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<p>This study examines the impact of FSP parameters, specifically pin profile and cooling medium, on the development of different aluminum matrices/Si<sub>3</sub>N<sub>4</sub> composites. A central groove was introduced into the stir zone to incorporate Si<sub>3</sub>N<sub>4</sub> powders. SEM and EDX analyses confirmed the incorporation of Si<sub>3</sub>N<sub>4</sub> particles within the aluminum matrices, resulting in enhanced surface characteristics. The as-received alloys exhibited significant microstructural refinement, while elemental mapping revealed a homogeneous distribution of Si<sub>3</sub>N<sub>4</sub> particles throughout the aluminum matrices. Mechanical testing revealed substantial improvements: the ultimate tensile strength (UTS) and yield strength (YS) increased by 62% and 101% in the (1050 + Si<sub>3</sub>N<sub>4</sub>) composite, and by 22% and 28%, in the (2011 + Si<sub>3</sub>N<sub>4</sub>) composite, and by 90% and 100% in the (6063 + Si<sub>3</sub>N<sub>4</sub>) composite, respectively. Hardness improvements of 38%, 31%, and 55% were observed in the (1050 + Si<sub>3</sub>N<sub>4</sub>), (2011 + Si<sub>3</sub>N<sub>4</sub>), and (6063 + Si<sub>3</sub>N<sub>4</sub>) composites. The strengthening phase was uniformly distributed along the grain boundaries, and the hardened surface layer was confirmed.</p>

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Effect of Si3N4 Powder Addition on Surface Modification of Different Aluminum Alloys Using Friction Stir Processing with Varying Cooling Media and Pin Profiles

  • 期刊论文

  • 发表日期：

    2025年11月20日

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  • Mohamed S. El-Sayed,
  • Masoud Ibrahim,
  • Ramadan N. Elshaer,
  • Ahmed I. Abdel-Aziz

摘要

This study examines the impact of FSP parameters, specifically pin profile and cooling medium, on the development of different aluminum matrices/Si3N4 composites. A central groove was introduced into the stir zone to incorporate Si3N4 powders. SEM and EDX analyses confirmed the incorporation of Si3N4 particles within the aluminum matrices, resulting in enhanced surface characteristics. The as-received alloys exhibited significant microstructural refinement, while elemental mapping revealed a homogeneous distribution of Si3N4 particles throughout the aluminum matrices. Mechanical testing revealed substantial improvements: the ultimate tensile strength (UTS) and yield strength (YS) increased by 62% and 101% in the (1050 + Si3N4) composite, and by 22% and 28%, in the (2011 + Si3N4) composite, and by 90% and 100% in the (6063 + Si3N4) composite, respectively. Hardness improvements of 38%, 31%, and 55% were observed in the (1050 + Si3N4), (2011 + Si3N4), and (6063 + Si3N4) composites. The strengthening phase was uniformly distributed along the grain boundaries, and the hardened surface layer was confirmed.