Effect of Processing Parameters on Microstructure and Mechanical Properties of an Al-Al11Ce3-Al2O3 In-Situ Composite Produced by Friction Stir Processing

Friction stir processing (FSP) was applied to produce aluminum-based in-situ composites from powder mixtures of Al-5 mol pct CeO2. A billet of powder mixtures was prepared using the conventional pressing and sintering route. The sintered billet was then subjected to multiple passages of FSP. This technique has combined the hot-working nature of FSP and the exothermic reaction between Al and CeO2. The reinforcing phases were identified as Al11Ce3 and delta (*) -Al2O3. The Al2O3 particles with an average size of similar to 10 nm are uniformly distributed in the aluminum matrix, which has an average grain size of approximately 390 to 500 nm. Both the sintering temperature and the tool traversing speed used in FSP have significant influence on the microstructure and mechanical properties of the composite. The composite produced by sintering at 833 K followed by FSP with a tool traversing speed of 30 mm/min possesses an enhanced modulus (E = 109 GPa) and strength (ultimate tensile strength (UTS) = 488 MPa) as well as a tensile ductility of similar to 3 pct.