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Aluminium metal matrix surface composites are gaining more attention in industries such as aerospace, marine and defence, due to the improved hardness, strength, ductility and better resistance to corrosion. In this study, Al/Ni–40Fe–10Ti surface composites were fabricated using friction stir processing (FSP) and the effect of tool rotational speed and transverse speed on the microstructural and mechanical properties was studied. Processing parameters chosen for the experiment are tool rotational speeds between 600 rpm and 1000 rpm, and transverse speeds between 70 mm/min and 210 mm/min. The results show that at a tool rotational speed of 1000 rpm and at transverse speeds of 140–210 mm/min, the hardness values were found to be improved significantly from 38 Hv of the base metal to 41 Hv of the friction stir processed (FSPed) surface. The tensile strength was also found to be improved in a sample produced at a rotational speed of 1000 rpm and transverse speed of 70 mm/min. Tool rotational speed and transverse speed have a greater influence on the mechanical properties of friction stirred process surface because of the high heat input generated in the weld region causing proper mixing and incorporation of the reinforcing Ni–40Fe–10Ti powder.

Characterisation of Aluminium Ni–40Fe–10Ti fabricated by friction stir processing