MODIFICATION OF MICROSTRUCTURE, MECHANICAL PROPERTIES AND WEAR PERFORMANCE OF 5083 ALUMINUM ALLOY USING FRICTION STIR PROCESSING | ||
| Journal of the Egyptian Society of Tribology | ||
| Volume 22, Issue 4, October 2025, Pages 60-71 PDF (1.41 M) | ||
| Document Type: Original Article | ||
| DOI: 10.21608/jest.2025.424053.1130 | ||
| Authors | ||
| M. G. Mahmoud* 1; A. O. Mosleh2 | ||
| 1Mechanical Design and Production Department, Faculty of Engineering, Cairo University, Giza,12613, Egypt | ||
| 2Mechanical Engineering Department, Faculty of Engineering at Shoubra, Benha University, Cairo 11629, Egypt | ||
| Abstract | ||
| Friction Stir Processing (FSP) was applied to as-rolled AA5083 aluminium alloy to enhance its wear resistance through microstructural refinement. Processing was conducted at a tool rotation speed of 1120 rpm and a traverse speed of 40 mm/min. The Peak processing temperature increased with the number of passes, reaching ~492°C after three passes, which, combined with severe plastic deformation, promoted dynamic recrystallization and grain refinement. Orientation maps confirmed progressive refinement in the nugget zone, with average grain size reduced from ~10 μm (one pass) to 4 μm (three passes). This refinement enhanced hardness in line with the Hall–Petch effect. Tribological testing showed that the as-rolled alloy had a wear rate of 6 × 10⁻³ g/min, which rose to 7 × 10⁻³ g/min after one FSP pass due to abrasive particle generation. With additional passes, the wear rate decreased to 5.5 × 10⁻³ g/min and 4.5 × 10⁻³ g/min, demonstrating improved resistance beyond the as-rolled condition. The enhancement is attributed to grain refinement, and higher hardness. | ||
| Keywords | ||
| Friction Stir Processing (FSP); AA5083; grain refinement; hardness; wear resistance | ||
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