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The work involved the fabrication of Al₂O₃ particle-size AA2024-T6 aluminum-matrix composites via friction stir processing (FSP). It investigated how varying the volume fraction of Al₂O₃ particles affected the microstructure, mechanical properties, and impact toughness of the composites. Al₂O₃ particles increased the degree of grain refinement. They promoted increases in ultimate tensile strength (UTS), hardness, and impact toughness, which can be attributed to grain-boundary strengthening and Orowan looping. This work demonstrates stable particle dispersion at 10 vol.% Al₂O₃, exceeding the previously reported reinforcement threshold, while achieving uniform microstructures. The optimized FSP was performed using a dual-pin tool to ensure even distribution and prevent clustering in the stir zone. A significant correlation was observed between reinforcement volume and dynamic recrystallization behavior, as well as the resulting mechanical properties, indicating a practical approach to producing lightweight, high-impact-abrasion-resistant aluminum-matrix composites for the aerospace and defense industries. It is suggested that an even distribution increases impact resistance through efficient energy absorption, crack deflection, and slowed crack propagation.
Sabry et al. (Sun,) studied this question.