Mechanical behaviour of aluminium 6061-ZRO2 composite fabricated through a hybrid route (STIR casting + additive friction STIR deposition)

Abstract

The mechanical behaviour of aluminium-based composites has gained significant attention in recent years due to their enhanced properties and wide-ranging applications. This study focuses on the mechanical behaviour of an aluminum 6061-ZrO2 composite fabricated through a hybrid route that combines conventional stir casting with innovative additive friction stir deposition (AFSD). The composite material was prepared by incorporating ZrO2 particles as the reinforcement into the aluminum matrix using the stir casting technique. Subsequently, the AFSD process was employed to further enhance the composite's microstructural characteristics and mechanical properties. The AFSD process involved using a rotating tool to induce severe plastic deformation and promote microstructure homogenization. The mechanical behaviour of the fabricated composite was investigated through a comprehensive analysis of its tensile strength, hardness, fatigue, and wear properties. The results revealed that the addition of ZrO2 particles significantly improved the mechanical properties of the aluminum matrix. The hybrid fabrication route combining stir casting and AFSD further enhanced these properties by promoting uniform reinforcement particle distribution and reducing composite porosity. Furthermore, microstructural analysis using scanning electron microscopy (SEM) and X-ray diffraction (XRD) techniques provided insights into the dispersion and bonding characteristics of the ZrO2 particles within the aluminum matrix. The SEM images revealed a fine and homogeneous distribution of the particles, while XRD analysis confirmed the absence of any unwanted phase formations.