Additive Manufacturing of AA6063-ZrO2 Composite Using Friction Stir Surface Additive Manufacturing

In the present work, aluminum matrix composite is manufactured layer by layer using ZrO2 as reinforcement through friction stir surface additive manufacturing process. Four holes in AA6063-T4 Al alloy consumable rod (matrix) are filled with ZrO2 reinforcement prior to additive manufacturing. Each layer is deposited at rod plunging speed of 60 mm/min, tool rotational speed of 1500 rpm, and substrate traverse speed of 200 mm/min. Two composites each possessing different percentage of ZrO2 (8% and 12%) revealed finer grains and homogenous distribution of reinforced particles. Composite with 12% ZrO2 showed maximum improvement in microhardness and ultimate tensile strength of 46% and 53%, respectively, than as-deposited rod. Wear resistance of composites was found to improve significantly compared to as-received rod irrespective of the applied normal load. The newly identified solid-state process would be useful over melting-based approaches for fabricating Al-based composites.