The effect of process parameters in friction stir processing of cast hypereutectic Al–Si alloy

S. S. Abdulmalik, Riad Ahmad, Mohammed Asmael

Research output: Contribution to journalArticlepeer-review


Friction stir processing FSP is an evolving metal-working process that allows microstructure in the surface of metallic materials to be modified. The effect of the tool rotation rates and traverse rate on Al–18Si–Cu–Ni alloy microstructure and tensile properties was investigated. In this work, the surface of as cast Al–18Si–Cu–Ni alloy was modified using FSP. The tensile properties were evaluated according to ASTM standards, and the microstructure using OM, SEM, and image analyses technique. FSP imposed severe plastic-deformation that resulted in a significant improvement of microstructure in the as-cast Al–18Si–Cu–Ni alloy, refining both the aluminium grain, Si particulates, and eliminating the porosity. The as-cast alloy shows mean area size of Si and intermetallic particles of about 151 μm2 and 123 μm2 , respectively. FSP considerably decreases both the mean area sizes of the particles. The sample friction stir processed at 800 RPM, 42 mm/min displayed the minimum mean area size 37.23 μm2 and 20.55 μm2 of the Si and intermetallic particles. The mean area sizes of the particles, increases with the tool rotation rate increase. The alloy’s strength and ductility significantly enhanced after FSP, the maximum increase of the tensile strength value after FSP was about 72%. The processed alloy exhibited 12.6% elongation which was almost nine times higher compared to 1.28% of the as-cast alloy. The significant improvement of the tensile properties was connected to the total changes/modification of the Si particles size and distribution along with dissolution of nickel rich intermetallics. This improvement could extend the usage of Al–18Si–Cu–Ni alloy.
Original languageEnglish
Pages (from-to)3993-3998
Number of pages6
JournalAdvanced Science Letters
Issue number6
Publication statusPublished - 01 Jun 2018
Externally publishedYes


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