The Role of Friction Stir Processing Parameters and Hybrid ZrC/WC Reinforcement Particles in Improving the Surface Composite Dissimilar Matrix’s Dynamic Behavior and Microstructure Refinement

This study examined the impact of hybrid reinforcement particles, specifically zirconium carbide (ZrC) and tungsten carbide (WC), as well as the parameters of friction stir processing (FSP), on the microstructure, mechanical properties, and dynamic behavior of aluminum alloys. The hybrid particles were integrated into the aluminum alloy using friction stir processing (FSP). The fabricated metal matrix composites (MMCs) were characterized using optical microscopy, scanning electron microscopy (SEM), and dynamic mechanical analysis (DMA). The results showed that the FSP parameters and reinforcement particles played an important role in improving the grain refinement of the MMCs. This study’s results suggest that the FSP samples’ UTS can be maximized using a tool rotation speed of 600 rpm and a traverse speed of 30 mm/min. The grain refinement in the composite surface was attributed to the dynamic recrystallization during the friction stir processing (FSP) process. The reinforcement particles also acted as grain growth restrictors, further refining the grain size. This resulted in a 34% increase in ultimate tensile strength compared to AA2024 alloys and a 12% increase compared to AA7075 alloys. The composite surface also exhibited enhanced dynamic properties, with an increase in impact energy of 26%. The free vibration test showed that the hybrid reinforcement particles significantly improved the strength and damping capacity of the aluminum alloys, resulting in a high resonant frequency. This is important for applications such as vibration damping and noise reduction.