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Improvement of Mechanical and Corrosion Properties of Al/SiC Functionally Graded Material Using a Novel Hybrid Tool in Friction Stir Processing

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Abstract

In the present investigation, Al-SiC functionally graded materials (FGM) were produced via. Friction stir processing (FSP) through a novel approach. The new approach involved a mathematical model for positioning holes in such a manner that the composition of the reinforcement (SiC) varied from maximum to minimum over a given length. Two tools with different pin profiles: conventional tool (CON) and hybrid tool (HYB), were employed for the process. The CON tool consisted of threads with zero flats while the HYB tool was a combination of threaded part and square (four flats) cross-section. The impact of pin profiles on the dispersion of SiC particles in the stir zone (SZ) of the processed specimens was studied and it was found be to more effective with HYB tool. This was because of the pulsating action induced by the flat edges and flow of material in downward direction. The HYB tool showed a 6.03% improvement in tensile strength vis-à-vis the sample processed by the CON tool as evidenced by mechanical properties and validated by electron backscatter diffraction analysis. The sizes of the grain in SZ for CON and HYB tools were 4.8 μm and 2.7 μm respectively and a huge fraction of high angle boundaries was observed in the HYB tool when compared to CON tool. The corrosion and wear resistance of FG samples also improved with the addition of SiC particles. The study brings out features of the mechanism of the process responsible for improved mechanical properties of functionally graded (FG) samples attained using HYB tool.

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Acknowledgements

The authors thank the Centre for Automation and Instrumentation (CAI), NIT Warangal for providing necessary computational facilities to carry out the work. The authors also thank Prof. Indraveer Samjdar, Incharge of OIM texture lab, IIT Bombay for providing them with EBSD facility. The first author acknowledges MHRD research fellowship from NIT Warangal.

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  1. Department of Mechanical Engineering, National Institute of Technology, Warangal, Telangana, 506004, India

    Venkatesh Bikkina, Sadasiva Rao Talasila & Kumar Adepu

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  1. Venkatesh Bikkina
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  2. Sadasiva Rao Talasila
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Venkatesh Bikkina: Investigation; Writing-Editing original draft; Sadasiva Rao Talasila: Reviewing original draft; Kumar Adepu: Conceptualization.

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Bikkina, V., Talasila, S.R. & Adepu, K. Improvement of Mechanical and Corrosion Properties of Al/SiC Functionally Graded Material Using a Novel Hybrid Tool in Friction Stir Processing. Silicon 14, 6123–6139 (2022). https://doi.org/10.1007/s12633-021-01380-1

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