Microstructural and Wear Behaviour of Al 6063–W Nanocomposites Developed Using Friction Stir Processing

Abstract

The goal of the present research is to introduce the Tungsten (W) nanoparticles as reinforcement into Al 6063 alloy to produce Al–W nanocomposites by the FSP technique. The vol% of the reinforcement was varied from 3 to 12 with a step of 3, besides the unreinforced Al matrix was considered as 0 vol% for comparison. The role of W nanoparticles in the Al 6063 matrix has been exhaustively investigated using advanced characterization techniques such as XRD analysis to observe the phases, FESEM to detect the distribution of reinforcements with their interparticle spacing and the average grain sizes, TEM analysis to study the strengthening factors, new phase formation at the interface between AA 6063 matrix and W particles, the morphology of the W nanoparticles. The achieved average matrix grains size was 42, 2, and 0.9 μm for 0, 6, and 12 vol% W nanocomposites, respectively. The obtained results disclosed the uniform dispersion of W nanoparticles, without any agglomeration, and with the absence of intermetallic compounds. The hardness and wear resistance of the fabricated nanocomposites were increased incommensurate with the incorporation of heavy metallic W element as reinforcement particle; which was due to the proper dispersion of W nanoparticles, refinement of matrix grains to ultrafine level, generation of dislocations, and clear interface between Al 6063 matrix and W nanoparticles. In a nutshell, AA 6063–12 vol% W nanocomposite has achieved the higher hardness (120 HV), lower wear rate (0.13 mm³/m), and friction coefficient (0.33) than other nanocomposites................The goal of the present research is to introduce the Tungsten (W) nanoparticles as reinforcement into Al 6063 alloy to produce Al–W nanocomposites by the FSP technique. The vol% of the reinforcement was varied from 3 to 12 with a step of 3, besides the unreinforced Al matrix was considered as 0 vol% for comparison. The role of W nanoparticles in the Al 6063 matrix has been exhaustively investigated using advanced characterization techniques such as XRD analysis to observe the phases, FESEM to detect the distribution of reinforcements with their interparticle spacing and the average grain sizes, TEM analysis to study the strengthening factors, new phase formation at the interface between AA 6063 matrix and W particles, the morphology of the W nanoparticles. The achieved average matrix grains size was 42, 2, and 0.9 μm for 0, 6, and 12 vol% W nanocomposites, respectively. The obtained results disclosed the uniform dispersion of W nanoparticles, without any agglomeration, and with the absence of intermetallic compounds. The hardness and wear resistance of the fabricated nanocomposites were increased incommensurate with the incorporation of heavy metallic W element as reinforcement particle; which was due to the proper dispersion of W nanoparticles, refinement of matrix grains to ultrafine level, generation of dislocations, and clear interface between Al 6063 matrix and W nanoparticles. In a nutshell, AA 6063–12 vol% W nanocomposite has achieved the higher hardness (120 HV), lower wear rate (0.13 mm³/m), and friction coefficient (0.33) than other nanocomposites.The goal of the present research is to introduce the Tungsten (W) nanoparticles as reinforcement into Al 6063 alloy to produce Al–W nanocomposites by the FSP technique. The vol% of the reinforcement was varied from 3 to 12 with a step of 3, besides the unreinforced Al matrix was considered as 0 vol% for comparison. The role of W nanoparticles in the Al 6063 matrix has been exhaustively investigated using advanced characterization techniques such as XRD analysis to observe the phases, FESEM to detect the distribution of reinforcements with their interparticle spacing and the average grain sizes, TEM analysis to study the strengthening factors, new phase formation at the interface between AA 6063 matrix and W particles, the morphology of the W nanoparticles. The achieved average matrix grains size was 42, 2, and 0.9 μm for 0, 6, and 12 vol% W nanocomposites, respectively. The obtained results disclosed the uniform dispersion of W nanoparticles, without any agglomeration, and with the absence of intermetallic compounds. The hardness and wear resistance of the fabricated nanocomposites were increased incommensurate with the incorporation of heavy metallic W element as reinforcement particle; which was due to the proper dispersion of W nanoparticles, refinement of matrix grains to ultrafine level, generation of dislocations, and clear interface between Al 6063 matrix and W nanoparticles. In a nutshell, AA 6063–12 vol% W nanocomposite has achieved the higher hardness (120 HV), lower wear rate (0.13 mm³/m), and friction coefficient (0.33) than other nanocomposites.

Graphic abstract