Optimization of Friction Stir Processing Parameters for Improvement of Mechanical Properties of AlSi7Mg0.2 Alloy

This paper investigates the effects of Friction Stir Processing (FSP) parameters on the microstructure and mechanical properties of an Al-Si7Mg0.2 alloy. The study’s findings indicate that augmenting the rotational velocity of the tool in the context of Friction Stir Processing can reduce grain size and enhance the alloy’s mechanical properties. The optimization of process temperature plays a vital role in managing the thermal profile and preventing undesirable consequences such as overheating or excessive cooling. These adverse effects can significantly impact the microstructure and properties of the alloy. The finer grain size of the FSPed samples resulted from the intense plastic deformation and dynamic recrystallization during the process. This grain refinement improved hardness, wear, and corrosion resistance. The temperature distribution during FSP using finite element simulation was highly dependent on the process parameters, such as the rotational speed and the dwell time. The results of this study are employed to develop a fitting model to predict the temperature distribution along the workpiece during the dwelling stage, which can be used to optimize the process parameters for different applications. The optimization of the heat generation inside the stirred zone plays a vital role in managing the thermal profile and preventing undesirable consequences such as overheating or excessive cooling. These adverse effects can significantly impact the microstructure and properties of the alloy.