Improvement of mechanical properties in the functionally-graded aluminum matrix nanocomposites fabricated via a novel multistep friction stir processing

Abstract

In the present study, the functionally graded bulk Al-SiC nanocomposites were successfully fabricated by applying a novel multistep friction stir processing. Microstructural observations by scanning electron microscope indicated a proper distribution of SiC nanoparticles in the Al 6061 matrix. Microhardness profiles descended to 50 from 160 Hv due to the formation of compositionally gradient of SiC nanoparticles along the thickness. The tensile behavior of graded samples revealed a simultaneous enhancement of ultimate tensile strength (44 pct), strain at maximum stress (244 pct), and work of fracture (492 pct) with respect to the homogeneous sample. Furthermore, the graded samples sustained up to 4 pct strain after initiation of primary cracking, while the catastrophic fracture occurred instantly after cracking in the homogenous sample. A dimple-like ductile fracture surface was observed for the graded layers in which an increase in the SiC particle content will result in smaller dimple size.