The powder fed friction stir process (FFSP) is a new and attractive solid-state manufacturing technique that enables the fabrication of polymer matrix nanocomposites (PNC). Herein, we present the fabrication of polycarbonate (PC)-based nanocomposites by in-situ injection of colloidal alumina nanoparticles (<100 nm) into the plasticized polymer under stir friction of a steel tool. Microstructural features and mechanical durability of the prepared nanocomposites were studied. The mechanical properties of the processed materials including hardness, tensile strength, flexural strength, and impact energy were elaborated. The tensile strength of PNC in the longitudinal direction was ~73 MPa, which was higher than the PC matrix by 109%. However, a lower bending strength (~48 MPa) compared with PC was measured. Fractographic studies determined the presence of mist patterns on flexural samples and crack growth from shrinkage holes and river patterns. The distribution of Al₂O₃ nanoparticles was found to improve the impact energy in both transverse and longitudinal directions by 111% (~28 kJ/m²) and 127% (32 kJ/m²), respectively. Crack deviation by the hard inclusions was found to be the mean mechanism of enhanced impact resistance.

粉末进料摩擦搅拌工艺（FFSP）是一种新颖且有吸引力的固态制造技术，可制造聚合物基质纳米复合材料（PNC）。在本文中，我们介绍了通过在钢工具的搅拌摩擦下将胶体氧化铝纳米颗粒（<100 nm）原位注入增塑的聚合物中来制备聚碳酸酯（PC）基纳米复合材料的方法。研究了制备的纳米复合材料的微观结构特征和机械耐久性。阐述了加工材料的机械性能，包括硬度，抗张强度，弯曲强度和冲击能。PNC的纵向拉伸强度为〜73 MPa，比PC基体高109％。但是，测得的弯曲强度比PC低（〜48 MPa）。分形研究确定了弯曲样品上是否存在雾状图案以及收缩孔和河流状图案的裂纹扩展。Al的分布发现₂ O ₃纳米颗粒可在横向和纵向上分别提高111％（〜28 kJ / m ²）和127％（32 kJ / m ²）的冲击能。发现硬质夹杂物引起的裂纹偏离是提高抗冲击性的平均机理。