Aluminum Alloy Chips Recycling using Friction Stir Consolidation

The purpose of this paper is to develop AA5052 aluminum alloy solid disc from machining wastes via friction stir consolidation (FSC) process & optimize its parameters: die rotational speed, pre-compact aspect ratio and processing time. At first, the required dedicated tooling designed built. Then, discs are fabricated chips using FSC process. Taguchi L9 orthogonal array used analyze Experimental parameters their levels considered speed (315, 400 500 rpm), (25.4/7, 25.4/5 25.4/3) time (30, 45 60 sec). Using standard tests, compressive strength, hardness microstructure consolidated evaluated. results reveal that successfully tooling, (500 (25.4/3) (60 sec) optimal conditions. Microstructure examination shows finer fully recrystallized grains in axial cross section orientation. Moreover, show strength comparable forged or cast suitable for most engineering structural applications.