Microstructure, microhardness and wear properties Investigation in Friction Stir Processing of Stir Cast Mg/B4C metal matrix composite

Abstract Friction Stir Processing (FSP) has emerged as an excellent processing approach to tailor the microstructural and other properties of cast alloys and composite materials. In the current investigation, a stir-cast magnesium metal matrix composite (MMMC) reinforced with 12 wt% B4C particles was processed using single-pass FSP. FSP was carried out with a simple cylindrical tool pin using different tool rotational speeds of 800, 1000, 1200 rpm and transverse speed of 60 mm/min. Severe deformation occurred during FSP which helped to refine the distribution of the B4C particles and grain refinement of as-cast composites. Microstructural examination showed an appreciable grain refinement from 98 to 5μm because of dynamic recrystallization during FSP. The maximum microhardness of the friction stir processed (FSPed) composites increased from 73 Hv to 105.4 Hv. Pin-on-disk wear tests were conducted under dry sliding conditions in the load range of 1 kg to 5 kg at a 1 m/s sliding velocity. The wear results indicated an enhancement of wear properties of FSPed composites in comparison to as-cast magnesium metal matrix composites. The improved hardness and wear resistance results were pertaining to the remarkable refinement in grain size coupled with refined B4C particulates and uniform distribution. The best results for hardness and wear resistance of the FSPed composite were obtained for a sample processed at a tool rotation speed of 1000 rpm. SEM/EDS of the worn samples was carried out. The wear mechanism was found as slight abrasion and oxidation. After single pass FSP, the surface of Mg/12wt% B4C cast composite showed remarkable changes in worn surface morphology.