Influence of tool rotational speed on mechanical and corrosion behaviour of friction stir processed AZ31/Al2O3 nanocomposite

Nano-sized reinforcements improved the mechanical characteristics efficiently by promoting more implicit particle hardening mechanisms compared to micron-sized reinforcements. Nano-sized particles lessen the critical particle solidification velocity for swamp and thus offers better dispersal. In the present investigation, the friction stir processing (FSP) is utilized to produce AZ31/Al2O3 nanocomposites at various tool rotation speeds (i.e., 900, 1200, and 1500 rpm) with an optimized 1.5% volume alumina (Al2O3) reinforcement ratio. The mechanical and corrosion behavior of AZ31/Al2O3-developed nanocomposites was investigated and compared with that of the AZ31 base alloy. The AZ31 alloy experienced a comprehensive dynamic recrystallization during FSP, causing substantial grain refinement. Grain-size strengthening is the primary factor contributed to the enhancement in the strength of the fabricated nanocomposite. Tensile strength and yield strength values were lower than those for the base metal matrix, although an upward trend in both values has been observed with an increase in tool rotation speed. An 19.72% increase in hardness along with superior corrosion resistance was achieved compared to the base alloy at a tool rotational speed of 1500 rpm. The corrosion currents (Jcorr) of all samples dropped with increase in the rotational speed, in contrast to the corrosion potentials (Ecorr), which increased. The values of Jcorr of AZ31/Al2O3 were 42.3%, 56.8%, and 65.5% lower than those of AZ31 alloy at the chosen rotating speeds of 900, 1200, and 1500 rpm, respectively. The corrosion behavior of friction stir processed nanocomposites have been addressed in this manuscript which has not been given sufficient attention in the existing literature. Further, this work offers an effective choice for the quality assurance of the FSP process of AZ31/Al2O3 nanocomposites. The obtained results are relevant to the development of lightweight automobile and aerospace structures and components.