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Friction stir processing (FSP) is a novel processing technique that is gaining wide recognition for manufacturing nano-dispersed surfaces, which are of high specific strength, hardness, and resistance to wear and corrosion. Herein, four-passes FSP were applied on aluminum alloy 7075 (AA7075) O with and without the addition of alumina nanoparticles (Al2O3) of average size ~40nm. All FSP parameters were constant at 40mm/min transverse speed, 500rpm and tilt angle of 3 . FSP rotation direction was reversed every two passes. The friction stir processed materials were sectioned and solution treated at 515C for 1.5hrs, followed by age hardening at 120 C for 12,24,46,48 and 60hrs. The effect of heat treatment regimes on microstructure, hardness and toughness was examined, as well as the fracture mode. The new friction-stir processed surfaces without and with nanodispersion showed enhancement in the hardness of the surface of the AA7075-O material (65 HV) to almost a double (100 and 140 HV) after 4 passes FSP without and with incorporating nano-alumina particles, respectively. After 48hrs aging at 120C a significant enhancement in impact toughness was achieved for both the friction stir processed without and with nanodispersion (181 and 134J, respectively), compared to the reference material AA7075 in T6 condition (104J).

THE EFFECT OF AGING TREATMENT ON THE FRICTION-STIRPROCESSED AA7075 ALLOY WITH AND WITHOUT SURFACE NANO-DISPERSION