Effect of friction stir processing tool probe on fabrication of SiC particle reinforced composite on aluminium surface

Abstract An investigation has been carried out of the effects of tool probe shape and size on the formation of surface composite by uniformly distributing SiC particles into a surface layer of an A1050-H24 aluminium plate through friction stir processing (FSP). Tool probes of three different diameters (3, 5 and 7 mm) and four different shapes (circular with threads, circular without threads, square and triangular) have been used to fabricate the surface layers at rotation speeds of 1500–2250 rev min−1 and a travelling speed of 1·66 mm s−1. The SiC particles were packed into a groove of 3 mm width and 1·5 mm depth cut on the aluminium plate and covered by an aluminium sheet of 2 mm thickness. A rotating tool was plunged into the plate through the cover sheet so that the tip of the probe reached beyond the bottom of the groove. As a result, it was found that the square probe dispersed the SiC particles homogeneously in the nugget zone compared with other probe shapes regardless of the rotation speeds. Furthermore, the distributed particles and also the aluminium matrix grain size became finer by the use of square probe than those of the other shapes. On the other hand, the wear rates of the square and triangular probes were higher than that of circular shape. The worn iron debris from the tool reacted with aluminium matrix and form fine iron aluminides compound dispersed in the nugget zone. The probe size had limited effects on the homogeneity of the SiC particles distribution in the nugget zone; the distribution of SiC particles obtained by triple FSP passes was less homogeneous when the probe size was smaller. Microhardness of the nugget zone was homogeneously increased to a level as high as 60 HV with tool of square probe shape after three passes to be compared with 23 HV of the aluminium matrix beside the nugget zone.