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<p>Al-4.4Cu-1.5&#xa0;Mg alloy matrix composites were produced via stir casting followed by friction stir processing to study the effects of pre-deformation and cooling conditions on their microstructure and mechanical behavior. Rolled and annealed sheets containing Al<sub>2</sub>O<sub>3</sub> particles were processed at 600&#xa0;rpm in air and underwater environments. The rolled specimen processed underwater showed complete consolidation and uniform particle dispersion with the finest dynamically recrystallized grains (7.0 ± 0.9&#xa0;µm). Increasing heat input during air processing or annealing resulted in coarser grains (up to 9.1 ± 0.7&#xa0;µm), confirming enhanced recrystallization. The underwater-processed rolled composite exhibited the highest microhardness (132.1 ± 2.4 HV), tensile strength (482.1 ± 11.3&#xa0;MPa), and fracture toughness (84.1 ± 1.3&#xa0;MJ&#xa0;m<sup>−3</sup>), significantly outperforming the annealed base alloy. Elongation reached 20.2 ± 1.3 %, indicating a good balance between strength and ductility. The lowest wear rate (4.6 ± 0.1&#xa0;µg/m) was also obtained under this condition due to grain refinement and uniform reinforcement distribution, which changed the dominant wear mechanism from adhesive to abrasive.</p>

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Investigation of Underwater Friction Stir Processing on Microstructure, Mechanical Properties, and Wear Resistance of Al-4.4Cu-1.5Mg Alloy Matrix Composite

  • 期刊论文

  • 发表日期：

    2025年11月23日

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  • Morteza Abedi,
  • Hamed Jamshidi Aval,
  • Roohollah Jamaati

摘要

Al-4.4Cu-1.5 Mg alloy matrix composites were produced via stir casting followed by friction stir processing to study the effects of pre-deformation and cooling conditions on their microstructure and mechanical behavior. Rolled and annealed sheets containing Al2O3 particles were processed at 600 rpm in air and underwater environments. The rolled specimen processed underwater showed complete consolidation and uniform particle dispersion with the finest dynamically recrystallized grains (7.0 ± 0.9 µm). Increasing heat input during air processing or annealing resulted in coarser grains (up to 9.1 ± 0.7 µm), confirming enhanced recrystallization. The underwater-processed rolled composite exhibited the highest microhardness (132.1 ± 2.4 HV), tensile strength (482.1 ± 11.3 MPa), and fracture toughness (84.1 ± 1.3 MJ m−3), significantly outperforming the annealed base alloy. Elongation reached 20.2 ± 1.3 %, indicating a good balance between strength and ductility. The lowest wear rate (4.6 ± 0.1 µg/m) was also obtained under this condition due to grain refinement and uniform reinforcement distribution, which changed the dominant wear mechanism from adhesive to abrasive.