Microstructure and mechanical properties of Al2O3/AZ61 Mg alloy surface composite developed using friction stir processing and groove reinforcement filling processes

Mohankumar Ashokkumar; Tushar Sonar; Arunkumar Thirugnanasambandam; Packkirisamy Vignesh; Mikhail Ivanov

doi:10.1515/mt-2024-0132

Article

Microstructure and mechanical properties of Al₂O₃/AZ61 Mg alloy surface composite developed using friction stir processing and groove reinforcement filling processes

Mohankumar Ashokkumar
Dr. Mohankumar Ashokkumar is working as Assistant Professor (Research) in Centre for Sustainable Materials and Surface Metamorphosis, Chennai Institute of Technology, Chennai, Tamil Nadu, India. He completed his PhD in Manufacturing Engineering from Annamalai University, Chidambaram, Tamil Nadu, India, in the year 2024. He has 4 years of research work experience. He has published 22 research papers in reputed journals and presented research papers at many international conferences. He is serving as reviewer for many peer-reviewed international journals. His research areas are thermal spray coating, surfacing, composite materials, and magnesium alloys.
, Tushar Sonar
Dr. Tushar Sonar is working as a Senior Research Scientist in the Department of Welding Engineering, South Ural State University, Chelyabinsk, Russia. He completed his Ph.D. in Manufacturing Engineering from Annamalai University in the year 2021. He is a recipient of the prestigious ISRO RESPOND research fellowship for the years 2017–2021. He is serving as the guest editor for International Journal on Interactive Design and Manufacturing (Scopus and ESCI indexed) and editorial board member for Frontiers in Materials Science (Scopus/SCIE indexed), and Journal of the Mechanical Behavior of Materials (Scopus/ESCI indexed) and as reviewer for many reputed international journals. He has total of 08 years of research work experience. His research interests include welding and joining, additive manufacturing, surfacing, coating, corrosion, and high entropy alloys.
, Arunkumar Thirugnanasambandam
Dr. Arunkumar Thirugnanasambandamhas over 15 years of teaching and research experience in mechanical engineering. Currently a Professor and Director of Centre for Sustainable Materials & Surface Metamorphosis at the Chennai Institute of Technology, his expertise includes surface coatings, additive manufacturing, ceramics, polymers, nanomaterials, and tribology. He completed a various funded research projects. He has published over 100 research articles with a cumulative impact factor of 200+, over 1300 citations, and an H-index of 18+. He has been listed among the world’s top 2 % scientists by Stanford University, USA, and Elsevier
, Packkirisamy Vignesh
Dr. Packkirisamy Vignesh is working as Assistant Professor (Research) Centre for Sustainable Materials and Surface Metamorphosis, Chennai Institute of Technology, Chennai, Tamil Nadu, India. He completed his PhD in Manufacturing Engineering from Annamalai University, Chidambaram, Tamil Nadu, India, in the year 2024. He has 3 years of research work experience. He has published 20 research papers in reputable journals and presented research papers at many international conferences. He is serving as reviewer for many peer-reviewed international journals. His research areas are composite materials, metal matrix composites, biomaterials tribology, magnesium alloys.
and Mikhail Ivanov
Prof. Mikhail Ivanov is working as a Head of the Department of Welding Engineering and Director of the Institution of Engineering and Technology at South Ural State University, Chelyabinsk, Russia. He completed his PhD Technical sciences (Foundry) from South Ural State University in the year 2007. He is recipient of many prestigious awards in Russia including Gratitude of the Minister of Education and Science of the Chelyabinsk Region and Honorary Diploma of the Rector for active participation in the preparation of high-quality applications for competitions and grants. He has total of 17 years of teaching and research work experience. His research interests include welding and joining, hot tears, cold cracks, simulation of welding phenomena.

Published/Copyright: October 28, 2024

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From the journal Materials Testing Volume 66 Issue 11

Abstract

In this work, the alumina (Al₂O₃) particles-reinforced AZ61 magnesium (Mg) alloy surface composite was fabricated using friction stir processing (FSP) and groove reinforcement filling methods. The Mg alloy surface composites were developed with and without the addition of Al₂O₃ reinforcing particles, and their mechanical performance was compared with each other and with unprocessed base metal (BM). The Al₂O₃ powder was compressed into a groove of 4.5 mm depth that had been created in AZ61 Mg alloy plates. The volume fraction of Al₂O₃ powder was increased to 5, 10, and 15 vol.% depending on the width of the groove. Results disclosed that the problem of cluster formation of reinforcing Al₂O₃ particles was minimized by performing FSP in five number of passes. The ultimate tensile strength (UTS) and hardness of AZ61 Mg alloy were enhanced by 6.07 % and 22.23 % when it was subjected to FSP. This is primarily correlated to the significant refining of grains due to the severe plastic deformation associated with FSP. The 15 vol.%-FSPed Al₂O₃/AZ61 Mg alloy surface composite showed a higher UTS of 630 MPa and hardness of 300 HV. This is due to the integration of a greater quantity of Al₂O₃ particles with substantial grain refining.

Keywords: friction stir processing; AZ61 magnesium alloy; Al2O3 ; surface composite; microstructure; mechanical properties

Corresponding author: Mohankumar Ashokkumar, Centre for Sustainable Materials and Surface metamorphosis, Chennai Institute of Technology, Chennai, 600069, Tamil Nadu, India, E-mail: ashokkumarm@citchennai.net

Funding source: Centre for Sustainable Materials and Surface metamorphosis, Chennai Institute of Technology, Chennai, India

Award Identifier / Grant number: CIT/CAM/2024/RP/004

About the authors

Mohankumar Ashokkumar

Dr. Mohankumar Ashokkumar is working as Assistant Professor (Research) in Centre for Sustainable Materials and Surface Metamorphosis, Chennai Institute of Technology, Chennai, Tamil Nadu, India. He completed his PhD in Manufacturing Engineering from Annamalai University, Chidambaram, Tamil Nadu, India, in the year 2024. He has 4 years of research work experience. He has published 22 research papers in reputed journals and presented research papers at many international conferences. He is serving as reviewer for many peer-reviewed international journals. His research areas are thermal spray coating, surfacing, composite materials, and magnesium alloys.

Tushar Sonar

Dr. Tushar Sonar is working as a Senior Research Scientist in the Department of Welding Engineering, South Ural State University, Chelyabinsk, Russia. He completed his Ph.D. in Manufacturing Engineering from Annamalai University in the year 2021. He is a recipient of the prestigious ISRO RESPOND research fellowship for the years 2017–2021. He is serving as the guest editor for International Journal on Interactive Design and Manufacturing (Scopus and ESCI indexed) and editorial board member for Frontiers in Materials Science (Scopus/SCIE indexed), and Journal of the Mechanical Behavior of Materials (Scopus/ESCI indexed) and as reviewer for many reputed international journals. He has total of 08 years of research work experience. His research interests include welding and joining, additive manufacturing, surfacing, coating, corrosion, and high entropy alloys.

Arunkumar Thirugnanasambandam

Dr. Arunkumar Thirugnanasambandamhas over 15 years of teaching and research experience in mechanical engineering. Currently a Professor and Director of Centre for Sustainable Materials & Surface Metamorphosis at the Chennai Institute of Technology, his expertise includes surface coatings, additive manufacturing, ceramics, polymers, nanomaterials, and tribology. He completed a various funded research projects. He has published over 100 research articles with a cumulative impact factor of 200+, over 1300 citations, and an H-index of 18+. He has been listed among the world’s top 2 % scientists by Stanford University, USA, and Elsevier

Packkirisamy Vignesh

Dr. Packkirisamy Vignesh is working as Assistant Professor (Research) Centre for Sustainable Materials and Surface Metamorphosis, Chennai Institute of Technology, Chennai, Tamil Nadu, India. He completed his PhD in Manufacturing Engineering from Annamalai University, Chidambaram, Tamil Nadu, India, in the year 2024. He has 3 years of research work experience. He has published 20 research papers in reputable journals and presented research papers at many international conferences. He is serving as reviewer for many peer-reviewed international journals. His research areas are composite materials, metal matrix composites, biomaterials tribology, magnesium alloys.

Mikhail Ivanov

Prof. Mikhail Ivanov is working as a Head of the Department of Welding Engineering and Director of the Institution of Engineering and Technology at South Ural State University, Chelyabinsk, Russia. He completed his PhD Technical sciences (Foundry) from South Ural State University in the year 2007. He is recipient of many prestigious awards in Russia including Gratitude of the Minister of Education and Science of the Chelyabinsk Region and Honorary Diploma of the Rector for active participation in the preparation of high-quality applications for competitions and grants. He has total of 17 years of teaching and research work experience. His research interests include welding and joining, hot tears, cold cracks, simulation of welding phenomena.

Research ethics: Not applicable.
Informed consent: Not applicable.
Author contributions: All the authors have accepted responsibility for the entire content of this submitted manuscript and approved submission.
Use of Large Language Models, AI and Machine Learning Tools: None declared.
Conflict of interests: The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.
Research funding: This work is funded by Centre for Sustainable Materials and Surface metamorphosis, Chennai Institute of Technology, Chennai, India (Funding number CIT/CAM/2024/RP/004).
Data availability: The data that supports the findings of this study is available within the article.

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Published Online: 2024-10-28

Published in Print: 2024-11-26

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Articles in the same Issue

https://doi.org/10.1515/mt-2024-0132

Keywords for this article

friction stir processing; AZ61 magnesium alloy; Al2O3; surface composite; microstructure; mechanical properties