Additive Manufacturing of AA6063-ZrO 2 Composite Using Friction Stir Surface Additive Manufacturing

In the present work, aluminum matrix composite is manufactured layer by layer using ZrO 2 as reinforcement through friction stir surface additive manufacturing process. Four holes in AA6063-T4 Al alloy consumable rod (matrix) are filled with ZrO 2 reinforcement prior to additive manufacturing. Each layer is deposited at rod plunging speed of 60 mm/min, tool rotational speed of 1500 rpm, and substrate traverse speed of 200 mm/min. Two composites each possessing different percentage of ZrO 2 (8% and 12%) revealed finer grains and homogenous distribution of reinforced particles. Composite with 12% ZrO 2 showed maximum improvement in microhardness and ultimate tensile strength of 46% and 53%, respectively, than as-deposited rod. Wear resistance of composites was found to improve significantly compared to as-received rod irrespective of the applied normal load. The newly identified solid-state process would be useful over melting-based approaches for fabricating Al-based composites.