Fabrication and Performance Evaluation of Quartz-Reinforced AA6063 Aluminium Composites via Friction Stir Processing
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Abstract
Friction Stir Processing (FSP) has evolved as a promising solid-state approach for producing Aluminium Matrix Composites (AMCs), offering a distinct advantage over liquid metallurgy by preventing casting-related defects. In this study, Quartz (SiO₂) particulates were incorporated into AA6063 alloy through a controlled single-pass FSP route to develop particle-reinforced composites. Before processing, longitudinal grooves were machined on the alloy substrate and filled with quartz powder. The reinforcement content was systematically varied from 0 to 18 vol. % in increments of 6 vol. % to assess its influence on the resulting properties. Microstructural characterisation of optical microscopy, SEM and TEM confirmed an excellent dispersion of quartz particles throughout the processed zone. Significant grain refinement was observed in the matrix, attributed to the combined effects of severe plastic deformation and particle-induced boundary pinning. The refined microstructure, coupled with effective particle-matrix interaction, led to notable improvement in micro hardness and wear performance. Moreover, the study offers knowledge regarding the role of quartz content on worn surface features and wear debris formation, demonstrating that increasing particulate addition enhances the overall mechanical and tribological response of the AA6063 alloy.
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