Baheer, N., Abbass, M., Aziz, I., Khoshnaw, F. (2025). Effect of friction stir processing of in-situ A356/Al3Ni composites: microstructure refinement and wear behavior. , 43(12), 1033-1050. doi: 10.30684/etj.2025.156833.1887
Noor A. Baheer; Muna K. Abbass; Israa A. Aziz; Fuad Khoshnaw. "Effect of friction stir processing of in-situ A356/Al3Ni composites: microstructure refinement and wear behavior". , 43, 12, 2025, 1033-1050. doi: 10.30684/etj.2025.156833.1887
Baheer, N., Abbass, M., Aziz, I., Khoshnaw, F. (2025). 'Effect of friction stir processing of in-situ A356/Al3Ni composites: microstructure refinement and wear behavior', , 43(12), pp. 1033-1050. doi: 10.30684/etj.2025.156833.1887
Baheer, N., Abbass, M., Aziz, I., Khoshnaw, F. Effect of friction stir processing of in-situ A356/Al3Ni composites: microstructure refinement and wear behavior. , 2025; 43(12): 1033-1050. doi: 10.30684/etj.2025.156833.1887

Effect of friction stir processing of in-situ A356/Al3Ni composites: microstructure refinement and wear behavior

Engineering and Technology Journal
Volume 43, Issue 12, December 2025, Pages 1033-1050    PDF (2.46 M)
Document Type: Research Paper
DOI: 10.30684/etj.2025.156833.1887
Authors
Noor A. Baheer* 1; Muna K. Abbass1; Israa A. Aziz1; Fuad Khoshnaw2
1Production Engineering and Metallurgy Dept., University of Technology-Iraq, Alsina’a street, 10066 Baghdad, Iraq.
2School of Engineering and Sustainable Development, De Montfort University, United Kingdom.
Abstract
This research investigated the impact of friction stir processing on grain refinement in the surface layer of composite materials. The in-situ composite was created by stir casting, incorporating 15% pure Ni into the Al matrix type A356. Microstructural analysis performed with optical microscopy and X-ray diffraction revealed the formation and dispersion of intermetallic phases such as AlNi, Al3Ni, and Al3Ni2, contributing to significant grain refinement. FSP further enhanced the micros structure by breaking and uniformly distributing small particles, including the primary Si phase and Al₃Ni, while refining α-Al dendrites. These microstructural changes resulted in improved mechanical properties, including a 13.81% increase in hardness for the A356/Al3Ni composite and a 14.47% increase for the base A356 alloy. Wear rate tests were conducted using a ball-on-disc apparatus under dry sliding conditions for both the base alloy A356 and the in-situ composite A356/Al3Ni, before and after FSP. Compared to the base alloy A356 and in situ composites before and after friction stir processing, the in-situ composite (A356/Al3Ni) after FSP exhibited a lower wear rate. However, during the wear test, the coefficient of friction decreased as the applied load increased for the base alloy A356 and the in-situ composite (A356/Al3Ni) following the friction stir process.

Highlights
  • A356/Al3Ni in-situ composites were fabricated using the stir casting method
  • FSP enhanced the microstructure by refining grains in A356 and the in-situ composite
  • FSP increased hardness to 87 HV for A356 and 173 HV for the A356/Al3Ni composite
  • The A356/Al3Ni composite after FSP showed superior wear resistance over the base and pre-FSP composite
Keywords
Al; alloy A356 Stir casting Friction stir processing In; situ composite Al3Ni Wear rate
References
  1. R. Pratip, S. Singh, and K. Pal, Enhancement of mechanical and tribological properties of SiC and CB-reinforced aluminum 7075 hybrid composites through friction stir processing, Adv. Compos. Mater., 28 (2019) 1-18. https://doi.org/10.1080/09243046.2017.1405596
  2. E. Efzan, M. Noor, N. Siti Syazwani, and A Mustafa Al Bakri, Fabrication method of aluminum matrix composite (AMCs): a review, Key Eng. Mater., 700 (2016) 102-110. https://doi.org/10.4028/www.scientific.net/KEM.700.102
  3. A. Mussatto, I. U. Ahad, R. T. Mousavian, Y. Delaure, D. Brabazon, Advanced production routes for metal matrix composite, Eng. Rep., 3 (2021) e12330. https://doi.org/10.1002/eng2.12330
  4. V. S. Ayar and M. P. Sutaria, Comparative Evaluation of Ex Situ and In Situ Method of Fabricating Aluminum/Tib2 Composites, Int. J. Met., 15 (2021) 1047-1056. https://doi.org/10.1007/s40962-020-00554-8
  5. N. Hoang Viet, N. Hoang Oanh, Microstructure and Electrical Property of Ex-Situ and In-Situ Copper Titanium Carbide Nanocomposites, Metals, 10 (2020) 1-10. https://doi.org/10.3390/met10060735
  6. M. Kumar Sahu, and R. Kumar Sahu, Fabrication of Aluminum Matrix Composites by Stir Casting Technique and Stirring Process Parameters Optimization, Advanced Casting Technologies, (2018) 111-122. https://doi.org/10.5772/intechopen.73485
  7. G. Atxaga, A. Pelayo, A. Irisarri, Effect of microstructure on fatigue behaviour of cast Al–7Si–Mg alloy, Mater. Sci. Technol., 17 (2001) 446-450. https://doi.org/10.1179/026708301101510023
  8. M. Santella, T. Engstrom, D. Storjohann, T.-Y. Pan, Effects of friction stir processing on mechanical properties of the cast aluminum alloys A319 and A356, Scr. Mater., 53 (2005) 201-206. https://doi.org/10.1016/j.scriptamat.2005.03.040
  9. Z. Ma, R.S. Mishra, M.W. Mahoney, Superplasticity in cast A356 induced via friction stir processing, Scr. Mater., 50 (2004) 931-935. https://doi.org/10.1016/j.scriptamat.2004.01.012
  10. S. Mohit Kumar, S. Raj Kumar, Fabrication of aluminum matrix composites by stir casting technique and stirring process parameters optimization, Adva. Cast. Technol., (2018) 111-122. https://doi.org/10.5772/intechopen.73485
  11. H. H. Zamel, S. Al-Ezzi, M. K Abbass, H. Soliman, Y. Zeng, Fabrication of AZ31/ZnO surface composite by friction stir processing: Evolution of microstructure, mechanical properties and corrosion behavior, Adv. Sci. Technol. Res. J., (5) (2025) 213-223. https://doi.org/10.12913/22998624/202274
  12. S. M. Aktarer, D. M Sekban, H. Yanar and G. Purçek, Effect of friction stir processing on tribological properties of Al-Si alloys, IOP Conference Series: Mater. Sci. Eng., IOP Publishing, 174 (2017) 1-8. https://doi.org/10.1088/1757-899X/174/1/012061
  13. H. Kumar, R. Prasad, P. Kumar, S. P. Tewari, J. K. Singh, Mechanical and tribological characterization of industrial wastes reinforced aluminum alloy composites fabricated via friction stir processing, J. Alloys Compd., 831 (2020) 154832. https://doi.org/10.1016/j.jallcom.2020.154832
  14. H. Daneshifar, A. Papi, M. Alishahi‏, Fabrication of Al-Si/Mg2Si in-situ composite by friction stir processing, Mater. Letter., 282 (2021) 128832. https://doi.org/10.1016/j.matlet.2020.128832
  15. P. Samal, B. Surekha, P. R. Vundavilli, Experimental Investigations on Microstructure, Mechanical Behavior and Tribological analysis of AA5154/SiC Composites by Stir Casting, Silicon, 14 (2022) 3317-3328. https://doi.org/10.1007/s12633-021-01115-2
  16. S. K. Gautam, S. K. Samanta, M. Mallik, H. Roy, A.K. Lohar, Wear and Mechanical Properties of In situ A356/5%Tib2 Composite Synthesis by Cooling Slope Technique, Int. J. Met., 17 (2022) 2239-2251. https://doi.org/10.1007/s40962-022-00931-5
  17. V. Singhal, VK Jain, RS Raman, D Patharia, V Mittal, S Mishra, H Kumar‏, Optimization of friction stir processing parameters for improving structural and mechanical properties in in-situ AA5083-H111/Al–Fe composites, Proceedings of the Institution of Mechanical Engineers, Part C: J. Mech. Eng. Sci., 238 (2023) 4477-4490.‏ https://doi.org/10.1177/09544062231211672
  18. V. Rubtsov, A Chumaevskii, A Gusarova, E Knyazhev, D Gurianov, A Zykova, T Kalashnikova, Macro-and microstructure of in situ composites prepared by friction stir processing of AA5056 admixed with copper powders, Materials, 16 (2023) 1-21. https://doi.org/10.3390/ma16031070
  19. K. K. Jlood, M. K. Abbass, M. M. Hanoon, Effect of Friction Stir Processing Parameters on Microstructure and Mechanical Properties of Aluminum Alloy AA6061-T6: Experimental and Statistical Study , Salud Cienc. Tecnol. - Ser. Conf., 3 (2024) 862-862. https://doi.org/10.56294/sctconf2024862
  20. Z. Y. Ma, S. R. Sharma, R.S. Mishra, Effect of friction stir processing on the microstructure of cast A356 aluminum, Mater. Sci. Eng., A, 433 (2006) 269-278. https://doi.org/10.1016/j.msea.2006.06.099
  21. S. Senthil, M. Raguraman, D. T. Manalan, Manufacturing processes & recent applications of aluminum metal matrix composite materials: A review, Mater. Today Proc., 45 (2021) 5934-5938. ‏https://doi.org/10.1016/j.matpr.2020.08.792
  22. N. A. Baheer, M. K. Abbass, I. A. Aziz, Effect of Friction Stir Processing on Microstructure and Mechanical Properties of In-Situ Composite A356/Al3Ni Fabricated by Stir Casting, Int. J. Comput. Methods Exp. Meas., 12 (2024) 453-461. https://doi.org/10.18280/ijcmem.120414
  23. Y. Zhao, X. Kai, G. Chen, W. Lin, C. Wang, Effects of friction stir processing on the microstructure and superplasticity of in situ nano-ZrB2/2024Al composite, Prog. Nat. Sci. Mater. Int., 26 (2016) 69-77. https://doi.org/10.1016/j.pnsc.2016.01.009
  24. P. A. Kumar, H. C. Madhu, A. Pariyar, C. S. Perugu, S. V. Kailas, U. Garg, P. Rohatgi‏, Friction stir processing of squeeze cast A356 with surface compacted graphene nanoplatelets (GNPs) for the synthesis of metal matrix composites, Mater. Sci. Eng., 769 (2020) 1-23. https://doi.org/10.1016/j.msea.2019.138517
  25. I. Dinaharan, G. A. Kumar, S. J. Vijay, N. Murugan‏, Development of Al3Ti and Al3Zr intermetallic particulate reinforced aluminum alloy AA6061 in situ composites using friction stir processing, Mater. Design, 63 (2014) 213-222. https://doi.org/10.1016/j.matdes.2014.06.008 ‏
  26. M. H. Mohammed, A. D. Subhi, Exploring the influence of process parameters on the properties of SiC/A380 Al alloy surface composite fabricated by friction stir processing, Eng. Sci. Technol. Int. J., 24 (2021) 1272-1280. https://doi.org/10.1016/j.jestch.2021.02.013
  27. A. Kurt, I. Uygur, E. Cete, Surface modification of aluminium by friction stir processing, J. Mater. Process. Technol., 211 (2011) 313-317. https://doi.org/10.1016/j.jmatprotec.2010.09.020
  28. M. K. Abbass, Effect of Cd on microstructure and dry sliding wear behavior of (Al-12% Si) alloy, J. Eng. Res., 7 (2010) 1-10. https://doi.org/10.24200/tjer.vol7iss1pp1-10
  29. M. K. Abbass, N. A. Baheer‏, Effect of SiC Particles on microstructure and wear behavior of AA6061-T6 aluminum alloy surface composite fabricated by friction stir processing, In IOP Conf. Ser. Mater. Sci. Eng., 671(2020) 1720-1732. https://doi.org/0.1088/1757-899X/671/1/012159
  30. M. K. Abbass, M. J. Fouad, Study of Wear Behavior of Aluminum Alloy Matrix Nano Composites Fabricated by Powder Technology, Eng. Technol. J., 32 (2014) 1720-1732. https://doi.org/10.30684/etj.32.7A9
  31. M. J. Fouad, M. K. Abbass, I. Inanc, Manufacture of Self-Lubricating Mechanical Parts from Al-Si Alloy Matrix Hybrid Nanocomposites, Tribol. Ind., 47 (2025) 112-124. https://doi.org/10.24874/ti.1752.09.24.02
  32. A. O. Shiba, S. S. Mohamed, T. S. Mahmoud, Influence of Friction Stir Processing on the Microstructural, Hardness and Tribological Characteristics of A356 Cast Aluminum Alloy, Chars., (2018) 24-31.
  33. N. A. Baheer, M. K. Abbass, I. A. Aziz, Microstructure and Wear Behavior of In-situ Composite A356/Al3Ni Fabricated by Stir Casting, AIP Conference Proceedings, 3229, 2024, 070030. https://doi.org/10.1063/5.0236495
  34. M. K. Abbass, N. B. Sharhan, Characteristics of Al6061-SiC-Al2O3 surface hybrid composites fabricated by friction stir processing, J. Mater. Eng. Struct., 4 (2023) 147-158. https://doi.org/10.61552/JME.2023.04.002
  35. V. Kishan, A. Devaraju, K. P. Lakshmi, Influence of volume percentage of NanoTiB2 particles on tribological & mechanical behaviour of 6061-T6 Al alloy nano-surface composite layer prepared via friction stir process, Def. Technol., 13 (2016) 1-6. https://doi.org/10.1016/j.dt.2016.11.002
  36. M. K. Abbass, Laser Surface Treatment and Modification of Aluminum Alloy Matrix Composites, Lasers Manuf. Mater. Process., 5 (2018) 81-94. https://doi.org/10.1007/s40516-018-0054-6.
  37. R. Srinivasu, A. S. Rao, G. M. Reddy, K. S. Rao, Friction stir surfacing of cast A356 Aluminum-silicon alloy with boron carbide and molybdenum disulphide powders, Def. Technol., 11 (2014) 1-18. https://doi.org/10.1016/j.dt.2014.09.004
  38. A. M. Al-Qutub, A. Khalil, N. Saheb, A. S. Hakeem, Wear and friction behavior of Al6061 alloy reinforced with carbon nanotubes, Wear, 297 (2013) 752-761.‏ https://doi.org/10.1016/j.wear.2012.10.006
  39. M. K. Akbari, S. Rajabi, K. Shirvanimoghaddam, H. Baharvandi, Wear and friction behavior of nanosized TiB2 and TiO2 particle-reinforced casting A356 aluminum nanocomposites: A comparative study focusing on particle capture in matrix, J. Compos. Article Mater., 49 (2015)1-17. https://doi.org/10.1177/0021998314568327
Statistics
Article View: 458
PDF Download: 201


Journal Management System. Powered by iJournalPro.com