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A double reinforced layer on an aluminum alloy surface was produced using friction stir processing (FSP) by adding 34CrNiMo6 powder into Al (AA2024) substrate for better wear resistance and gradient transitions. The microstructures of the composites were analyzed using scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS). The phase composition was examined by X-ray diffraction (XRD). The results show that the double reinforced layer of the Al13Fe4 intermetallic compound could be successfully fabricated via FSP. The volume fraction of Al13Fe4 in the double reinforced layer was higher than in the single reinforced layer due to adding 34CrNiMo6 powder and reinforced twice, and the Al13Fe4 particles were dispersed more homogeneously in the double reinforced layer. The interfaces between the double and single reinforced layer had a good metallurgical bond. The microhardness of the double reinforcement layer was significantly increased. Compared with the AA2024 substrate, the microhardness of the double and single reinforced layers increased five(576 HV) and two-fold (254 HV), respectively.

Double Reinforcement of Al–Fe Intermetallic Composites Fabricated by Friction Stir Processing