B-Tech

PROJECT FINAL REVIEW

11/05/2018
FABRICATION OF Al2014/TiC SURFACE
COMPOSITE BY FRICTION STIR
PROCESSING

Guided by Presented by
Karthik Narayanan M V Anand J L (TCT15ME006)
Asst.Professor, Mechanical Krishnaprasad K (TCT15ME014)
Nithin Stephen (TCT15ME015)
Vishnu Mohan M (TCT15ME027)
Aim & Objectives :

To fabricate Al2014/TiC surface composite-

• To design and manufacture the appropriate tool which favours the

fabrication of surface composites.

• Investigate the effects of different reinforcement technique for

increasing hardness of the base metal (Aluminium 2014 Alloy).

• Investigate the effect of FSP on the resulting hardness of the processed

material.
 SURFACE COMPOSITES: A NEW CLASS OF
ENGINEERED MATERIALS

• Suitable materials for engineering applications encountering surface

interactions.
• Phase composition is linearly graded as a function of distance from the
surface
• Reinforcement material are only found on surface phase.
FRICTION STIR PROCESSING (FSP)

• Derived from FSW

• FSP is a thermo mechanical process for material property improvement &
development of materials .
• FSP is a technology that allows one to manipulate & refine the structure of
cast components & thus enhance their performance.
• Method for microstructural modification
 LITERATURE SURVEY
Process principle

Mishra, R.S.; Mahoney, M.W.; McFadden, S.X.; Mara, N.A.; Mukherjee, A.K. High
strain rate superplasticity in a friction stir processed 7075 Al alloy. Scr. Mater. 1999, 42,
163–168.

 Mishra in 1999, found out the feasibility of FSP as an exciting possibility to

enhance then grain size dependent properties- micro structure
 He found out FSP can be implemented on FSW machines
 Non–consuming tool with a pin & shoulder
 Tool rotates > plunges into the workpiece > transverse to the process direction.
 Finally due to intense plastic deformation the material recrystallizes due to the
temperature attained due to friction & gets remoulded
Microstructure Transformation

Wang, Y.B.; Huang, Y.X.; Meng, X.C.; Wan,L.; Feng, J.C. Microstructural
evolution and mechanical properties of Mg-Zn-Y-Zr alloy during friction stir
processing. J. Alloy. Compd. 2017, 696, 875–883.

 Process region via FSP is divided into stir zone, thermo mechanical
affected zone, heat affected zone & base metal zone.

 Stir experiences high peak temp & severe plastic deformation

 A typical onion ring is seen in stir zone due to plastic material layer
flow from front of the tool to back of the tool
Influence of process parameters

Sathiskumar, R.; Murugan, N.; Dinaharan, I.; Vijay, S.J. Role of

friction stir processing parameters on microstructure and
microhardness of boron carbide particulate reinforced copper surface
composites. Sadhana Acad. Proc. Eng. Sci. 2013, 38, 1433–1450.

 Main parameters include tool rotational speed, traverse speed,

tool tilt angle multi pass times
 Rotational speed & transvers speed controls the heat inputs &
flow of plastic material
 More heat gen. with high rotation speed & low transverse speed
 Tool tilt angle is usually less than 5
 Multi pass FSP is appreciable for the production of composites
Influence of tool geometry

Patel, V.V.; Badheka, V.J.; Kumar, A. Influence of pin profile

on the tool plunge stage in friction stir processing of Al-Zn-
Mg-Cu alloy. Trans. Indian Inst. Met. 2017, 70, 1151–1158.

 2 categories of tools used- tool with pin & pinless tool

 Pinless tools are employed for encapsulating reinforced particles
 tools having pin, the shoulder to pin dia is usually 3
 Reinforcement distribution will be more square or triangular pin
 TOOL DESIGN
• Square pin with 4mm length and 5mm diagonal
• Concave shoulder of 5 degree and 18 mm diameter
• Shoulder length of 50 mm
 FABRICATION & EXPERIMENT
LAYOUT
• The first phase of the project work focuses on the manufacturing of the
FSP tool. Hot die steel (H-13 grade) rod of 25 mm dia has been machined
to required design. The facing and turning operations are done on the lathe.
The concave face of the shoulder and the pin is machined on electrical
discharge machine.

• The second phase of the project is dealt with the fabrication of slots and
blind holes in the aluminium 2014 plates for adding reinforcement. The
slot and holes was machined in electric discharge machine
• The slot dimensions are 1mm dia., 70mm length and 2mm depth.
blind hole dimension are 2mm dia and 2mm depth.

• In the third phase of the project, aluminium 2014 alloy and

reinforcement particle of TiC (2 μm) are used for fabricating surface
composites by FSP route.

• In the fourth phase Vickers hardness test is done in the areas having
metallurgical change, and the process is studied based on the methods
of adding reinforcement particles.
EXPERIMENTAL
• Case1-groove capped with pinless tool followed by processing with FSP
tool
• Case 2-plate with groove are directly subjected to FSP
• Case 3-plate with blind holes are directly subjected to FSP
• Rotational speed-1400 rpm and Traverse speed-40mm/min
• Tool tilt angle of 2.5 deg is given.
• After the process the Vickers micro hardness test is done in areas of
metallurgical change at 100 gf load and 15 sec dwell time
 RESULT & DISCUSSION

• As seen in the table the FSP helped to improve the hardness

significantly
• Hardness of the base alloy 115 HV is elevated to some appreciable value
• Specimen 1 showed a difference of 8 HV.
• Capping action was effective since it helps the reinforcement particle
to get seated as well as it prevent the flow over the groove

• Specimen 2 also showed a increase in hardness, not much that of

specimen 1
• Clustering of RP is observed on the top of the plate, results in non
uniform material flow.
• It is also observed that the tool used has worn out considerably at a
high rate because of continuous interaction of tool shoulder with RP
• This wearing rate of tool is not observed in Specimen 1 since capping
prevent direct interaction of tool shoulder and the RP
• Specimen 3 showed negligible change in hardness compared to
Specimen 1
• Hardness obtained is not uniform
• Defects like cavity was found in specimen 3
• Hardness variation for base metal is shown above
• Hardness goes on increasing of about 18 mm towards the centre
of stir zone.
• Hardness get max at the centre of stir zone
• Coming to the tool wear, the max wear was found at pin length
1/3 from the pin root
CONCLUSION

• Specimen 1 has highest value of microhardness of 123HV

• Specimen 2 has the microhardness of 119 HV,with maximum tool wear
• Specimen 3 has the value of 118 HV with defect- Cavity formation
 SUMMARY AND OUTLOOK
In this project, the surface composites are fabricated by using various
reinforcement strategies.
• More complete theoretical support and process standards are needed. Most
fabrications are only in the feasibility stage. Practical applications require a
stable and reliable process. Mathematical physics models can explain the
mechanism of FSP, and the use of parameter optimization systems can help
us formulate suitable processes.
• The process of composite fabrication should be improved. It is difficult to
obtain complete and uniform composite materials through existing
reinforcement phase addition methods.
• The wear of stir tools also limits industrial applications of FSP. Although the
tools used in FSP are, in principle, non-consumable, they do experience
severe wear during this process. Frequent tool replacement not only affects
efficiency but also increases production costs.
REFERENCES

• Mishra, R.S.; Mahoney, M.W.; McFadden, S.X.; Mara, N.A.; Mukherjee, A.K. High
strain rate superplasticity in a friction stir processed 7075 Al alloy. Scr. Mater.
1999, 42, 163–168.
• Wang, Y.B.; Huang, Y.X.; Meng, X.C.; Wan,L.; Feng, J.C. Microstructural
evolution and mechanical properties of Mg-Zn-Y-Zr alloy during friction stir
processing. J. Alloy. Compd. 2017, 696, 875–883.
• Sathiskumar, R.; Murugan, N.; Dinaharan, I.; Vijay, S.J. Role of friction stir
processing parameters on microstructure and microhardness of boron carbide
particulate reinforced copper surface composites. Sadhana Acad. Proc. Eng. Sci.
2013, 38, 1433–1450.
• Patel, V.V.; Badheka, V.J.; Kumar, A. Influence of pin profile on the tool plunge
stage in friction stir processing of Al-Zn-Mg-Cu alloy. Trans. Indian Inst. Met. 2017,
70, 1151–1158.
• Mehta, K.P.; Badheka, V.J. Effects of tilt angle on the properties of dissimilar
friction stir welding copper to aluminum. Mater. Manuf. Process. 2016, 31, 255–
263.
THANKYOU