Additive manufacturing of AA2024/Al2O3 nanocomposites via friction surfacing: Investigating metallurgical, mechanical, and tribological properties
Friction surfacing (FS) is a solid-state additive manufacturing method that uses high-temperature plastic deformation to produce fully dense multilayer samples with a fine-grained microstructure. This study uses the FS process to fabricate composite samples of AA2024-T4 reinforced with 1.5 wt% nano-...
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Elsevier
2025-05-01
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| Series: | Journal of Materials Research and Technology |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785425012797 |
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| author | Milad Abbasi Nahr Seyyed Ehsan Mirsalehi Ahmad Papi |
| author_facet | Milad Abbasi Nahr Seyyed Ehsan Mirsalehi Ahmad Papi |
| author_sort | Milad Abbasi Nahr |
| collection | DOAJ |
| description | Friction surfacing (FS) is a solid-state additive manufacturing method that uses high-temperature plastic deformation to produce fully dense multilayer samples with a fine-grained microstructure. This study uses the FS process to fabricate composite samples of AA2024-T4 reinforced with 1.5 wt% nano-Al2O3 alongside non-composite counterparts for comparison. This study aims to improve microstructure by examining deposition parameters, including rod rotational speeds (600–1200 rpm), travel speed (70–85 mm/min), and feeding rate (30–45 mm/min), which affect the heat input during FS. Evaluations of the consumable rod and deposition multilayer samples included macro- and microstructural analyses using OM, XRD, and SEM equipped with EDS, along with evaluation of hardness and wear properties. Results demonstrated that successfully produced defect-free multilayer AA2024/Al2O3 nanocomposites with well-bonded layers, uniform Al2O3, and precipitates distribution, fragmented intermetallic compounds, and fine-grained microstructure with an average grain size of 3–10 μm. The FS-produced composites exhibited improved hardness and wear resistance compared to non-composites. Increasing rotational speed widened samples (3.7 mm) and reduced thickness (4.56 mm). The optimal microstructure, achieved at a rotational, traverse and feed speed of 1000 rpm, 80 mm/min, and 40 mm/min, features a grain size of 3.74 ± 1.01 μm, a hardness of 123.75 ± 9.28 HV, and a wear rate of 6.6 × 10−4 mg/N·m. Additionally, of the 14 samples produced, this particular sample showed a hardness increase of 20.5 % and 20.3 %, a grain size reduction of 22.9 % and 17.8 %, and a wear rate decline of 5.7 % and 12.9 % compared to the non-composite counterpart and the highest-performing samples, respectively. |
| format | Article |
| id | doaj-art-bd598689fc034fddb3579ef2dc856661 |
| institution | OA Journals |
| issn | 2238-7854 |
| language | English |
| publishDate | 2025-05-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Materials Research and Technology |
| spelling | doaj-art-bd598689fc034fddb3579ef2dc8566612025-08-20T01:55:30ZengElsevierJournal of Materials Research and Technology2238-78542025-05-01368609863110.1016/j.jmrt.2025.05.124Additive manufacturing of AA2024/Al2O3 nanocomposites via friction surfacing: Investigating metallurgical, mechanical, and tribological propertiesMilad Abbasi Nahr0Seyyed Ehsan Mirsalehi1Ahmad Papi2Department of Materials and Metallurgical Engineering, Amirkabir University of Technology (Tehran Polytechnic), Tehran, 15875-4413, IranCorresponding author.; Department of Materials and Metallurgical Engineering, Amirkabir University of Technology (Tehran Polytechnic), Tehran, 15875-4413, IranDepartment of Materials and Metallurgical Engineering, Amirkabir University of Technology (Tehran Polytechnic), Tehran, 15875-4413, IranFriction surfacing (FS) is a solid-state additive manufacturing method that uses high-temperature plastic deformation to produce fully dense multilayer samples with a fine-grained microstructure. This study uses the FS process to fabricate composite samples of AA2024-T4 reinforced with 1.5 wt% nano-Al2O3 alongside non-composite counterparts for comparison. This study aims to improve microstructure by examining deposition parameters, including rod rotational speeds (600–1200 rpm), travel speed (70–85 mm/min), and feeding rate (30–45 mm/min), which affect the heat input during FS. Evaluations of the consumable rod and deposition multilayer samples included macro- and microstructural analyses using OM, XRD, and SEM equipped with EDS, along with evaluation of hardness and wear properties. Results demonstrated that successfully produced defect-free multilayer AA2024/Al2O3 nanocomposites with well-bonded layers, uniform Al2O3, and precipitates distribution, fragmented intermetallic compounds, and fine-grained microstructure with an average grain size of 3–10 μm. The FS-produced composites exhibited improved hardness and wear resistance compared to non-composites. Increasing rotational speed widened samples (3.7 mm) and reduced thickness (4.56 mm). The optimal microstructure, achieved at a rotational, traverse and feed speed of 1000 rpm, 80 mm/min, and 40 mm/min, features a grain size of 3.74 ± 1.01 μm, a hardness of 123.75 ± 9.28 HV, and a wear rate of 6.6 × 10−4 mg/N·m. Additionally, of the 14 samples produced, this particular sample showed a hardness increase of 20.5 % and 20.3 %, a grain size reduction of 22.9 % and 17.8 %, and a wear rate decline of 5.7 % and 12.9 % compared to the non-composite counterpart and the highest-performing samples, respectively.http://www.sciencedirect.com/science/article/pii/S2238785425012797Friction surfacing (FS)Additive manufacturing (AM)Multilayer depositionHeat inputAluminum alloy compositesAluminum oxide (Al2O3) |
| spellingShingle | Milad Abbasi Nahr Seyyed Ehsan Mirsalehi Ahmad Papi Additive manufacturing of AA2024/Al2O3 nanocomposites via friction surfacing: Investigating metallurgical, mechanical, and tribological properties Journal of Materials Research and Technology Friction surfacing (FS) Additive manufacturing (AM) Multilayer deposition Heat input Aluminum alloy composites Aluminum oxide (Al2O3) |
| title | Additive manufacturing of AA2024/Al2O3 nanocomposites via friction surfacing: Investigating metallurgical, mechanical, and tribological properties |
| title_full | Additive manufacturing of AA2024/Al2O3 nanocomposites via friction surfacing: Investigating metallurgical, mechanical, and tribological properties |
| title_fullStr | Additive manufacturing of AA2024/Al2O3 nanocomposites via friction surfacing: Investigating metallurgical, mechanical, and tribological properties |
| title_full_unstemmed | Additive manufacturing of AA2024/Al2O3 nanocomposites via friction surfacing: Investigating metallurgical, mechanical, and tribological properties |
| title_short | Additive manufacturing of AA2024/Al2O3 nanocomposites via friction surfacing: Investigating metallurgical, mechanical, and tribological properties |
| title_sort | additive manufacturing of aa2024 al2o3 nanocomposites via friction surfacing investigating metallurgical mechanical and tribological properties |
| topic | Friction surfacing (FS) Additive manufacturing (AM) Multilayer deposition Heat input Aluminum alloy composites Aluminum oxide (Al2O3) |
| url | http://www.sciencedirect.com/science/article/pii/S2238785425012797 |
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