Thesis (M.Sc.) - Cairo University - Faculty of Engineering - Department of Mechanical Design and Production

In the present study, 5052 AL/WC metal matrix composite (MMCs) was fabricated using Friction Stir Process (FSP). The mechanical properties of 5052 Al/WC MMCs were studied. Several rotation speeds, travel speeds are used to choose the optimum conditions of the FSP. Results show that using rotation speed 840 rpm and travel speed 26 mm/min gives sound specimens, without tunnels and voids. This study proved that FSP is an effective technique to fabricate MMCs surface. MMC was fabricated using FSP with one pass, two and three passes with and without change in the rotation direction between passes. The results show that increasing the number of passes and changing the rotation direction between the passes enhanced the distribution of WC particles and decreased their size. A remarked change in base metal grain size was observed in stirring zone. Grain size was decreased to one third of its value without stirring process. The hardness of the 5052 Al alloy base metal was measured and it was about 55 HV. By increasing the number of passes to three passes with changing the tool rotational direction between the passes, the hardness increased to 155 HV. So increasing number of passes and changing direction between the passes enhanced the hardness and increased it 3 times than that of the base metal. Wear resistance of 5052 Al alloy base metal and Friction Stir Processed specimen was measured under dry condition. Wear rate was calculated using weight loss technique. The new surface coefficient of friction increased by 25%

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