M. Karbalai-Rashid S. A., H. Abdollah-Pour,
Volume 11, Issue 2 (12-2025)
In this study, an AA5083/Al12Mo surface composite containing approximately 10 vol.% of pre-synthesized molybdenum aluminide particles was fabricated using Friction Stir Processing (FSP) under optimized conditions, including six passes, a rotational speed of 1000 rpm, and a traverse speed of 52 mm/min. Multiple FSP passes reduced the particle size from about 20 µm to nearly 1.7 µm and improved their distribution uniformity, while simultaneously refining the matrix grains and enhancing the strain-hardening capability. These microstructural improvements led to a ~16% increase in tensile strength compared to the unreinforced FSPed alloy and ~20% relative to the as-received base metal, along with ~50% and ~63% hardness enhancement in the 4-pass and 6-pass samples, respectively. Quantitative analysis of the strengthening mechanisms revealed that strain hardening contributed the most to the overall strength increment, and the presence of reinforcing particles delayed the onset of the Portevin–Le Chatelier (PLC) serrated flow. Fractography indicated a mixed fracture mode consisting of particle fracture, particle–matrix decohesion, and matrix rupture. Furthermore, corrosion tests demonstrated a decrease in corrosion resistance, mainly due to the discontinuity of the protective aluminum oxide layer and the formation of defects at particle–matrix interfaces caused by severe plastic deformation.
