Microstructural and sensor data analysis of friction stir processing in fabricating Al6061 surface composites

Abstract Aluminium alloys, having high strength, ductility, and toughness, are useful structural materials. Composites of these with ceramic reinforcements improve the hardness wear-resistance, making them suitable for use in aerospace automobile industries. Since surface properties play a crucial role most applications, manufacturing composites aluminum alloys is recommended. For this purpose, friction stir processing (FSP) being utilized nowadays. It refines microstructure homogeneous dispersion into matrix improves physical characteristics like hardness, wear resistance, etc, while retaining original remaining volume. The study aims to investigate compare temperature vibration sensor data Al6061 hybrid by using FSP tools different geometries. method utilised fabrication copper graphite powders mixture (1:1), reinforced two H13 pin profiles - threaded cylindrical plain cylindrical. Holes diameters depths drilled on reinforcement addition. This process investigated thermal gun Cross-Domain Development kit measurement. variation signals occurring composite workpiece during entire measurements at equal intervals, obtained. found that both amplitudes (400 °C 1111Hz) lower fabricated tool profile than (455 1305 Hz). Also, processed samples Field Emission Scanning Electron Microscope Energy-Dispersive x-ray Spectroscopy tests. dispersed more uniformly much reduced size (0.5482 μ m) when prepared pin, particles heterogeneously less (1.11 processes pin. research can be used further monitor control temperature, vibration, force, current, obtain uniform improved mechanical preparation FSP.