Corrosion Behavior of Aluminum Surface Composites with Metallic, Ceramic, and Hybrid Reinforcements Using Friction Stir
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LIGHTWEIGHT and high-specific strength make aluminum (Al) alloys suitable candidates for aerospace and automotive applications.[1,2] However, the applications are limited by reduced corrosion resistance in chloride environments, low surface hardness, and wear resistance. The corrosion resistance of Al alloys due to the natural oxide layer on the surface is affected by the environments containing chloride ions.[3] Surface composition modification is an effective way to improve surface properties.[4–6] Such modifications can be introduced by both liquid- and solid-state processing techniques. A solid-state processing technique such as friction stir processing (FSP) can avoid the formation of intermetallics, which has been reported in liquid-state
V. P. MAHESH, ANURAG GUMASTE, NEHA MEENA, and AMIT ARORA are with the Advanced Materials Processing Research Group, Materials Science and Engineering, Indian Institute of Technology Gandhinagar, Gandhinagar, Gujarat 382355, India. Contact e-mail: [email protected] J. ALPHONSA is with the Institute for Plasma Research, Gandhinagar, Gujarat 382428, India. Manuscript submitted December 31, 2019.
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processing such as Laser surface alloying (LSA).[7–9] FSP results in wider and deeper processed area, better mechanical properties and almost no porosity, intermetallics, and flash compared to the Tungsten Inert Gas (TIG) processing.[10] Surface properties such as hardness and wear resistance also improve with FSP apart from no matrix–reinforcement interfacial reactions.[11–13] Surface composites can improve the corrosion resistance in chloride environment, where the reinforcement can be either ceramic (boron carbide (B4C), silicon carbide (SiC), alumina (Al2O3) etc.), or metal (molybdenum (Mo), chromium (Cr), tungsten (W) etc.).[14–18] Among the metallic reinforcements, Mo has very low solubility in Al and results in higher hardness, wear resistance, and corrosion resistance compared to Al alloys.[19–23] The uniform distribution of elemental Mo particles in Al 6082 matrix leads to enhanced tensile properties without reducing the ductility.[21] The corrosion resistance is increased with the addition of Mo particles and increased number of processing passes for Al-Mo surface composites fabricated by FSP groove method.[24] Laser surface alloying of Aluminum 2014 with Mo has also reported an increase in corrosion resistance.[25] Among the ceramic reinforcements, B4C has higher hardness, wear resistance, and neutron
shielding capacity which makes B4C-reinforced composite materials a suitable candidate for structural and nuclear applications.[26] The AA6063-B4C surface composites fabricated by FSP show higher hardness and wear resistance compared to the AA6063 base alloy.[18] A study on AA5083-B4C composite fabricated by stir casting method reported decrease in corrosion resistance with increase in B4C content.[27] The mono-reinforced composites with either Mo or B4C as reinforcement have exhibited improved mechanical properties. The Mo-reinf
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