS400. Our results confirmed the effect of alloying elements on the phase transformation and mechanical properties of the friction stir processed zone.

To evaluate the development of the microstructure and mechanical properties on surface modified and post-heat-treated Inconel 718 alloy, this study was carried out. A friction stir process as a surface modification method was employed,and overlap welded Inconel 718 alloy as an experimental material was selected. The friction stir process was carried out ata tool rotation speed of 200 rpm and tool down force of 19.6-39.2kN; post-heat-treatment with two steps was carried out at720oC for 8h and 620oC for 6h in vacuum. To prevent the surface oxidation of the specimen, the method of using argongas as shielding was utilized during the friction stir process. As a result, applying the friction stir process was effective todevelop the grain refinement accompanied by dynamic recrystallization, which resulted in enhanced mechanical properties ascompared to the overlap welded material. Furthermore, the post-heat-treatment after the friction stir process accelerated theformation of precipitates, such as gamma prime (γ') and MC carbides, which led to the significant improvement of mechanicalproperties. Consequently, the microhardness, yield, and tensile strengths of the post-heat-treated material were increased morethan 110%, 124% and 85%, respectively, relative to the overlap welded material. This study systematically examined therelationship between precipitates and mechanical properties.