Additive manufacturing of AA5083/TiN-Diamond hybrid nanocomposite parts via additive friction stir deposition: Metallurgical structure, mechanical, tribological, and electrochemical properties

Nano-diamond (ND) is a special ultrafine reinforcement whose agglomeration properties and weak interfacial bonding limit its application in aluminum matrix composites. This study used the additive friction stir deposition (AFSD) technique to produce AA5083-H321/2.5 wt% nano TiN/ND additive manufacturing deposition hybrid composite parts (AMDCPs) and a non -composite part (AMDNCP) was also deposited for comparative analysis. The aim was to improve the microstructure and examine the effect of the deposition process parameters, which include 900, 1250, and 1600 rpm rod rotation speed and 5 and 12 mm/min feed rate. The AFSD process parameters were used to calculate the heat input. The consumable rod and AMD parts were evaluated for their macrostructure, microstructure, macro-hardness, tribological, and corrosion properties. The microstructural features were examined using an OM, XRD, and SEM equipped with an EDS. The worn and corrosion surface morphology was investigated using SEM, and hardness was also evaluated as contour maps. The results show that defect-free deposited multilayer AA5083-nano TiN/ND hybrid composite parts were successfully manufactured, and analysis revealed a lower D/H ratio, well-bonded layers, homogeneously distributed TiN/ND and fragmented IMC components, and equiaxed refined grain microstructures. The deposited composites via AFSD showed a lower corrosion rate, higher hardness, and wear resistance than the deposited AA5083 consumable rod and AMDNCP. The AMDP C900-12 demonstrates an optimized deposition process parameter (900 rpm, 12 mm/ min) with superior properties, including an increase in hardness by 9.3%, a reduction in grain size by 54%, and a decrease in corrosion rate by 45.2% related to the AMDNC part.