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Friction stir processing (FSP) was used to fabricate an Al3003 metal matrix surface composite reinforced by in-situ formed Al 3 Zr particles. Zirconium elemental powders were incorporated into the surface of Al3003-H14 alloy base metal and subjected to six FSP passes. Microstructural properties, wear behavior and corrosion resistance of the surface composite were investigated and compared with the FSPed and un-FSPed base metal. Results showed that aluminide particles formed at the interface between the aluminum matrix and zirconium particles, and thereafter fragmented and distributed throughout the matrix on stirring. Microstructural modification induced by FSP accompanied with in-situ formed particles improved hardness and wear resistance but reduced the corrosion resistance of the alloy.

Wear and corrosion of in-situ formed Al 3 Zr aluminide reinforced Al3003 surface composite