Recently friction stir processing (FSP) has emerged as an effective tool for enhancing sheet metal properties through microstructure modification. Significant grain refinement and homogenization can be achieved in a single FSP pass leading to improved formability, especially at elevated temperatures. FSP is a solid-state process where the material within the processed zone undergoes intense plastic deformation resulting in dynamically recrystallized grain structure. Most of the research conducted on FSP focuses on aluminum alloys. Despite the potential weight reduction that can be achieved using Titanium dioxide(B4C) alloys. In this work, we examine the possibility of using FSP to modify the microstructure and properties of commercial A356-B4C alloy particles. The effect of various process parameters on thermal histories, resulting microstructure and properties to be investigated.

1. EXPERIMENTAL INVESTIGATION AND MATERIAL
CHARACTERIZATION OF A356 BASED
COMPOSITE (B4C) BY FRICTION STIR
PROCESSING
By
SATHISHKUMAR G
(sathishsak111@gmail.com)

2. ABSTRACT
 Recently friction stir processing (FSP) has emerged as an effective
tool for enhancing sheet metal properties through microstructure
modification. Significant grain refinement and homogenization can be
achieved in a single FSP pass leading to improved formability, especially at
elevated temperatures.
 FSP is a solid-state process where the material within the processed zone
undergoes intense plastic deformation resulting in dynamically
recrystallized grain structure.
 Most of the research conducted on FSP focuses on aluminum alloys.
Despite the potential weight reduction that can be achieved using Titanium
dioxide(B4C) alloys.
 In this work, we examine the possibility of using FSP to modify the
microstructure and properties of commercial A356-B4C alloy particles. The
effect of various process parameters on thermal histories, resulting
microstructure and properties to be investigated.

3. OUTLINE OF THE
PRESENTATION
• OBJECTIVES
• PROBLEM IDENTIFICATION
• BACKGROUND OF PROBLEM
• LITERATURE REVIEW
• EXISTING SYSTEM
• PROPOSED SYSTEM

4. OBJECTIVES
• Friction Stir Processing (FSP) is a recent outgrowth of the Friction Stir
Welding (FSW) process and relies on solid-state deformation to modify the
surface of the working materials.
• FSP has been eliminate casting defects and to refine the microstructure of
alloys to improve their mechanical properties and enhance corrosion
resistance.
• Such improvements have important implications for manufactured
components for a variety of automotive and other industrial applications.

5. PROBLEM DEFINITION
• Friction stir processing is a method of changing the properties of
a metal through intense, localized plastic deformation.
• This deformation is produced by forcibly inserting a non-consumable
tool into the workpiece, and revolving the tool in a stirring motion as
it is pushed laterally through the workpiece.
• The main roles of the FSP tools are to heat the workpiece, induce
material flow and constrain the heated metal beneath the tool shoulder.
• Heating is created by the friction of the rotating tool shoulder and
probe with the workpiece and by the severe plastic deformation of the
metal in the workpiece.
• The localised heating softens the material around the probe. The tool
rotation and translation cause the movement of the material from the
front to the back of the probe. The tool shoulder also restricts the
metal flow under the bottom shoulder surface.

6. A schematic of FSP (a) showing the rotating, non-consumable tool ,
(b) frictional heating upon plunging into the work piece in, (c) frictional and
heating in and (d) traversing of the tool to process the work piece in.

7. BACKGROUND OF THE PROBLEM
• Solid state process.
• Low thermal distortion.
• Good dimensional stability.
• No loss in alloying elements.
• Excellent metallurgical properties.
• Fine micro structure.
• No cracking, porosity and other welding defects.
• Environmental friendly hence called green welding Technology.
– No shielding gas.
– No use of chemical for cleaning.
– No slag and fumes.

8. YEAR Authors Journal
name/Experimental
Method/
Title
Test Result
2007 Y. Mazaheri,
M.H.
Enayati
A novel technique for
development of A356/Al2O3
surface nanocomposite by
friction stir processing.
The uniform distribution of Al2O3
particles in A356 matrix by FSP
process can improve the mechanical
properties of specimens.
2013 Magdy M.
El-Rayesa,
Ehab A. El-
Danafa,
The influence of multi-pass
friction stir processing on the
microstructural and
mechanical properties of
Aluminum Alloy 6082
1. The effect of increasing the number
of passes led to an increase in the SZ-
grain size.
2. The influence of increasing the tool
rotational speed on the SZ mechanical
properties are improved.

9. YEA
R
Authors Journal
name/Experimental
Method/
Title
Test Result
2013 H. Izadia,
A. Noltingb,
C. Munro
Friction stir processing of
Al/SiC composites fabricated
by powder metallurgy
An increase in hardness of all samples
are observe after friction stir processing
which was attributed to the improvement
in particle distribution and elimination of
porosity.
.
2012 Mohammad
Ali
Moghaddas
Effects of thermal conditions
on microstructure in
nanocomposite of Al/Si3N4
produced by friction stir
processing
1.The increasing of rotational to traverse
speed ratio causes to higher stir zone
area.The effect of rotational speed on stir
zone area is greater than traverse speed.
2. The increasing of traverse speed
leaded to higher hardness values, also
the decreasing of rotational speed caused
to higher hardness except the rotational
speed of 1800rpm.The increasing of pass
numbers caused to higher stir zone area.

10. YEAR Authors Journal
name/Experimental
Method/
Title
Test Result
2012 Don-Hyun,
Yong-Hwan,
Byung-
Wook .
Microstructure and mechanical
property of A356 based
composite by friction stir
processing.
The mechanical properties of the SZ
with SiC particles, compared to the
BM and SZ without SiC, were
improved by the dispersed Si, SiC
particles and the homogeneous
microstructure.The hardness is
improved.
2012 Thangarasu.
A,
N. Murugan,
I. Dinaharan
Microstructure and
microhardness of AA1050/TIC
surface composite fabricated
using friction stir processing
The result showed that AA1050/TiC
was fabricated using FSP. The
fabricated AA1050/TiC composite
layer was well-bonded to the aluminum
substrate. TiC particles were
distributed homogeneously in the FSP
zone. The hardness of the FSW zone
increased by 45% higher than that of
the matrix alloy.

11. YEAR Authors Journal
name/Experimental
Method/
Title
Test Result
2009 Yoshihiko
Hangaia,
Takao
Utsunomiya,
Makoto
Hasegawac
Effect of tool rotating rate on
foaming properties of porous
aluminum fabricated by using
friction stir processing
1. The porosity of porous aluminum is
only affected by the amount of stirring
action (tool rotating rate X number of
FSP times).
2. The minimum necessary amount of
stirring action and provide a guideline
for improving productivity.
2007 B.M.
Darras,
M.K.
Khraisheh
Friction stir processing of
commercial AZ31
magnesium alloy
Observed that increasing the rotational
speed tends to
decrease the resulting hardness.

12. PROBLEM DESCRIPTION
• From the literature review, it is observed that most of the researchers
concentrated on aluminium sheet by adding various composites. By concerning
the above, it is proposed to develop a surface layer composite and analyse the
various effects of process parameter and consider the microstructure of the
elements showing the mechanical properties.
• FSP technique has been successfully used for producing the fine-grained
structure and surface composite.
• Defect free aluminium matrix B4C reinforced composite to be produced in
friction stir techniques as more design engineers incorporate new designs in
aluminium materials by increasing their mechanical properties. It has been
demonstrated that FSP was an appropriate method to modify the
microstructure and mechanical properties of A356-alloy with B4C particles.
• The increasing demand of light-weight materials in the emerging industrial
applications, fabrication of aluminium-Titanium dioxide composites is required.
A356 materials widely used in aircraft structure and aircraft pumps.B4C
materials have high strength. So combinations of A356 and B4C product have
good properties.

13. SELECTION OF MATERIAL
BASE MATERIAL : Aluminium (A356)
COMPOSITES : boron carbide (B4C)
TOOL PIN PROFILE : Hexagonal pin profile tool
TOOL MATERIAL : High Speed Steel

14. PROPERTIES OF ALUMINIUM (A356)
• A356 has greater elongation
• Higher strength
• Considerably higher ductility
• It has improved mechanical properties because of lower iron
content.
• Solidus temperature is 555ºC.

15. COMPOSITION OF A356
Elements A356 Alloys
Si 6.85
Fe 0.17
Cu 0.04
Mn 0.031
Mg 0.42
Zn 0.03
Ti 0.09
Cr 0.008
Ni 0.008
Pb 0.035
Sn 0.003
P 0.006
Li Nil
Al 92.16
The chemical composition details shown in table. Concentration of
alloying elements in substrate(wt.%)

16. EXISTING SYSTEM
• Extreme hardness
• Good chemical resistance
• Good nuclear properties
• Low density

17. APPLICATIONS OF A356
• Airframe castings
• Machine parts
• Truck chassis parts
• Aircraft and Missile components
• Structural parts, etc.

18. FRICTION STIR PROCESS
A schematic diagram of Friction stir processing
a) Specimen(A356)
b) Packing without pin
c) Tool with pin
Groove

19. FSP PARAMETERS
• Tool geometry
Shoulder Diameter (18mm)
Pin Diameter (6mm)
Depth of Pin (3mm)
• Tool rotational and traverse speed
Specimen 1 (1200rpm, 30mm/min)
Specimen 2 (1500rpm, 30mm/min)
Specimen 3 (2000rpm, 30mm/min)
• Tool tilt angle
Tilt angle (2 degree)
• Tool Material
High speed steel (H-13)

20. FSP Machine

21. Specimen
Specimen A356
before FSP

22. WEAR TEST
• A pin on disc type wear monitor (WINDUCOM)
with data acquisition system was used to evaluate
the wear behaviour of aluminium A356 against
hardened ground steel (En-31)
• Disc having hardness of RC60 and surface
roughness (Ra) 0.5μm.
• The sample wear pin dimension is 25×3×3 mm.
• The applying load is 9.82N, Rotation speed of the
disc is 191rpm, velocity is 1m/sec, the Diameter of
the disc is 100mm and duration is 30min.
Pin on Disc

23. THANK YOU