Dual sided composite formation in Al 6061/B4C using novel bobbin tool friction stir processing

Abstract A novel material processing approach using the bobbin tool technique called bobbin tool friction stir processing (BTFSP) was developed to simultaneously fabricate two-side composites. The feasibility of simultaneous fabrication of composites on the top and bottom sides of the workpiece using B4C reinforcement particles into Al 6061 alloy was successfully studied in the present paper. Excellent dispersion of the B4C particles obtained at the bottom side of the workpiece by this technique. The metallurgical investigation of Al 6061/B4C double side composites was carried out using optical and scanning electron microscopy. The mechanical properties include sliding wear behavior, and microhardness of the fabricated composites was studied in detail. The results indicated a more uniform distribution of B4C particles with 3 passes. The grain refinement and homogeneous distribution of the B4C significantly improved microhardness and wear properties of the fabricated composites compared to as-received Al.