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IncorporatingSolid-state additive manufacturing reinforced particlesMetal matrix composite into lightweight materials like aluminumAluminum to produce mechanically strong metal matrix compositesMetal matrix composite (MMCs) is a promising approach for automotive components such as brake rotors and connecting rods. However, the fabrication of MMCs using fusion-based additive manufacturingAdditive manufacturing poses challenges, specifically in second, sixth, and seventh-series aluminum alloysAluminum alloys. Fabricating MMCs by utilizing the solid-deposition principle of friction stir surfacingFriction stir surfacing-based additive manufacturingAdditive manufacturing (FSSAM) can be a potential solution. In this work, FSSAM was performed to produce AA6063/SiCSiC composite with a customized mechtrode fabricated from a tube and solid rod featuring a narrow clearance filled with SiCSiC powder, followed by additional friction stir processingFriction stir processing (FSP). The FSP facilitated a smooth deposited layer with uniform intermixing of SiCSiC particles in the Al matrix. The wearWear test results showed significant wearWear resistance of MMC over base Al. Moreover, the interlayer diffusion showed good mechanical bonding between the substrate and the deposited layer.

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A Solid-State Additive Manufacturing Approach for the Fabrication of SiC-Reinforced Metal Matrix Composite in Automotive Components of Light Metal

  • 会议论文

  • 发表日期：

    2025年

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  • Souvik Karmakar,
  • Surjya Kanta Pal

摘要

IncorporatingSolid-state additive manufacturing reinforced particlesMetal matrix composite into lightweight materials like aluminumAluminum to produce mechanically strong metal matrix compositesMetal matrix composite (MMCs) is a promising approach for automotive components such as brake rotors and connecting rods. However, the fabrication of MMCs using fusion-based additive manufacturingAdditive manufacturing poses challenges, specifically in second, sixth, and seventh-series aluminum alloysAluminum alloys. Fabricating MMCs by utilizing the solid-deposition principle of friction stir surfacingFriction stir surfacing-based additive manufacturingAdditive manufacturing (FSSAM) can be a potential solution. In this work, FSSAM was performed to produce AA6063/SiCSiC composite with a customized mechtrode fabricated from a tube and solid rod featuring a narrow clearance filled with SiCSiC powder, followed by additional friction stir processingFriction stir processing (FSP). The FSP facilitated a smooth deposited layer with uniform intermixing of SiCSiC particles in the Al matrix. The wearWear test results showed significant wearWear resistance of MMC over base Al. Moreover, the interlayer diffusion showed good mechanical bonding between the substrate and the deposited layer.