Publication

Abstract : The shape of the tool is a decisive factor that influences the material flow and, thereby, the tribological and mechanical characteristics of composites in FSP. Thus, the impact of single-pin (SP) and double-pin (DP) tools on the microstructure, mechanical, and wear behavior of newly developed AA5083/AlCoCrFeNi HEA surface composites is studied in detail. The findings demonstrated that using a DP tool for the FSP of the AA5083/AlCoCrFeNi HEA surface composite significantly reduced the average grain size from 10.38 to 6.18 μm through continuous dynamic recrystallization (CDRX), while also making it easier for AlCoCrFeNi particles to spread across the AA5083 substrate/matrix. This improvement can be attributed to the DP tool's facilitation of flow velocity and excess plastic deformation. It was also found that due to grain refinement, better AlCoCrFeNi particle dispersion, and eradicating typical FSP defects, such as the clustering of reinforcing particulates, the AA5083/AlCoCrFeNi surface composite developed with the DP tool resulted in an improvement of 18 % over the sample processed with the single-pin tool. Results also revealed that using double-pin triggered a slight decrease in the wear rate (0.41–0.32 mm3/Nm) and the friction coefficient (0.40–0.33) owing to effective dispersion and minimization of the reinforcement particles across the matrix.