El-Sayed Mohamed S, Ibrahim Masoud, Abdel-Aziz Ahmed I
Mechanical Engineering Department, Faculty of Engineering, Fayoum University, Fayoum, Egypt.
Sci Rep. 2025 Jul 25;15(1):27066. doi: 10.1038/s41598-025-11948-1.
This research presents a pioneering investigation into friction stir processing (FSP) of different aluminum alloys reinforced with silicon nitride powders (SiN). By optimizing FSP parameters, such as stir tool profile and cooling medium, this study aims to enhance the microstructure and mechanical properties. The findings of this research contribute to the development of advanced FSP techniques for improving the performance of these alloys in different industries. FSP of three aluminum alloys (1050, 2011, and 6063) reinforced with SiN powders was conducted under different processing parameters was investigated. Tensile tests and hardness evaluations were conducted to assess the mechanical properties. The best combinations of processing parameters were defined using the Taguchi L orthogonal array, while a response surface methodology (RSM) with a central composite design of three factors and three levels was employed to develop the relationship between the FSP parameters (material type, pin profile, and cooling rate). The selected outputs included yield strength (YS), ultimate tensile strength (UTS), hardness (Hv), and elongation percentage (El%). An analysis of variance (ANOVA) was conducted to identify the significant process parameters affecting the responses. The results after FSP on Al plates indicate that the optimum UTS and YS values are achieved by performing FSP on 2011 AA with a conical pin profile and under indirect air-cooling. The highest hardness value was obtained under the same conditions but with indirect R-410 A cooling. Conversely, the optimum value of El% was reached by conducting FSP on 1050 AA with a cylindrical pin profile and indirect R-410a cooling. The maximum UTS, YS, El, and HV values are 286 MPa, 167 MPa, 40%, and 118 HV, respectively. Material type (M) was the primary dominant parameter affecting mechanical properties, while the cooling media ranked second.
本研究对用氮化硅粉末（SiN）增强的不同铝合金进行搅拌摩擦加工（FSP）展开了开创性研究。通过优化搅拌摩擦加工参数，如搅拌工具外形和冷却介质，本研究旨在改善微观结构和力学性能。本研究结果有助于开发先进的搅拌摩擦加工技术，以提高这些合金在不同行业的性能。研究了在不同加工参数下对三种用SiN粉末增强的铝合金（1050、2011和6063）进行搅拌摩擦加工的情况。进行了拉伸试验和硬度评估以评定力学性能。使用田口L正交阵列确定加工参数的最佳组合，同时采用具有三因素三水平中心复合设计的响应面方法（RSM）来建立搅拌摩擦加工参数（材料类型、搅拌针外形和冷却速率）之间的关系。选定的输出指标包括屈服强度（YS）、极限抗拉强度（UTS）、硬度（Hv）和伸长率（El%）。进行了方差分析（ANOVA）以确定影响响应的显著工艺参数。对铝板进行搅拌摩擦加工后的结果表明，对2011铝合金采用锥形搅拌针外形并在间接风冷条件下进行搅拌摩擦加工可获得最佳的UTS和YS值。在相同条件下但采用间接R - 410 A冷却时可获得最高硬度值。相反，对1050铝合金采用圆柱形搅拌针外形并进行间接R - 410a冷却可达到最佳的El%值。最大UTS、YS、El和HV值分别为286 MPa、167 MPa、40%和118 Hv。材料类型（M）是影响力学性能的主要主导参数，而冷却介质位居第二。
