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Abstract
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This paper aims to understand the impact of post-multi-pass friction stir processing (FSP) on the microstructure,
mechanical, wear and fracture behaviors of the fabricated 10 cycle-accumulative roll bonded Al-2%B4C composites.
The increase in the number of tool-passes directly improved homogeneity and fragmentation of B4C
particles, microhardness, tensile strength (86.84–173.92 MPa) and fracture resilience of the Al-2%B4C composite.
The tribological properties of the composite are improved with a rise in the number of tool passes. Wear
rate, upper boundaries and mid-fluctuation lines of the friction coefficient decreased from 6.198×10−5 to
1.095×10−5mm3/Nm, 0.56 to 0.19, and 0.31 to 0.11 respectively as the number of tool passes was varied
between 1 and 8 passes. An increase in the sliding distance caused an overshoot of the complete waveform of
friction coefficient to be above the mid-line of fluctuation due to the induced frictional/thermal input emanating
from the prolonged surface-surface contact. Homogenous particle dispersion imposes abrasion wear mechanism
on the composite. Ductile fracture is the predominant failure mode of the composites. Post-multi-pass friction stir
processing of the accumulative roll bonded Al-2%B4C composite is an effective approach of achieving high
performance in Al-B4C composite.
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