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<p>The present research focuses on the influence of the tool pin’s geometric shape on the evolution of microstructure, microhardness, and tribological properties of FSPed aluminum alloy 2024. To examine the effect of the geometrical shape of tool pin, three types of pins—triangular (TPG), square (SPG) and hexagonal (HPG)—were used under constant speed parameters (1000&#xa0;rpm, 40&#xa0;mm/min). Microstructure results reveal that grain size was smaller in SPG (5.3 ± 2.4&#xa0;µm) and HPG (4.5 ± 1.9&#xa0;µm) than in TPG (7.2 ± 3.5&#xa0;µm), thereby ensuring better grain-size uniformity. The precipitate size distribution also became finer, from 1.2 ± 0.9&#xa0;µm (TPG) to 0.8 ± 0.5&#xa0;µm (HPG), as revealed by SEM. Moreover, increases in microhardness from 118 ± 5 HV (TPG) to 132 ± 4 HV (SPG) and 146 ± 3 HV (HPG) further confirm the improvement in hardness. During the dry sliding process, the COF value obtained for HPG was lower than those for SPG and TPG pins (~ 1.42 and ~ 1.40, respectively), at 1.34.</p>

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Tribological Performance and Microstructural Evolution of AA2024 Alloy Processed with Different Friction Stir Tool Pin Geometry Designs

  • 期刊论文

  • 发表日期：

    2026年6月1日

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  • Koundinya Viswa Chakra Musunuri,
  • N. Raghu Ram,
  • P. Phani Prasanthi

摘要

The present research focuses on the influence of the tool pin’s geometric shape on the evolution of microstructure, microhardness, and tribological properties of FSPed aluminum alloy 2024. To examine the effect of the geometrical shape of tool pin, three types of pins—triangular (TPG), square (SPG) and hexagonal (HPG)—were used under constant speed parameters (1000 rpm, 40 mm/min). Microstructure results reveal that grain size was smaller in SPG (5.3 ± 2.4 µm) and HPG (4.5 ± 1.9 µm) than in TPG (7.2 ± 3.5 µm), thereby ensuring better grain-size uniformity. The precipitate size distribution also became finer, from 1.2 ± 0.9 µm (TPG) to 0.8 ± 0.5 µm (HPG), as revealed by SEM. Moreover, increases in microhardness from 118 ± 5 HV (TPG) to 132 ± 4 HV (SPG) and 146 ± 3 HV (HPG) further confirm the improvement in hardness. During the dry sliding process, the COF value obtained for HPG was lower than those for SPG and TPG pins (~ 1.42 and ~ 1.40, respectively), at 1.34.