Microstructural characterization and mechanical properties of AA5083/Coal composites fabricated by friction stir processing

Abstract

This study evaluates the development and characterization of AA5083/Coal composite joints using Friction Stir Processing (FSP) technology. The primary findings reveal significant improvements in the grain structure, with the utilization of FSP leading to an average mean grain size of 31.173 μm, representing a reduction of 50.8598% compared to the AA5083-H111 base material. This grain refinement contributed to a notable increase in hardness, achieving an average of 91.42 HV for the AA5083/Coal composite. The highest tensile strength recorded was 280 MPa, with a yield strength of 225.6 MPa. Additionally, flexural strength analysis indicated a significant difference between face and root specimens, with face specimens demonstrating a maximum ultimate flexural strength of 747.53 MPa. However, the agglomeration of coal particles and non-uniform particle distribution negatively impacted the mechanical properties, resulting in a slight reduction in the ultimate tensile strength compared to the AA5083-H111 base material. This work offers valuable insights into the fabrication and characterization of AA5083/Coal composite joints, contributing to the development of lightweight and cost-effective materials. The study underscores the importance of optimizing process parameters to minimize defects and enhance mechanical performance.