Enhancing Corrosion and Wear Resistance of AA6061 by Friction Stir Processing with Fe78Si9B13 Glass Particles

The AA6061-T6 aluminum alloy samples including annealed Fe78Si₉B13 particles were prepared by friction stir processing (FSP) and investigated by various techniques. The Fe78Si₉B13-reinforced particles are uniformly dispersed in the aluminum alloy matrix. The XRD results indicated that the lattice parameter of α-Al increases and the preferred orientation factors F of (200) plane of α-Al reduces after friction stir processing. The coefficient of thermal expansion (CTE) for FSP samples increases at first with the temperature but then decreases as the temperature further increased, which can be explained by the dissolving of Mg and Si from β phase and Fe78Si₉B13 particles. The corrosion and wear resistance of FSP samples have been improved compared with that of base metal, which can be attributed to the reduction of grain size and the CTE mismatch between the base metal and reinforced particles by FSP, and the lubrication effect of Fe78Si₉B13 particles also plays a role in improving wear resistance. In particular, the FSP sample with reinforced particles in amorphous state exhibited superior corrosion and wear resistance due to the unique metastable structure.