Influence of Friction Stir Process on the Physical, Microstructural, Corrosive, and Electrical Properties of an Al-Mg Alloy Modified with Ti-B Additives

Production of Hybrid Nanocomposites Based on Iron Waste Reinforced with Niobium Carbide/Granite Nanoparticles with Outstanding Strength and Wear Resistance for Use in Industrial Applications

The main objective of this work is to recycle unwanted industrial waste in order to produce innovative nanocomposites with improved mechanical, tribological, and thermal properties for use in various industrial purposes. In this context, powder metallurgy (PM) technique was used to fabricate iron (Fe)/copper (Cu)/niobium carbide (NbC)/granite nanocomposites having outstanding mechanical, wear and thermal properties. Transmission electron microscopy (TEM) and X-ray diffraction (XRD) examinations were used to investigate the particle size, crystal size, and phase composition of the milled samples. Additionally, it was investigated how different volume percentages of the NbC and granite affected the sintered specimens in terms of density, microstructure, mechanical and wear properties, and coefficient of thermal expansion (CTE). According to the findings, the milled powders included particles that were around 55 nm in size and clearly contained agglomerates. The results showed that the addition of 4 vol.% NbC and 8 vol.% granite nanoparticles caused a reduction in the Fe-Cu alloy matrix particle sizes up to 47.8 nm and served as a barrier to the migration of dislocations. In addition, the successive increase in the hybrid concentrations led to a significant decrease in the crystal size of the samples prepared as follows: 29.73, 27.58, 22.69, 19.95 and 15.8 nm. Furthermore, compared with the base Fe-Cu alloy, the nanocomposite having 12 vol.% of hybrid reinforcement demonstrated a significant improvement in the microhardness, ultimate strength, Young's modulus, longitudinal modulus, shear modulus, bulk modulus, CTE and wear rate by 94.3, 96.4, 61.1, 78.2, 57.1, 73.6, 25.6 and 61.9%, respectively. This indicates that both NbC and granite can actually act as excellent reinforcements in the Fe alloy.

Macro- and Microstructure of In Situ Composites Prepared by Friction Stir Processing of AA5056 Admixed with Copper Powders

This paper is devoted to using multi-pass friction stir processing (FSP) for admixing 1.5 to 30 vol.% copper powders into an AA5056 matrix for the in situ fabrication of a composite alloy reinforced by Al-Cu intermetallic compounds (IMC). Macrostructurally inhomogeneous stir zones have been obtained after the first FSP passes, the homogeneity of which was improved with the following FSP passes. As a result of stirring the plasticized AA5056, the initial copper particle agglomerates were compacted into large copper particles, which were then simultaneously saturated by aluminum. Microstructural investigations showed that various phases such as α-Al(Cu), α-Cu(Al) solid solutions, Cu₃Al and CuAl IMCs, as well as both S and S'-Al₂CuMg precipitates have been detected in the AA5056/Cu stir zone, depending upon the concentration of copper and the number of FSP passes. The number of IMCs increased with the number of FSP passes, enhancing microhardness by 50-55%. The effect of multipass FSP on tensile strength, yield stress and strain-to-fracture was analyzed.

Ultralight Functionally Graded Hybrid Nanocomposites Based on Yttrium and Silica-Reinforced Mg10Li5Al Alloy: Thermal and Tribomechanical Properties

Despite the amazing properties of lightweight Mg₁₀Li₅Al alloy, its use in industrial applications is highly limited due to its low mechanical properties, wear resistance, and coefficient of thermal expansion (CTE). In this context, this work aimed to improve the above properties without sacrificing the important benefit of this alloy being lightweight. Therefore, function grade composites (FGCs) were prepared based on the Mg₁₀Li₅Al alloy reinforced by yttrium (Y) and silica fume using the powder metallurgy technique. Then, the nanocomposite's microstructure, mechanical properties, artificial aging, wear resistance, and thermal expansion were examined. The results indicated that the precipitation (MgAlLi₂), softening (AlLi₂), and Mg₂₄Y₅ phases were formed in high-reinforced samples during high-energy milling. Furthermore, the addition of reinforcements accelerated the decomposition from the MgAlLi₂ phase to the Al-Li phase (softening point). For the layer containing the highest reinforcement content, microhardness, strength, and Young's modulus improved up to 40, 22.8, and 41%, respectively, due to the combined effect of the high strength of silica fume and the dispersion strengthening Mg₂₄Y₅ phase. Meanwhile, the same sample exhibited a remarkable improvement in wear rate and the CTE value to about 43 and 16.5%, respectively, compared to the non-reinforced alloy.