Development of Functionally Graded Material through Friction Stir Processing

B V, Himasekhar Sai (2014) Development of Functionally Graded Material through Friction Stir Processing. Masters thesis, Indian Institute of Technology Hyderabad.

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Abstract

Functionally Graded Material (FGM) belongs to a new class of advanced material characterized by gradual variation in composition and the mechanical properties. The overall properties of the FGM are unique and different from the individual material used. Previous investigations show that various techniques such as powder metallurgy, centrifugal method, vapor deposition techniques, solid freeform fabrication methods and friction stir processing etc. have been used to fabricate the FGM. In order to overcome the control over the composition, the present study presents a method to fabricate functionally graded material using friction stir processing and hole drilling electrical discharge machine. Holes are drilled on an aluminum plate and filled with Alumina nano-particles of size (<50nm) and Titanium Carbide (TiC) particles of 325 mesh size and stirred using FSP. A mathematical model for positioning of holes in order to acquire a range of maximum to minimum composition of nano particles over a given length is presented. By aligning FSP tool center to hole center, multipass FSP is carried out in the same directions and in opposite directions to understand the material flow and mixing. SEM images and hardness analysis were used to evaluate the material flow and particle distribution. The strain variation along the longitudinal section parallel to the surface is measured. The mathematical model is applied to different combinations of composition ranges and is evaluated under different conditions.

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