Testing and analysis of mechanical, and corrosion properties of 2024 aluminum alloy using Friction Stir Processing

The friction stir method, an emerging metalworking technique, has the ability to locally and deliberately change the microstructures in the near-surface layers of a treated metallic component. A significant amount of material is permanently deformed, mixed, and exposed to heat in the treatment zone as part of this surface modification procedure, which significantly alters the material's microstructure. The treated zone is distinguished by a recrystallized fine-grained structure. This strategy was developed from friction stir welding, a type of solid-state joining technique that employs friction to permanently bond metals. The friction stir technique is used to preserve the bulk qualities of the base material while further enhancing resistance to wear, creep, and fatigue. Because of its high specific strength, lightweight, and machinability, There are numerous applications for aluminum and the associated alloys. The AA2024 is one of the strongest aluminum alloys, and it will contain copper as a primary alloying element. Owing to its substantial strength-to-weight ratio, The AA2024 is a material utilised in the aviation industry, notably fuselage structures and orthopaedic equipment. The microstructure and mechanical characteristics of the treated zone can be manipulated by adjusting the tool design and FSP parameters. The current effort tries to determine the best range of processing parameters by altering the tool rotational speed, traverse speed, and applied force. This experiment included tool rotational speeds of 1000, 1300, and 1600 rpm, tool traverse speeds of 15 mm/min, 30 mm/min, and 45 mm/min, and applied loads of 8 kg, 10.25 kg, and 12.5 kg. The experiment is designed using the Box-Behnken optimization technique, which considers three factors at three different levels. To improve material flow for the reinforcing particles, a cylindrical pin of H13 tool steel bearing a hardness of 60 HRC is designed and produced. The ultimate tensile strength (UTS) of FSPed AA2024 samples was tested using a universal testing machine in accordance with ASTM E8 standards. The Vicker's hardness testing machine was used to perform microhardness tests as per ASTM E384 standards to determine the hardness of FSPed AA2024 samples. By comparing the sample weights before and after testing, the corrosion rates had been determined using the immersion corrosion testing method. The 2D-surface roughness tests were carried out using Taylor Hobson's Surtronic S-128 roughness testing machine to determine the roughness value of FSPed AA2024 samples. The most effective friction stir process variables are chosen using Grey Relational Analysis (GRA), which is applied to the outcomes of many response tests. At a 95% confidence level, the most important contributing friction stir process factors are identified using an analysis of variance (ANOVA).