A Study on Friction Stir Processing Parameters of Recycled AA 6063/TiO2 Surface Composites for Better Tribological Performance
Abstract
:1. Introduction
2. Materials and Methods
2.1. Substrate Material and Reinforcement Particles
2.2. Groove Cutting and Reinforcement Particles Allocation
2.3. Capping Process
2.4. Friction Stir Processing (FSP)
2.5. Surface Roughness Measurement
2.6. Microstructure Analysis
2.7. Surface Microhardness Measurement
2.8. Friction and Wear Tests
3. Results and Discussion
3.1. Microstructure Analysis
3.2. Microhardness Measurement
3.3. Surface Roughness Measurement
3.4. Tribological Performance
4. Conclusions
- The highest surface microhardness is achieved by the FSPed recycled AA6063/TiO2 sample produced at 2442 rpm and 50 mm/min: 55.6 HV1. This surface microhardness is 16% higher than FSPed recycled AA 6063 and 45% higher than the substrate material.
- The microstructure of the FSPed recycled AA6063/TiO2 sample that was produced at 2442 rpm and 50 mm/min exhibits the most uniform distribution of TiO2 and it also achieves the greatest reduction of grain size.
- The FSPed recycled AA6063/TiO2 sample produced at 1200 rpm with 30 mm/min, 1800 rpm with 45 mm/min and 2442 rpm with 50 mm/min give relatively low friction coefficients, while only the sample produced at 2442 rpm and 50 mm/min has the lowest friction coefficient and wear rate. This sample has an average friction coefficient of 0.33 and a wear rate of 0.43 × 10−5 gN−1m−1. This result reduced the friction coefficient and wear rate of the substrate by 39% and 73%, respectively.
- The wear morphology shows that both adhesive and abrasive wear can be observed. The FSPed samples have mostly plastic deformation with some fractures and a small number of voids. However, only plastic deformation can be observed in the sample produced at 2442 rpm and 50 mm/min.
- In short, the most suitable processing parameters used in this study for the fabrication of FSPed recycled AA 6063/TiO2 are 2442 rpm and 50 mm/min. These parameters produced the sample with the highest surface microhardness, and lowest wear rate and friction coefficient. However, further study is needed to investigate the effect of rotational speeds and feed rates that are higher and lower than 2442 rpm and 50 mm/min for enhancing tribological performance of FSPed recycled AA 6063/TiO2 surface composites.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Element | Zn | Mg | Cu | Si | Fe | Mn | Cr | Ni | Ti | Al |
---|---|---|---|---|---|---|---|---|---|---|
wt.% | 0.0331 | 0.581 | 0.0338 | 0.43 | 0.309 | 0.0252 | 0.0335 | 0.0333 | 0.0269 | Balance |
Sample | Processing Parameters | |
---|---|---|
Rotational Speed (rpm) | Feed Rate (mm/min) | |
1200-30 | 1200 | 30 |
1200-35 | 1200 | 35 |
1400-25 | 1400 | 25 |
1400-30 | 1400 | 30 |
1600-30 | 1600 | 30 |
1600-35 | 1600 | 35 |
1600-40 | 1600 | 40 |
1600-45 | 1600 | 45 |
1800-35 | 1800 | 35 |
1800-40 | 1800 | 40 |
1800-45 | 1800 | 45 |
2000-25 | 2000 | 25 |
2000-35 | 2000 | 35 |
2000-40 | 2000 | 40 |
2442-50 | 2442 | 50 |
Tribo-Tests | Parameters |
---|---|
Varying nominal contact pressures | Nominal contact pressures: 0.08 MPa, 0.16 MPa, 0.24 MPa, 0.32 MPa, 0.41 MPa, 0.47 MPa Speed: 5.18 m/s Sliding duration: 120 s |
Varying speeds | Speeds: 1 m/s, 2 m/s, 3 m/s, 4 m/s, 5 m/s, 6 m/s Nominal contact pressure: 0.28 MPa Sliding duration: 120 s |
Varying sliding distances | Sliding distance: 2.5 km Speed: 2.88 m/s Nominal contact pressure: 0.24 MPa |
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Teo, G.S.; Liew, K.W.; Kok, C.K. A Study on Friction Stir Processing Parameters of Recycled AA 6063/TiO2 Surface Composites for Better Tribological Performance. Metals 2022, 12, 973. https://doi.org/10.3390/met12060973
Teo GS, Liew KW, Kok CK. A Study on Friction Stir Processing Parameters of Recycled AA 6063/TiO2 Surface Composites for Better Tribological Performance. Metals. 2022; 12(6):973. https://doi.org/10.3390/met12060973
Chicago/Turabian StyleTeo, Guo Sheng, Kia Wai Liew, and Chee Kuang Kok. 2022. "A Study on Friction Stir Processing Parameters of Recycled AA 6063/TiO2 Surface Composites for Better Tribological Performance" Metals 12, no. 6: 973. https://doi.org/10.3390/met12060973