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<p>Friction stir processing (FSP) has been an efficient technique to enhance the microstructures and mechanical properties of magnesium nanocomposites. However, the incorporation of multiwall carbon nanotubes (MWCNT) reinforcements in high concentration (5&#xa0;wt.%) and achieving uniform distribution of individual nanoparticles in magnesium alloy matrix are still being researched. This work proposes a novel synergistic role of ultrasonic-assisted casting and friction stir processing are used to synthesize AZ31-5&#xa0;wt.% MWCNT nanocomposites and the influence of variation in traverse speed (TS) are investigated to understand the microstructural changes, mechanical performance, and electrochemical corrosion behavior of the nanocomposite. The single-pass FSP was carried out on as-cast AZ31-5&#xa0;wt.% MWCNT nanocomposite plate with five TS (15, 30, 45, 60, and 75 mm/min), and all other FSP parameters were kept constant. The ultimate tensile strength (↑11%), yield strength (↑22%), microhardness (↑11%), and impact toughness (↑24%) showed maximum improvement for nanocomposite prepared with an optimal traverse speed of 45&#xa0;mm/min when compared with the lowest TS. The corrosion resistance of nanocomposite processed at 45&#xa0;mm/min TS showed good improvement by 56%. The enhancement in mechanical and corrosion behavior was attributed to the ultrafine grain refinement formed by adequate heat input, uniform β-phase dispersion, and homogeneous mixing of MWCNT reinforcements, which were split into shorter lengths due to high shearing energy of FSP, as investigated using SEM-EDS and TEM. These results emphasize the significance of optimized FSP parameters to produce high-strength, corrosion-resistant magnesium nanocomposites to be used as lightweight structural, aerospace, and automobile materials with superior mechanical and electrochemical stability.</p>

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Synergetic Effect of Ultrasonication-Assisted Casting and Friction Stir Processing on the Mechanical and Corrosion Resistance of Magnesium Nanocomposites: Influence of Traverse Speed Variations

  • 期刊论文

  • 发表日期：

    2025年6月3日

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  • S. C. Amith,
  • Thirugnanasambandam Arunkumar,
  • G. Saravan,
  • S. Krishnakumar

摘要

Friction stir processing (FSP) has been an efficient technique to enhance the microstructures and mechanical properties of magnesium nanocomposites. However, the incorporation of multiwall carbon nanotubes (MWCNT) reinforcements in high concentration (5 wt.%) and achieving uniform distribution of individual nanoparticles in magnesium alloy matrix are still being researched. This work proposes a novel synergistic role of ultrasonic-assisted casting and friction stir processing are used to synthesize AZ31-5 wt.% MWCNT nanocomposites and the influence of variation in traverse speed (TS) are investigated to understand the microstructural changes, mechanical performance, and electrochemical corrosion behavior of the nanocomposite. The single-pass FSP was carried out on as-cast AZ31-5 wt.% MWCNT nanocomposite plate with five TS (15, 30, 45, 60, and 75 mm/min), and all other FSP parameters were kept constant. The ultimate tensile strength (↑11%), yield strength (↑22%), microhardness (↑11%), and impact toughness (↑24%) showed maximum improvement for nanocomposite prepared with an optimal traverse speed of 45 mm/min when compared with the lowest TS. The corrosion resistance of nanocomposite processed at 45 mm/min TS showed good improvement by 56%. The enhancement in mechanical and corrosion behavior was attributed to the ultrafine grain refinement formed by adequate heat input, uniform β-phase dispersion, and homogeneous mixing of MWCNT reinforcements, which were split into shorter lengths due to high shearing energy of FSP, as investigated using SEM-EDS and TEM. These results emphasize the significance of optimized FSP parameters to produce high-strength, corrosion-resistant magnesium nanocomposites to be used as lightweight structural, aerospace, and automobile materials with superior mechanical and electrochemical stability.