Development of Dissimilar AA2014 and AA2024 Based Composite by Using nano-TiC as Reinforcement Via FSP Technique to Categorize Microstructure, Interfacial Layer, and Mechanical Properties

Development of Dissimilar AA2014 and AA2024 Based Composite by Using nano-TiC as Reinforcement Via FSP Technique to Categorize Microstructure, Interfacial Layer, and Mechanical Properties | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Development of Dissimilar AA2014 and AA2024 Based Composite by Using nano-TiC as Reinforcement Via FSP Technique to Categorize Microstructure, Interfacial Layer, and Mechanical Properties Shashi Prakash Dwivedi, Ambuj Saxena, Shubham Sharma This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-2893732/v1 This work is licensed under a CC BY 4.0 License Status: Posted Version 1 posted You are reading this latest preprint version Abstract In the present study, dissimilar aluminum alloys AA2014 and AA2024 alloys have been taken as a base matrix material to develop the composite material by using nano-TiC particles as reinforcement. The friction stir process (FSP) technique was employed to develop the composite. The number of tool passes on the workpiece surface i.e. single, double, triple, and fourth were varied in this experiment. Nono-TiC particles were encapsulated in the groove. Homogeneous distribution and proper interfacial reaction layer of nano-TiC particles were observed in the processed surface of AA2014 and AA2024 alloy for the composite fabricated after the triple tool pass. XRD analysis illustrated the occurrence of Al, TiC, and Al 2 Cu phases inside the composite. The average tensile strength of aluminum alloys (average of AA2014 and AA2024) was found to be 225 MPa. The tensile strength of the nano-TiC reinforced AA2014 and AA2024-based composite material after the triple tool pass was found to be 256 MPa. There was a 20.54% improvement in the hardness after the addition of nano-TiC in the aluminum alloy (AA2014 and AA2024) developed after the triple tool pass. The friction stir process produced a nanocrystalline layer near the surface of the material, which improved the wear resistance of the composite. FSP technique nano-TiC Interfacial layer Mechanical Properties Wear Figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 1. Introduction Aluminum alloy is one of the most popular materials used in industry due to its unique properties, such as its low density, high corrosion resistance, and exceptional strength. Now, aluminum alloys have become the material of choice in many applications for various industries like aerospace, automotive, construction, and electronics [ 1 ]. In aerospace, aluminum alloys are used in aircraft parts that require both strength and lightness, such as wings, fuselage, and landing gear. In automobiles, aluminum alloy is used in engine blocks, wheels, and body panels to reduce weight and increase fuel efficiency [ 2 ]. In construction, aluminum alloys are used for their resistance to rust and their lightweight properties for window frames and roofing. In the electronic industry, aluminum alloys are used for their excellent conductivity and corrosion resistance for electrical wiring and as heat sinks. However, aluminum alloy is a versatile material used in a wide range of applications due to its excellent mechanical and physical properties, making it one of the most commonly used materials in the industry today [ 3 – 5 ]. Aluminum-based composites are materials that are used in manufacturing components for various industries. These composites consist of a matrix of aluminum and are reinforced with one or more materials, such as titanium carbide silicon carbide, alumina, graphite, carbon fibers, etc.. One of the main advantages of aluminum-based composites is their excellent strength-to-weight ratio. They are lightweight and have high stiffness, making them ideal for use in aerospace, automotive, and military applications [ 6 – 8 ]. These composites are also known for their excellent resistance to corrosion, wear, and temperature. Applications of aluminum-based composites are numerous and varied. In the aerospace industry, these composites are used to manufacture engine components, landing gears, and other structural components. In the automotive industry, they are used in brake discs, suspension systems, and engine blocks. In the military, these composites are used to manufacture armor and ballistic protection systems [ 10 – 11 ]. Aluminum-based composites have a high potential for use in various industries due to their excellent properties. Their lightweight and durability make them a popular choice for aerospace, automotive, and military applications. Their use is expected to grow as new applications are developed in the coming years [ 12 – 13 ]. FSP is used to combine materials that are typically difficult to weld. FSP can be used to produce homogeneous composites with improved mechanical properties and minimized defects [ 14 ]. The process involves a rotating tool that is driven into the workpiece material, generating frictional heat and plastic deformation at the interface. The workpiece material is then consolidated through the movement of the tool, resulting in a solid-state joining of the materials [ 15 ]. The development of composites by the FSP technique has gained popularity due to the unique advantages that FSP offers. This process technique provides relatively low-temperature joining with evading the problems associated with the melting of constituents. It can easily accommodate the preheated workpiece followed by the FSP. The frictional heating due to FSP causes the present constituents to undergo plastic deformation which facilitates the mixing of the constituents faster and easier than the traditional manufacturing methods [ 16 ]. Friction Stir Composites are now being widely used in various industries including aerospace, transportation, and defense due to their superior properties. However, the versatility of FSP is still in its infancy, and further research is required to explore the full potential of this technique, such as hybridization with traditional processing methods and improvements in the production of bulk composites [ 17 – 18 ]. An archival study shows that only a small number of scientists have used the FSP technique to fabricate AA2014 and AA2024 Based Composite materials by Using TiC as Reinforcement. With these considerations in mind, the current study attempts to fabricate AA2014 and AA2024 Based Composite materials by Using TiC reinforcement particles. Microstructure, wettability of reinforcement particles, and mechanical and XRD analysis of the developed composite were observed to identify the TiC addition effect on AA2014 and AA2024 dissimilar alloys. 2. Materials and Methods 2.1 Primary Matrix Material AA2014 aluminum alloy was chosen as the primary matrix material via FSP Technique. AA2014 Aluminium Alloy is a high-strength aluminium alloy, commonly used in aerospace and structural applications. It is a primary alloy with additions of copper, manganese, and magnesium which provides exceptional strength and excellent resistance to fatigue while maintaining its machinability and corrosion resistance. This alloy also has good welding and brazing properties and is often used in aircraft structures, landing gears, and missile components. AA2014 has a typical ultimate tensile strength of about 220 MPa and can withstand temperatures up to 120°C. The surface hardness of AA2014 was found to be 70 HV. AA2014 aluminum alloy contains Aluminum (Al): 90.7%, Copper (Cu): 4.5%, Silicon (Si): 0.5%, Iron (Fe): 0.7%, Magnesium (Mg): 0.5%, Manganese (Mn): 0.4%, Zinc (Zn): 0.25%, Titanium (Ti): 0.15% and Chromium (Cr): 0.1% 2.2 Secondary Matrix Material In this study, AA2024 aluminum alloy was selected as the secondary matrix material. AA2024 Aluminium Alloy is a high-strength alloy that belongs to the 2xxx series of aluminum alloys. It contains copper as its primary alloying element along with magnesium, manganese, and chromium. The combination of these elements makes AA2024 highly resistant to fatigue, corrosion, and erosion. Due to its exceptional strength-to-weight ratio, it is commonly used in aircraft and aerospace applications, as well as in the manufacturing of high-stress structural and coupling components in the automotive, construction, and marine industries. Its superior properties are also ideal for high-performance sporting equipment and military hardware. However, AA2024 is difficult to weld due to its high sensitivity to heat, which can cause cracks and structural deformations. AA2024 has a typical ultimate tensile strength of about 230 MPa. The surface hardness of AA2024 was found to be 76 HV. AA2024 Aluminium Alloy contains Aluminum (Al): 90.7%, Copper (Cu): 3.8%, Magnesium (Mg): 1.2%, Manganese (Mn): 0.5%, Silicon (Si): 0.5%, Iron (Fe): 0.5%, Zinc (Zn): 4.0% and Chromium (Cr): 0.1%. 2.3 Reinforcement Particles Titanium carbide (80 nano-meter particle size) was selected as the reinforcement particle to develop the dissimilar-based aluminum alloy composite. Titanium carbide (TiC) is a ceramic compound with the chemical formula TiC. It is widely used as a hardening element in materials such as steel or other alloys. Titanium carbide is also used in cutting tools and machinery due to its high melting point, hardness, and strength. It is also a good conductor of heat and electricity, making it an ideal choice for electronic circuitry and semiconductors. TiC is known for its exceptional wear resistance, high thermal conductivity, and good chemical stability, making it perfect for applications in harsh environments such as in the aerospace and defense industries. Its unique properties and versatility have made it an essential material in various industries today. Nanoparticles addition in composites improves their mechanical, thermal, electrical, and chemical properties. They have a high surface area to volume ratio which leads to better bonding with the matrix, and the small size enables greater dispersion throughout the composite. This results in enhanced strength, stiffness, and durability of the composite material. Powder XRD shows the 99% purity of nanoparticles (Fig. 1 ). 2.4 Experimental Procedure Aluminum plates (AA2014 and AA2024) have been taken as matrix material. The size of the plates was (100 x 50 x 10) mm. A vertical milling machine (VMM) was used to make a groove in the aluminum plate. The groove has a 1 mm width and 3 mm depth [ 16 – 18 ]. The number of tool passes on the workpiece surface i.e. single, double, triple, and fourth were varied in this experiment. TiC particles were encapsulated in the groove. For stirring purposes, the HCHCr steel tool was used. FSP was done on a VMM (Fig. 2 ). Table 1 shows the selected VMM and FSP tool parameters. Metallographic samples were developed as per ASTM E3-95 standard to perform optical microscopy tests. To observe the microstructure, the FSP specimens were polished and etched by using Keller's reagent (10 ml HF + 50ml H 2 O + 15ml HCL + 25ml HNO 3 ). The tensile specimens were made as per ASTM-E8-04 standard. The center zone of the FSP workpiece was measured as a reference (0 points) and hardness experiments were performed at a linear distance of 15 mm on both sides of this reference. Table 1 FSP parameters Sr. No. Parameters Values 1 Length of pin (mm) 3 2 Diameter of pin(mm) 6 3 The tilt angle of the tool (°) 0 4 Tool’s profile Threaded 5 Diameter of the shoulder (mm) 18 6 Tool transverse speed (mm/min) 23 7 Tool rotational speed (rpm) 950 3. Results and Discussion 3.1 Microstructural Observation Figure 3 (a-d) shows the macrostructure sem image of the developed FSP composite after single tool pass, double tool pass, triple tool pass, and fourth tool pass respectively. The properly processed surface can be observed for TiC-reinforced AA2014 and AA2024-based composite material after a triple tool pass. Further, Fig. 4 shows the SEM image of the developed FSP composite after a single tool pass, double tool pass, triple tool pass, and fourth tool pass respectively. Uniform distribution of nano TiC particles can be observed for the composite developed after the Triple tool pass. The addition of titanium carbide (TiC) particles in aluminum composite plays a crucial role in controlling the grain size of the material. When TiC particles are added to the aluminum composite, it acts as a nucleating agent and promotes the formation of fine grains. The smaller grain size leads to increased strength and hardness of the composite. The TiC particles effectively inhibit grain growth by imparting a pinning effect on grain boundaries. The particles act as obstacles to the mobility of grain boundaries, thus minimizing the coarsening of grains. As a result, the dislocation density in the composite increases, which leads to an increase in the strength of the material. The size and distribution of TiC particles affect the microstructure and mechanical properties of the composite. Smaller TiC particles lead to a more uniform distribution and finer grain size in the composite. This, in turn, enhances the mechanical properties. The addition of titanium carbide particles has a significant effect on the grain size of aluminum composite. It promotes the formation of fine grains, inhibits the growth of grains, and increases the mechanical strength and ductility of the material. Figure 5 shows the interfacial layer developed between nano TiC and aluminum alloys (AA2014 and AA2024) fabricated at Triple tool pass. Proper interfacial layer developed between the reinforcement particles and aluminum alloy. A proper interfacial reaction layer promotes the mechanical properties of composites. The interfacial layer between the matrix and reinforcement particles plays a crucial role in determining the mechanical properties of composite materials. In general, a strong interfacial bond between the matrix and reinforcement particles provides a more efficient load transfer from the matrix to the reinforcement particles, resulting in improved mechanical properties. On the other hand, a weak interfacial bond can lead to debonding and ultimately failure of the composite material. Further, Wettability is a crucial factor in the formation of composites since it contributes to the bonding between the matrix and the reinforcement. The wettability between these two materials is determined by the contact angle between them. Ideally, the contact angle should be as small as possible, indicating the absence of any repulsive forces between the two materials. In this study, wettability has been identified on the basis of layer formation between the matrix and reinforcement particles. A high surface tension of the matrix material prevents wetting the reinforcement completely, leading to weak interfacial bonding. On the other hand, the low surface energy of the reinforcement material may lead to poor wetting of the matrix material and the formation of voids in the composite. A suitable surface energy compatibility between the matrix and the reinforcement materials guarantees a strong interfacial bond. Low contact angles between the two materials lead to good wettability and enhance the adhesion between them. This is often achieved through surface treatments such as plasma etching, mechanical abrasion, or chemical modification of the matrix or reinforcement materials. However, proper wettability between the matrix and the reinforcement materials of composites is an important factor that affects the interfacial bonding and the mechanical properties of the composite. The surface energy compatibility between the two materials should be properly considered during the composite fabrication process. 3.2 Tensile Strength Investigation Figure 6 (a) shows the Tensile strength of the nano-TiC-reinforced AA2014 and AA2024-based composite material. The average tensile strength of aluminum alloys (average of AA2014 and AA2024) was found to be 225 MPa. The tensile strength of the nano-TiC reinforced AA2014 and AA2024-based composite material after the triple tool pass was found to be 256 MPa. There was a 13.77% increment in the tensile strength after the addition of nano TiC particles in AA2014 and AA2024 by FSP technique with triple tool pass. The addition of nano titanium carbide (TiC) to aluminum (Al) has been found to significantly improve the tensile strength of the metal. TiC is a hard and strong material, which when added to Al acts as a strengthening agent by forming a composite material. The tensile strength of the composite material is enhanced through the reinforcement of the Al matrix (AA2014 and AA2024) with TiC particles. The strengthening mechanism works by dispersing TiC particles uniformly throughout the Al matrix. The particles act as barriers to the movement of dislocations and as a result, the material becomes more resistant to deformation. This results in an increase in the load-bearing capacity of the material and an increase in the ultimate tensile strength. The tensile strength of the composite material increases with the increasing volume fraction of TiC particles. Studies have shown that the addition of nano-TiC to Al can increase the tensile strength of the material by up to 13.77%. However, it is important to note that the addition of nano-TiC may also have detrimental effects on other mechanical properties, such as hardness. 3.3 Hardness Analysis Figure 6 (b) illustrates the hardness of nano TiC-reinforced composite material produced by using the FSP technique. The hardness of the developed composite is highest (88 HV) when a triple tool -pass is used. The addition of nano-TiC to aluminum has a significant impact on its hardness. There was a 20.54% improvement in the hardness after the addition of nano-TiC in the aluminum alloy (AA2014 and AA2024). This is because TiC is an extremely hard and wear-resistant material, and when added to aluminum, its hard particles fill the gaps between the aluminum matrix. This leads to an increase in the strength and stiffness of the material and subsequently an increase in its hardness. The hard particles of TiC provide a strong reinforcing effect, which reduces the dislocation movement within the aluminum lattice structure. This leads to an elevated level of hardness as the material resists deformation and plasticity under stress, making it more robust and durable. Moreover, the hardness of the aluminium-TiC composite is higher developed after the third tool pass. This is because the denser the packing of TiC particles within the aluminum matrix, the more effective it is in restricting the deformation of the matrix. Consequently, a higher level of hardness is achieved. 3.4 Wear Behaviour Figure 6 (c & d) shows the wear and friction behavior of AA2014 and AA2024-based composite material reinforced with nano-TiC particles developed by the FSP technique. The wear test of the composite was performed at a load of 15 N, sliding distance of 1000 m, and sliding speed of 2 m/s. The minimum wear rate was found to be 0.0025 mm 3 /m for the composite material developed after the triple tool pass. The coefficient of friction for the triple tool pass composite was 0.214. Titanium Carbide (TiC) is a ceramic compound that is known for its exceptional toughness, hardness, and wear resistance. It is commonly used as an additive in composites to enhance their mechanical and tribological properties. When TiC particles are added to aluminum, they form a reinforcement network that can significantly improve wear resistance. The addition of TiC in aluminum matrix composites increases their hardness and modulus, making them more resistant to wear. The hard TiC particles act as abrasive wear-resistant agents and prevent wear caused by sliding friction. The addition of TiC also provides thermal stability to the composite material, which makes it less susceptible to wear and tear over a range of temperatures. Moreover, the uniform distribution of TiC particles in the matrix results in improved interfacial bonding and increases the wear resistance of the composite. This leads to a reduction in surface softening and cracking under the influence of wear and deformation. Further, the hard and uniform nano-TiC particles protect against abrasive wear and prevent surface damage, extending the lifespan of the material. The grain structure of composites plays a significant role in determining the strength and durability of the material. Furthermore, the friction stir process produced a nanocrystalline layer near the surface of the material, which improve the wear resistance of the composite. 3.5 XRD Observation of Composite Material XRD analysis was performed to detect the existence of various phases after solidification in the Al/TiC composite developed by the FSP technique as shown in Fig. 7 . XRD analysis illustrates the occurrence of Al, TiC, and Al 2 Cu phases inside the composite. The existence of the hard phases (TiC and Al 2 Cu) in the prepared composite is responsible for improving the hardness and tensile strength of the fabricated material. 4. Conclusions The FSP technique was successfully used to develop the surface composites. Through the conducted experiment, the following results can be concluded. AA2014 and AA2024 dissimilar alloy-based composite materials can be developed by using the nano-TiC particles as reinforcement material via the FSP technique. The proper processed surface was observed for nano-TiC reinforced AA2014 and AA2024-based composite material after a triple tool pass. Further, uniform distribution of nano TiC particles was observed for the composite developed after the Triple tool pass. There was a 13.77% increment in the tensile strength after the addition of nano TiC particles in AA2014 and AA2024 by FSP technique with triple tool pass. There was a 20.54% improvement in the hardness after the addition of nano-TiC in the aluminum alloy (AA2014 and AA2024). The wear test of the composite was performed at a sliding speed of 2 m/s, sliding distance of 1000 m, and a load of 15 N. Miniumum wear rate was found to be 0.0025 mm 3 /m for the composite material developed after triple tool pass. The coefficient of friction for the triple tool pass composite was 0.214. XRD analysis illustrates the occurrence of Al, TiC, and Al 2 Cu phases inside the composite. The existence of the hard phases (TiC and Al 2 Cu) in the prepared composite is responsible for improving the hardness and tensile strength of the fabricated material. Declarations Ethics approval: This study do not need any ethical approvals . Consent to participate: Consent was obtained from all individual participants included in the study. Consent for publication: Not applicable Availability of data and materials: All data generated or analysed during this study are included in this published article Competing interests: The authors declare that they have no competing interests Funding: Not applicable Authors' contributions Shashi Prakash Dwivedi: Conceptulization, drafting, writing, editing Ambuj Saxena: Editing, writting Shubham Sharma: Editing, reviewing Acknowledgements: Not applicable References Kumar, S., Dwivedi, S.P., Dwivedi, V.K. Synthesis and characterization of ball-milled eggshell and Al 2 O 3 reinforced hybrid green composite material. Journal of Metals, Materials and Minerals. 2020, 30, 67-75. Dwivedi, S.P., Srivastava, A.K, Maurya, N.K., Sahu, R. Microstructure and Mechanical Behaviour of Al/SiC/Agro-Waste RHA Hybrid Metal Matrix Composite. Revue des Composites et des Matériaux Avancés. 2020, 30, 43-47. Dwivedi, S.P., Sharma, P., Saxena, A. Utilization of waste spent alumina catalyst and agro-waste rice husk ash as reinforcement materials with scrap aluminium alloy wheel matrix. Proc IMechE Part E: J Process Mechanical Engineering IMechE. 2020, DOI: 10.1177/0954408920930634. Dwivedi, S.P. Effect of ball-milled MgO and Si 3 N 4 addition on the physical, mechanical and thermal behaviour of aluminium based composite developed by hybrid casting technique. International Journal of Cast Metals Research. 2020, 33, 35-49. Dwivedi, S.P., Mishra, V. R. Physico-Chemical, Mechanical and Thermal Behaviour of Agro-waste RHA-Reinforced Green Emerging Composite Material. Arabian Journal for science and engineering. 2019, 44, 8129–8142. Dwivedi, S.P., Srivastava, A.K. Utilization of Chrome Containing Leather Waste in Development of Aluminium Based Green Composite Material. International Journal of Precision Engineering and Manufacturing-Green Technology. 2020, 7, 781-790. Dwivedi, S.P., Saxena, A. Extraction of collagen powder from chrome containing leather waste and its composites with alumina employing different casting techniques. Materials Chemistry and Physics. 2020, 253, 123274. Singh, C.V., Pachauri, P., Dwivedi, S.P., Sharma, S., Singari, R. M. Formation of Functionally Graded Hybrid Composite Materials with Al 2 O 3 and RHA Reinforcements using Friction Stir Process. Australian Journal of Mechanical Engineering. 2019, https://doi.org/10.1080/14484846.2019.1679583. Kanhu Charan Nayak, Parag Rajendra Deshmukh, Ankit Kumar Pandey, Premkumar Vemula, Prashant P. Date, “Microstructural, physical and mechanical characterization of grinding sludge based aluminium metal matrix composite”, Materials Science and Engineering: A, (2020), Vol. 773, 138895. Nurul Hidayah Roslan, Mohammad Ismail, Nur Hafizah A. Khalid, Bala Muhammad, “Properties of concrete containing electric arc furnace steel slag and steel sludge”, Journal of Building Engineering, (2020), Vol. 28, 101060. L. A. Ryabicheva, A. T. Tsyrkin, N. V. Beloshitskii, “Powder produced from steel 40Kh10S2M grinding sludge”, Powder Metallurgy and Metal Ceramics, (2007), Vol. 46, pp. 298–302. T. Shimizu, K. Hanada, S. Adachi, M. Katoh, K. Hatsukano, K. Matsuzaki, “Recycling of Stainless Steel Grinding Sludge”, Materials Science Forum, (2007), Vol. 534–536, 997–1000. Prangnell, P.B., Heason, C.P., Grain structure formation during friction stir welding observed by the stop action technique. Acta Mater. 2005, 53, 3179–3192. Yang, K., Li, W.Y., Niu, P.L., Yang, X.W., Xu, Y.X. Cold sprayed AA2024/Al 2 O 3 metal matrix composites improved by friction stir processing: Microstructure characterization, mechanical performance and strengthening mechanisms. J. Alloy. Compd. 2018, 736, 115–123. Shashi Prakash Dwivedi, Praveen Pachauri, Manish Maurya, Ambuj Saxena, Ravi Butola, Rohit Sahu and Shubham Sharma, “Alumina catalyst waste utilization for aluminumbased composites using the friction stir process”, Materials Testing 2022; 64(4): 533–540. Anas Islam, Vijay K. Dwivedi, Shashi Prakash Dwivedi, “Effect of Friction Stir Process Parameters on Mechanical Properties of Al/Eggshell/SiC Composite Material”, Annales de Chimie - Science des Matériaux, Vol. 45, No. 1, February, 2021, pp. 51-57. Shashi Prakash Dwivedi (2021): Extraction of Cr from CCLW and its utilization in the development of composite by friction stir process, Australian Journal of Mechanical Engineering, DOI: 10.1080/14484846.2021.1953265 Anas Islam, Shashi Prakash Dwivedi, Vijay Kumar Dwivedi, Rajat Yadav, “Extraction of Chromium Oxide from CCLW to Develop the Aluminium Based Composite by FSP as Reinforcement alongwith Alumina”, EVERGREEN Joint Journal of Novel Carbon Resource Sciences & Green Asia Strategy, Vol. 09, Issue 04, pp993-1002 Additional Declarations No competing interests reported. Cite Share Download PDF Status: Posted Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-2893732","acceptedTermsAndConditions":true,"allowDirectSubmit":true,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":198791322,"identity":"4cdaf55e-3b5f-4641-a5a4-f329005fa522","order_by":0,"name":"Shashi Prakash Dwivedi","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAAvUlEQVRIiWNgGAWjYHACA4aHDTZAmrHxAPFaEhvSQFoaSNJyGMwiTov87ObNLxJ3nLdb234YaEuNTTRhK+4cK7NIPHM7eduZRKCWY2m5DQS1SOSYGSS23U42OwDUwthwmLAW+RlgLeeSzc4/JFILw40c4weJbQfszG4QawvILwyJZ5ITzG4AbUkgxi+gEPvwcYedvdn59IcPPtTYEOEwCQY2CSCVCFaZQFA5RAvzByBlT5TiUTAKRsEoGJkAADdWTU8ymidiAAAAAElFTkSuQmCC","orcid":"","institution":"GL Bajaj Institute of Technology and Management","correspondingAuthor":true,"submittingAuthor":false,"prefix":"","firstName":"Shashi","middleName":"Prakash","lastName":"Dwivedi","suffix":""},{"id":198791324,"identity":"d36acf56-035a-4e8f-bde5-4c50000e1c68","order_by":1,"name":"Ambuj Saxena","email":"","orcid":"","institution":"GL Bajaj Institute of Technology and Management","correspondingAuthor":false,"submittingAuthor":false,"prefix":"","firstName":"Ambuj","middleName":"","lastName":"Saxena","suffix":""},{"id":198791325,"identity":"176c86e7-b62d-40d6-beef-41c0e6893917","order_by":2,"name":"Shubham Sharma","email":"","orcid":"","institution":"Chandigarh University","correspondingAuthor":false,"submittingAuthor":false,"prefix":"","firstName":"Shubham","middleName":"","lastName":"Sharma","suffix":""}],"badges":[],"createdAt":"2023-05-04 11:14:22","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-2893732/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-2893732/v1","draftVersion":[],"editorialEvents":[],"editorialNote":"","failedWorkflow":false,"files":[{"id":36973599,"identity":"955f1c1d-8e99-457e-8e35-02f717b7dfe3","added_by":"auto","created_at":"2023-05-12 20:50:56","extension":"png","order_by":1,"title":"Figure 1","display":"","copyAsset":false,"role":"figure","size":13654,"visible":true,"origin":"","legend":"\u003cp\u003ePowder XRD of nano TiC powder\u003c/p\u003e","description":"","filename":"floatimage1.png","url":"https://assets-eu.researchsquare.com/files/rs-2893732/v1/00e8abbeaff935476af8bd3c.png"},{"id":36973604,"identity":"77bee36d-7561-46d1-b573-2e5ac058ac35","added_by":"auto","created_at":"2023-05-12 20:50:56","extension":"png","order_by":2,"title":"Figure 2","display":"","copyAsset":false,"role":"figure","size":33348,"visible":true,"origin":"","legend":"\u003cp\u003eComposite development\u003c/p\u003e","description":"","filename":"floatimage2.png","url":"https://assets-eu.researchsquare.com/files/rs-2893732/v1/b2d16347569f58441847ad64.png"},{"id":36973600,"identity":"e7ddd76b-2095-44a4-8a8b-d089c470113a","added_by":"auto","created_at":"2023-05-12 20:50:56","extension":"png","order_by":3,"title":"Figure 3","display":"","copyAsset":false,"role":"figure","size":175769,"visible":true,"origin":"","legend":"\u003cp\u003eMacrostructure SEM image of Developed FSP Composite; (a) Single tool pass, (b) Double tool pass, (c) Triple tool pass, (d) Fourth tool pass\u003c/p\u003e","description":"","filename":"floatimage3.png","url":"https://assets-eu.researchsquare.com/files/rs-2893732/v1/3bde0d150078a8151a596d06.png"},{"id":36973601,"identity":"2baa4f80-8eae-4dac-afed-816e7323a9a4","added_by":"auto","created_at":"2023-05-12 20:50:56","extension":"png","order_by":4,"title":"Figure 4","display":"","copyAsset":false,"role":"figure","size":276008,"visible":true,"origin":"","legend":"\u003cp\u003eSEM image of Developed FSP Composite (a) Single tool pass, (b) Double tool pass, (c) Triple tool pass, (d) Fourth tool pass\u003c/p\u003e","description":"","filename":"floatimage4.png","url":"https://assets-eu.researchsquare.com/files/rs-2893732/v1/f8ab7afd50f9413666f03c8e.png"},{"id":36973603,"identity":"19da4306-85dc-4360-99d1-79e7a7cb06f7","added_by":"auto","created_at":"2023-05-12 20:50:56","extension":"png","order_by":5,"title":"Figure 5","display":"","copyAsset":false,"role":"figure","size":123559,"visible":true,"origin":"","legend":"\u003cp\u003eWettability of Developed at Triple tool pass FSP Composite\u003c/p\u003e","description":"","filename":"floatimage5.png","url":"https://assets-eu.researchsquare.com/files/rs-2893732/v1/3d41abf8f0c3601221c1db02.png"},{"id":36973605,"identity":"777f5a99-4376-4c86-a87d-f976585cb8cd","added_by":"auto","created_at":"2023-05-12 20:50:56","extension":"png","order_by":6,"title":"Figure 6","display":"","copyAsset":false,"role":"figure","size":224886,"visible":true,"origin":"","legend":"\u003cp\u003eCharacteristics of fabricated composite; (a) Tensile strength, (b) Hardness, (c) Wear behavior, (d) Friction behavior\u003c/p\u003e","description":"","filename":"floatimage6.png","url":"https://assets-eu.researchsquare.com/files/rs-2893732/v1/804620dbc53a6164f1f5ef27.png"},{"id":36974468,"identity":"4ed5c265-58cf-493d-99c6-79326cde5381","added_by":"auto","created_at":"2023-05-12 20:58:56","extension":"png","order_by":7,"title":"Figure 7","display":"","copyAsset":false,"role":"figure","size":57413,"visible":true,"origin":"","legend":"\u003cp\u003eXRD Analysis of Fabricated Composite Material by FSP method reinforced with nano-TiC particles\u003c/p\u003e","description":"","filename":"floatimage7.png","url":"https://assets-eu.researchsquare.com/files/rs-2893732/v1/275b481db53aecb47c0506b5.png"},{"id":37033225,"identity":"03fdf6f4-dce5-4beb-aff0-4b9a4f044743","added_by":"auto","created_at":"2023-05-15 12:29:43","extension":"pdf","order_by":0,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":1191431,"visible":true,"origin":"","legend":"","description":"","filename":"manuscript.pdf","url":"https://assets-eu.researchsquare.com/files/rs-2893732/v1/e29ecd08-236c-4913-ad95-d01c5a97667e.pdf"}],"financialInterests":"No competing interests reported.","formattedTitle":"Development of Dissimilar AA2014 and AA2024 Based Composite by Using nano-TiC as Reinforcement Via FSP Technique to Categorize Microstructure, Interfacial Layer, and Mechanical Properties","fulltext":[{"header":"1. Introduction","content":" \u003cp\u003eAluminum alloy is one of the most popular materials used in industry due to its unique properties, such as its low density, high corrosion resistance, and exceptional strength. Now, aluminum alloys have become the material of choice in many applications for various industries like aerospace, automotive, construction, and electronics [\u003cspan citationid=\"CR1\" class=\"CitationRef\"\u003e1\u003c/span\u003e]. In aerospace, aluminum alloys are used in aircraft parts that require both strength and lightness, such as wings, fuselage, and landing gear. In automobiles, aluminum alloy is used in engine blocks, wheels, and body panels to reduce weight and increase fuel efficiency [\u003cspan citationid=\"CR2\" class=\"CitationRef\"\u003e2\u003c/span\u003e]. In construction, aluminum alloys are used for their resistance to rust and their lightweight properties for window frames and roofing. In the electronic industry, aluminum alloys are used for their excellent conductivity and corrosion resistance for electrical wiring and as heat sinks. However, aluminum alloy is a versatile material used in a wide range of applications due to its excellent mechanical and physical properties, making it one of the most commonly used materials in the industry today [\u003cspan additionalcitationids=\"CR4\" citationid=\"CR3\" class=\"CitationRef\"\u003e3\u003c/span\u003e\u0026ndash;\u003cspan citationid=\"CR5\" class=\"CitationRef\"\u003e5\u003c/span\u003e].\u003c/p\u003e \u003cp\u003eAluminum-based composites are materials that are used in manufacturing components for various industries. These composites consist of a matrix of aluminum and are reinforced with one or more materials, such as titanium carbide silicon carbide, alumina, graphite, carbon fibers, etc.. One of the main advantages of aluminum-based composites is their excellent strength-to-weight ratio. They are lightweight and have high stiffness, making them ideal for use in aerospace, automotive, and military applications [\u003cspan additionalcitationids=\"CR7\" citationid=\"CR6\" class=\"CitationRef\"\u003e6\u003c/span\u003e\u0026ndash;\u003cspan citationid=\"CR8\" class=\"CitationRef\"\u003e8\u003c/span\u003e]. These composites are also known for their excellent resistance to corrosion, wear, and temperature. Applications of aluminum-based composites are numerous and varied. In the aerospace industry, these composites are used to manufacture engine components, landing gears, and other structural components. In the automotive industry, they are used in brake discs, suspension systems, and engine blocks. In the military, these composites are used to manufacture armor and ballistic protection systems [\u003cspan citationid=\"CR10\" class=\"CitationRef\"\u003e10\u003c/span\u003e\u0026ndash;\u003cspan citationid=\"CR11\" class=\"CitationRef\"\u003e11\u003c/span\u003e]. Aluminum-based composites have a high potential for use in various industries due to their excellent properties. Their lightweight and durability make them a popular choice for aerospace, automotive, and military applications. Their use is expected to grow as new applications are developed in the coming years [\u003cspan citationid=\"CR12\" class=\"CitationRef\"\u003e12\u003c/span\u003e\u0026ndash;\u003cspan citationid=\"CR13\" class=\"CitationRef\"\u003e13\u003c/span\u003e].\u003c/p\u003e \u003cp\u003eFSP is used to combine materials that are typically difficult to weld. FSP can be used to produce homogeneous composites with improved mechanical properties and minimized defects [\u003cspan citationid=\"CR14\" class=\"CitationRef\"\u003e14\u003c/span\u003e]. The process involves a rotating tool that is driven into the workpiece material, generating frictional heat and plastic deformation at the interface. The workpiece material is then consolidated through the movement of the tool, resulting in a solid-state joining of the materials [\u003cspan citationid=\"CR15\" class=\"CitationRef\"\u003e15\u003c/span\u003e]. The development of composites by the FSP technique has gained popularity due to the unique advantages that FSP offers. This process technique provides relatively low-temperature joining with evading the problems associated with the melting of constituents. It can easily accommodate the preheated workpiece followed by the FSP. The frictional heating due to FSP causes the present constituents to undergo plastic deformation which facilitates the mixing of the constituents faster and easier than the traditional manufacturing methods [\u003cspan citationid=\"CR16\" class=\"CitationRef\"\u003e16\u003c/span\u003e]. Friction Stir Composites are now being widely used in various industries including aerospace, transportation, and defense due to their superior properties. However, the versatility of FSP is still in its infancy, and further research is required to explore the full potential of this technique, such as hybridization with traditional processing methods and improvements in the production of bulk composites [\u003cspan citationid=\"CR17\" class=\"CitationRef\"\u003e17\u003c/span\u003e\u0026ndash;\u003cspan citationid=\"CR18\" class=\"CitationRef\"\u003e18\u003c/span\u003e].\u003c/p\u003e \u003cp\u003eAn archival study shows that only a small number of scientists have used the FSP technique to fabricate AA2014 and AA2024 Based Composite materials by Using TiC as Reinforcement. With these considerations in mind, the current study attempts to fabricate AA2014 and AA2024 Based Composite materials by Using TiC reinforcement particles. Microstructure, wettability of reinforcement particles, and mechanical and XRD analysis of the developed composite were observed to identify the TiC addition effect on AA2014 and AA2024 dissimilar alloys.\u003c/p\u003e"},{"header":"2. Materials and Methods","content":"\u003cdiv id=\"Sec3\" class=\"Section2\"\u003e \u003ch2\u003e2.1 Primary Matrix Material\u003c/h2\u003e \u003cp\u003eAA2014 aluminum alloy was chosen as the primary matrix material via FSP Technique. AA2014 Aluminium Alloy is a high-strength aluminium alloy, commonly used in aerospace and structural applications. It is a primary alloy with additions of copper, manganese, and magnesium which provides exceptional strength and excellent resistance to fatigue while maintaining its machinability and corrosion resistance. This alloy also has good welding and brazing properties and is often used in aircraft structures, landing gears, and missile components. AA2014 has a typical ultimate tensile strength of about 220 MPa and can withstand temperatures up to 120\u0026deg;C. The surface hardness of AA2014 was found to be 70 HV. AA2014 aluminum alloy contains Aluminum (Al): 90.7%, Copper (Cu): 4.5%, Silicon (Si): 0.5%, Iron (Fe): 0.7%, Magnesium (Mg): 0.5%, Manganese (Mn): 0.4%, Zinc (Zn): 0.25%, Titanium (Ti): 0.15% and Chromium (Cr): 0.1%\u003c/p\u003e \u003c/div\u003e \u003cdiv id=\"Sec4\" class=\"Section2\"\u003e \u003ch2\u003e2.2 Secondary Matrix Material\u003c/h2\u003e \u003cp\u003eIn this study, AA2024 aluminum alloy was selected as the secondary matrix material. AA2024 Aluminium Alloy is a high-strength alloy that belongs to the 2xxx series of aluminum alloys. It contains copper as its primary alloying element along with magnesium, manganese, and chromium. The combination of these elements makes AA2024 highly resistant to fatigue, corrosion, and erosion. Due to its exceptional strength-to-weight ratio, it is commonly used in aircraft and aerospace applications, as well as in the manufacturing of high-stress structural and coupling components in the automotive, construction, and marine industries. Its superior properties are also ideal for high-performance sporting equipment and military hardware. However, AA2024 is difficult to weld due to its high sensitivity to heat, which can cause cracks and structural deformations. AA2024 has a typical ultimate tensile strength of about 230 MPa. The surface hardness of AA2024 was found to be 76 HV. AA2024 Aluminium Alloy contains Aluminum (Al): 90.7%, Copper (Cu): 3.8%, Magnesium (Mg): 1.2%, Manganese (Mn): 0.5%, Silicon (Si): 0.5%, Iron (Fe): 0.5%, Zinc (Zn): 4.0% and Chromium (Cr): 0.1%.\u003c/p\u003e \u003c/div\u003e \u003cdiv id=\"Sec5\" class=\"Section2\"\u003e \u003ch2\u003e2.3 Reinforcement Particles\u003c/h2\u003e \u003cp\u003eTitanium carbide (80 nano-meter particle size) was selected as the reinforcement particle to develop the dissimilar-based aluminum alloy composite. Titanium carbide (TiC) is a ceramic compound with the chemical formula TiC. It is widely used as a hardening element in materials such as steel or other alloys. Titanium carbide is also used in cutting tools and machinery due to its high melting point, hardness, and strength. It is also a good conductor of heat and electricity, making it an ideal choice for electronic circuitry and semiconductors. TiC is known for its exceptional wear resistance, high thermal conductivity, and good chemical stability, making it perfect for applications in harsh environments such as in the aerospace and defense industries. Its unique properties and versatility have made it an essential material in various industries today. Nanoparticles addition in composites improves their mechanical, thermal, electrical, and chemical properties. They have a high surface area to volume ratio which leads to better bonding with the matrix, and the small size enables greater dispersion throughout the composite. This results in enhanced strength, stiffness, and durability of the composite material. Powder XRD shows the 99% purity of nanoparticles (Fig.\u0026nbsp;\u003cspan refid=\"Fig1\" class=\"InternalRef\"\u003e1\u003c/span\u003e).\u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003c/div\u003e \u003cdiv id=\"Sec6\" class=\"Section2\"\u003e \u003ch2\u003e2.4 Experimental Procedure\u003c/h2\u003e \u003cp\u003eAluminum plates (AA2014 and AA2024) have been taken as matrix material. The size of the plates was (100 x 50 x 10) mm. A vertical milling machine (VMM) was used to make a groove in the aluminum plate. The groove has a 1 mm width and 3 mm depth [\u003cspan additionalcitationids=\"CR17\" citationid=\"CR16\" class=\"CitationRef\"\u003e16\u003c/span\u003e\u0026ndash;\u003cspan citationid=\"CR18\" class=\"CitationRef\"\u003e18\u003c/span\u003e]. The number of tool passes on the workpiece surface i.e. single, double, triple, and fourth were varied in this experiment. TiC particles were encapsulated in the groove. For stirring purposes, the HCHCr steel tool was used. FSP was done on a VMM (Fig.\u0026nbsp;\u003cspan refid=\"Fig2\" class=\"InternalRef\"\u003e2\u003c/span\u003e). Table\u0026nbsp;\u003cspan refid=\"Tab1\" class=\"InternalRef\"\u003e1\u003c/span\u003e shows the selected VMM and FSP tool parameters. Metallographic samples were developed as per ASTM E3-95 standard to perform optical microscopy tests. To observe the microstructure, the FSP specimens were polished and etched by using Keller's reagent (10 ml HF\u0026thinsp;+\u0026thinsp;50ml H\u003csub\u003e2\u003c/sub\u003eO\u0026thinsp;+\u0026thinsp;15ml HCL\u0026thinsp;+\u0026thinsp;25ml HNO\u003csub\u003e3\u003c/sub\u003e). The tensile specimens were made as per ASTM-E8-04 standard. The center zone of the FSP workpiece was measured as a reference (0 points) and hardness experiments were performed at a linear distance of 15 mm on both sides of this reference.\u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003cp\u003e \u003cdiv class=\"gridtable\"\u003e\u003ctable float=\"Yes\" id=\"Tab1\" border=\"1\"\u003e \u003ccaption language=\"En\"\u003e \u003cdiv class=\"CaptionNumber\"\u003eTable 1\u003c/div\u003e \u003cdiv class=\"CaptionContent\"\u003e \u003cp\u003eFSP parameters\u003c/p\u003e \u003c/div\u003e \u003c/caption\u003e \u003ccolgroup cols=\"3\"\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c1\" colnum=\"1\"\u003e\u003c/div\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c2\" colnum=\"2\"\u003e\u003c/div\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c3\" colnum=\"3\"\u003e\u003c/div\u003e \u003cthead\u003e \u003ctr\u003e \u003cth align=\"left\" colname=\"c1\"\u003e \u003cp\u003eSr. No.\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c2\"\u003e \u003cp\u003eParameters\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c3\"\u003e \u003cp\u003eValues\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003c/thead\u003e \u003ctbody\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e1\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003eLength of pin (mm)\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c3\"\u003e \u003cp\u003e3\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e2\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003eDiameter of pin(mm)\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c3\"\u003e \u003cp\u003e6\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e3\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003eThe tilt angle of the tool (\u0026deg;)\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c3\"\u003e \u003cp\u003e0\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e4\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003eTool\u0026rsquo;s profile\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c3\"\u003e \u003cp\u003eThreaded\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e5\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003eDiameter of the shoulder (mm)\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c3\"\u003e \u003cp\u003e18\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e6\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003eTool transverse speed (mm/min)\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c3\"\u003e \u003cp\u003e23\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e7\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003eTool rotational speed (rpm)\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c3\"\u003e \u003cp\u003e950\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003c/tbody\u003e \u003c/colgroup\u003e \u003c/table\u003e\u003c/div\u003e \u003c/p\u003e \u003c/div\u003e"},{"header":"3. Results and Discussion","content":"\u003cdiv id=\"Sec8\" class=\"Section2\"\u003e \u003ch2\u003e3.1 Microstructural Observation\u003c/h2\u003e \u003cp\u003eFigure \u003cspan refid=\"Fig3\" class=\"InternalRef\"\u003e3\u003c/span\u003e (a-d) shows the macrostructure sem image of the developed FSP composite after single tool pass, double tool pass, triple tool pass, and fourth tool pass respectively. The properly processed surface can be observed for TiC-reinforced AA2014 and AA2024-based composite material after a triple tool pass. Further, Fig.\u0026nbsp;\u003cspan refid=\"Fig4\" class=\"InternalRef\"\u003e4\u003c/span\u003e shows the SEM image of the developed FSP composite after a single tool pass, double tool pass, triple tool pass, and fourth tool pass respectively. Uniform distribution of nano TiC particles can be observed for the composite developed after the Triple tool pass. The addition of titanium carbide (TiC) particles in aluminum composite plays a crucial role in controlling the grain size of the material. When TiC particles are added to the aluminum composite, it acts as a nucleating agent and promotes the formation of fine grains. The smaller grain size leads to increased strength and hardness of the composite. The TiC particles effectively inhibit grain growth by imparting a pinning effect on grain boundaries. The particles act as obstacles to the mobility of grain boundaries, thus minimizing the coarsening of grains. As a result, the dislocation density in the composite increases, which leads to an increase in the strength of the material. The size and distribution of TiC particles affect the microstructure and mechanical properties of the composite. Smaller TiC particles lead to a more uniform distribution and finer grain size in the composite. This, in turn, enhances the mechanical properties. The addition of titanium carbide particles has a significant effect on the grain size of aluminum composite. It promotes the formation of fine grains, inhibits the growth of grains, and increases the mechanical strength and ductility of the material. Figure\u0026nbsp;\u003cspan refid=\"Fig5\" class=\"InternalRef\"\u003e5\u003c/span\u003e shows the interfacial layer developed between nano TiC and aluminum alloys (AA2014 and AA2024) fabricated at Triple tool pass. Proper interfacial layer developed between the reinforcement particles and aluminum alloy. A proper interfacial reaction layer promotes the mechanical properties of composites. The interfacial layer between the matrix and reinforcement particles plays a crucial role in determining the mechanical properties of composite materials. In general, a strong interfacial bond between the matrix and reinforcement particles provides a more efficient load transfer from the matrix to the reinforcement particles, resulting in improved mechanical properties. On the other hand, a weak interfacial bond can lead to debonding and ultimately failure of the composite material.\u003c/p\u003e \u003cp\u003eFurther, Wettability is a crucial factor in the formation of composites since it contributes to the bonding between the matrix and the reinforcement. The wettability between these two materials is determined by the contact angle between them. Ideally, the contact angle should be as small as possible, indicating the absence of any repulsive forces between the two materials. In this study, wettability has been identified on the basis of layer formation between the matrix and reinforcement particles. A high surface tension of the matrix material prevents wetting the reinforcement completely, leading to weak interfacial bonding. On the other hand, the low surface energy of the reinforcement material may lead to poor wetting of the matrix material and the formation of voids in the composite. A suitable surface energy compatibility between the matrix and the reinforcement materials guarantees a strong interfacial bond. Low contact angles between the two materials lead to good wettability and enhance the adhesion between them. This is often achieved through surface treatments such as plasma etching, mechanical abrasion, or chemical modification of the matrix or reinforcement materials. However, proper wettability between the matrix and the reinforcement materials of composites is an important factor that affects the interfacial bonding and the mechanical properties of the composite. The surface energy compatibility between the two materials should be properly considered during the composite fabrication process.\u003c/p\u003e\u003c/div\u003e \u003cdiv id=\"Sec9\" class=\"Section2\"\u003e \u003ch2\u003e3.2 Tensile Strength Investigation\u003c/h2\u003e \u003cp\u003eFigure \u003cspan refid=\"Fig6\" class=\"InternalRef\"\u003e6\u003c/span\u003e (a) shows the Tensile strength of the nano-TiC-reinforced AA2014 and AA2024-based composite material. The average tensile strength of aluminum alloys (average of AA2014 and AA2024) was found to be 225 MPa. The tensile strength of the nano-TiC reinforced AA2014 and AA2024-based composite material after the triple tool pass was found to be 256 MPa. There was a 13.77% increment in the tensile strength after the addition of nano TiC particles in AA2014 and AA2024 by FSP technique with triple tool pass. The addition of nano titanium carbide (TiC) to aluminum (Al) has been found to significantly improve the tensile strength of the metal. TiC is a hard and strong material, which when added to Al acts as a strengthening agent by forming a composite material. The tensile strength of the composite material is enhanced through the reinforcement of the Al matrix (AA2014 and AA2024) with TiC particles. The strengthening mechanism works by dispersing TiC particles uniformly throughout the Al matrix. The particles act as barriers to the movement of dislocations and as a result, the material becomes more resistant to deformation. This results in an increase in the load-bearing capacity of the material and an increase in the ultimate tensile strength. The tensile strength of the composite material increases with the increasing volume fraction of TiC particles. Studies have shown that the addition of nano-TiC to Al can increase the tensile strength of the material by up to 13.77%. However, it is important to note that the addition of nano-TiC may also have detrimental effects on other mechanical properties, such as hardness.\u003c/p\u003e \u003c/div\u003e \u003cdiv id=\"Sec10\" class=\"Section2\"\u003e \u003ch2\u003e3.3 Hardness Analysis\u003c/h2\u003e \u003cp\u003eFigure \u003cspan refid=\"Fig6\" class=\"InternalRef\"\u003e6\u003c/span\u003e (b) illustrates the hardness of nano TiC-reinforced composite material produced by using the FSP technique. The hardness of the developed composite is highest (88 HV) when a triple tool -pass is used. The addition of nano-TiC to aluminum has a significant impact on its hardness. There was a 20.54% improvement in the hardness after the addition of nano-TiC in the aluminum alloy (AA2014 and AA2024). This is because TiC is an extremely hard and wear-resistant material, and when added to aluminum, its hard particles fill the gaps between the aluminum matrix. This leads to an increase in the strength and stiffness of the material and subsequently an increase in its hardness. The hard particles of TiC provide a strong reinforcing effect, which reduces the dislocation movement within the aluminum lattice structure. This leads to an elevated level of hardness as the material resists deformation and plasticity under stress, making it more robust and durable. Moreover, the hardness of the aluminium-TiC composite is higher developed after the third tool pass. This is because the denser the packing of TiC particles within the aluminum matrix, the more effective it is in restricting the deformation of the matrix. Consequently, a higher level of hardness is achieved.\u003c/p\u003e \u003c/div\u003e \u003cdiv id=\"Sec11\" class=\"Section2\"\u003e \u003ch2\u003e3.4 Wear Behaviour\u003c/h2\u003e \u003cp\u003eFigure \u003cspan refid=\"Fig6\" class=\"InternalRef\"\u003e6\u003c/span\u003e (c \u0026amp; d) shows the wear and friction behavior of AA2014 and AA2024-based composite material reinforced with nano-TiC particles developed by the FSP technique. The wear test of the composite was performed at a load of 15 N, sliding distance of 1000 m, and sliding speed of 2 m/s. The minimum wear rate was found to be 0.0025 mm\u003csup\u003e3\u003c/sup\u003e/m for the composite material developed after the triple tool pass. The coefficient of friction for the triple tool pass composite was 0.214. Titanium Carbide (TiC) is a ceramic compound that is known for its exceptional toughness, hardness, and wear resistance. It is commonly used as an additive in composites to enhance their mechanical and tribological properties. When TiC particles are added to aluminum, they form a reinforcement network that can significantly improve wear resistance. The addition of TiC in aluminum matrix composites increases their hardness and modulus, making them more resistant to wear. The hard TiC particles act as abrasive wear-resistant agents and prevent wear caused by sliding friction. The addition of TiC also provides thermal stability to the composite material, which makes it less susceptible to wear and tear over a range of temperatures. Moreover, the uniform distribution of TiC particles in the matrix results in improved interfacial bonding and increases the wear resistance of the composite. This leads to a reduction in surface softening and cracking under the influence of wear and deformation. Further, the hard and uniform nano-TiC particles protect against abrasive wear and prevent surface damage, extending the lifespan of the material. The grain structure of composites plays a significant role in determining the strength and durability of the material. Furthermore, the friction stir process produced a nanocrystalline layer near the surface of the material, which improve the wear resistance of the composite.\u003c/p\u003e \u003c/div\u003e \u003cdiv id=\"Sec12\" class=\"Section2\"\u003e \u003ch2\u003e3.5 XRD Observation of Composite Material\u003c/h2\u003e \u003cp\u003eXRD analysis was performed to detect the existence of various phases after solidification in the Al/TiC composite developed by the FSP technique as shown in Fig.\u0026nbsp;\u003cspan refid=\"Fig7\" class=\"InternalRef\"\u003e7\u003c/span\u003e. XRD analysis illustrates the occurrence of Al, TiC, and Al\u003csub\u003e2\u003c/sub\u003eCu phases inside the composite. The existence of the hard phases (TiC and Al\u003csub\u003e2\u003c/sub\u003eCu) in the prepared composite is responsible for improving the hardness and tensile strength of the fabricated material.\u003c/p\u003e\u003c/div\u003e"},{"header":"4. Conclusions","content":"\u003cp\u003eThe FSP technique was successfully used to develop the surface composites. Through the conducted experiment, the following results can be concluded.\u003c/p\u003e \u003cp\u003e \u003col\u003e \u003cspan\u003e \u003cli\u003e \u003cp\u003eAA2014 and AA2024 dissimilar alloy-based composite materials can be developed by using the nano-TiC particles as reinforcement material via the FSP technique.\u003c/p\u003e \u003c/li\u003e \u003c/span\u003e \u003cspan\u003e \u003cli\u003e \u003cp\u003eThe proper processed surface was observed for nano-TiC reinforced AA2014 and AA2024-based composite material after a triple tool pass. Further, uniform distribution of nano TiC particles was observed for the composite developed after the Triple tool pass.\u003c/p\u003e \u003c/li\u003e \u003c/span\u003e \u003cspan\u003e \u003cli\u003e \u003cp\u003eThere was a 13.77% increment in the tensile strength after the addition of nano TiC particles in AA2014 and AA2024 by FSP technique with triple tool pass. There was a 20.54% improvement in the hardness after the addition of nano-TiC in the aluminum alloy (AA2014 and AA2024).\u003c/p\u003e \u003c/li\u003e \u003c/span\u003e \u003cspan\u003e \u003cli\u003e \u003cp\u003eThe wear test of the composite was performed at a sliding speed of 2 m/s, sliding distance of 1000 m, and a load of 15 N. Miniumum wear rate was found to be 0.0025 mm\u003csup\u003e3\u003c/sup\u003e/m for the composite material developed after triple tool pass. The coefficient of friction for the triple tool pass composite was 0.214.\u003c/p\u003e \u003c/li\u003e \u003c/span\u003e \u003cspan\u003e \u003cli\u003e \u003cp\u003eXRD analysis illustrates the occurrence of Al, TiC, and Al\u003csub\u003e2\u003c/sub\u003eCu phases inside the composite. The existence of the hard phases (TiC and Al\u003csub\u003e2\u003c/sub\u003eCu) in the prepared composite is responsible for improving the hardness and tensile strength of the fabricated material.\u003c/p\u003e \u003c/li\u003e \u003c/span\u003e \u003c/ol\u003e \u003c/p\u003e"},{"header":"Declarations","content":"\u003cp\u003e\u003cstrong\u003eEthics approval:\u0026nbsp;\u003c/strong\u003e\u003cem\u003eThis study do not need any ethical approvals\u003c/em\u003e.\u003c/p\u003e\n\u003cp\u003e\u003cstrong\u003eConsent to participate:\u0026nbsp;\u003c/strong\u003eConsent was obtained from all individual participants included in the study.\u003c/p\u003e\n\u003cp\u003e\u003cstrong\u003eConsent for publication:\u0026nbsp;\u003c/strong\u003eNot applicable\u003c/p\u003e\n\u003cp\u003e\u003cstrong\u003eAvailability of data and materials:\u0026nbsp;\u003c/strong\u003eAll data generated or analysed during this study are included in this published article\u003c/p\u003e\n\u003cp\u003e\u003cstrong\u003eCompeting interests:\u0026nbsp;\u003c/strong\u003eThe authors declare that they have no competing interests\u003c/p\u003e\n\u003cp\u003e\u003cstrong\u003eFunding:\u0026nbsp;\u003c/strong\u003eNot applicable\u003c/p\u003e\n\u003cp\u003e\u003cstrong\u003eAuthors\u0026apos; contributions\u003c/strong\u003e\u003c/p\u003e\n\u003cp\u003eShashi Prakash Dwivedi: Conceptulization, drafting, writing, editing\u003c/p\u003e\n\u003cp\u003eAmbuj Saxena: Editing, writting\u003c/p\u003e\n\u003cp\u003eShubham Sharma:\u0026nbsp;Editing, reviewing\u003c/p\u003e\n\u003cp\u003e\u003cstrong\u003eAcknowledgements:\u0026nbsp;\u003c/strong\u003eNot applicable\u003c/p\u003e"},{"header":"References","content":"\u003col\u003e\n \u003cli\u003eKumar, S., Dwivedi, S.P., Dwivedi, V.K. Synthesis and characterization of ball-milled eggshell and Al\u003csub\u003e2\u003c/sub\u003eO\u003csub\u003e3\u003c/sub\u003e reinforced hybrid green composite material. Journal of Metals, Materials and Minerals. 2020, 30, 67-75.\u003c/li\u003e\n \u003cli\u003eDwivedi, S.P., Srivastava, A.K, Maurya, N.K., Sahu, R. Microstructure and Mechanical Behaviour of Al/SiC/Agro-Waste RHA Hybrid Metal Matrix Composite. Revue des Composites et des Mat\u0026eacute;riaux Avanc\u0026eacute;s. 2020, 30, 43-47.\u003c/li\u003e\n \u003cli\u003eDwivedi, S.P., Sharma, P., Saxena, A. Utilization of waste spent alumina catalyst and agro-waste rice husk ash as reinforcement materials with scrap aluminium alloy wheel matrix. Proc IMechE Part E: J Process Mechanical Engineering IMechE. 2020, DOI: 10.1177/0954408920930634.\u003c/li\u003e\n \u003cli\u003eDwivedi, S.P.\u0026nbsp;Effect of ball-milled MgO and Si\u003csub\u003e3\u003c/sub\u003eN\u003csub\u003e4\u0026nbsp;\u003c/sub\u003eaddition on the physical, mechanical and thermal behaviour of aluminium based composite developed by hybrid casting technique. International Journal of Cast Metals Research. 2020, 33, 35-49.\u003c/li\u003e\n \u003cli\u003eDwivedi, S.P., Mishra, V. R. \u0026nbsp;Physico-Chemical, Mechanical and Thermal Behaviour of Agro-waste RHA-Reinforced Green Emerging Composite Material. Arabian Journal for science and engineering. 2019, 44,\u0026nbsp;8129\u0026ndash;8142.\u003c/li\u003e\n \u003cli\u003eDwivedi, S.P., Srivastava, A.K. Utilization of Chrome Containing Leather Waste in Development of Aluminium Based Green Composite Material. International Journal of Precision Engineering and Manufacturing-Green Technology. 2020, 7, 781-790.\u003c/li\u003e\n \u003cli\u003eDwivedi, S.P., Saxena, A. Extraction of collagen powder from chrome containing leather waste and its composites with alumina employing different casting techniques. Materials Chemistry and Physics. 2020, 253, 123274.\u003c/li\u003e\n \u003cli\u003eSingh, C.V., Pachauri, P., Dwivedi, S.P., Sharma, S., Singari, R. M. \u0026nbsp;Formation of Functionally Graded Hybrid Composite Materials with Al\u003csub\u003e2\u003c/sub\u003eO\u003csub\u003e3\u003c/sub\u003e and RHA Reinforcements using Friction Stir Process. Australian Journal of Mechanical Engineering. 2019, https://doi.org/10.1080/14484846.2019.1679583.\u003c/li\u003e\n \u003cli\u003eKanhu Charan Nayak, Parag Rajendra Deshmukh, Ankit Kumar Pandey, Premkumar Vemula, Prashant P. Date, \u0026ldquo;Microstructural, physical and mechanical characterization of grinding sludge based aluminium metal matrix composite\u0026rdquo;, Materials Science and Engineering: A, (2020), Vol. 773, 138895.\u003c/li\u003e\n \u003cli\u003eNurul Hidayah Roslan, Mohammad Ismail, Nur Hafizah A. Khalid, Bala Muhammad, \u0026ldquo;Properties of concrete containing electric arc furnace steel slag and steel sludge\u0026rdquo;, Journal of Building Engineering, (2020), Vol. 28, 101060.\u003c/li\u003e\n \u003cli\u003eL. A. Ryabicheva, A. T. Tsyrkin, N. V. Beloshitskii, \u0026ldquo;Powder produced from steel 40Kh10S2M grinding sludge\u0026rdquo;, Powder Metallurgy and Metal Ceramics, (2007), Vol. 46, pp. 298\u0026ndash;302.\u003c/li\u003e\n \u003cli\u003e\u0026nbsp;T. Shimizu, K. Hanada, S. Adachi, M. Katoh, K. Hatsukano, K. Matsuzaki, \u0026ldquo;Recycling of Stainless Steel Grinding Sludge\u0026rdquo;, Materials Science Forum, (2007), Vol. 534\u0026ndash;536, 997\u0026ndash;1000.\u003c/li\u003e\n \u003cli\u003ePrangnell, P.B., Heason, C.P., Grain structure formation during friction stir welding observed by the stop action technique. Acta Mater. 2005, 53, 3179\u0026ndash;3192.\u003c/li\u003e\n \u003cli\u003eYang, K., Li, W.Y., Niu, P.L., Yang, X.W., \u0026nbsp;Xu, Y.X. Cold sprayed AA2024/Al\u003csub\u003e2\u003c/sub\u003eO\u003csub\u003e3\u003c/sub\u003e metal matrix composites improved by friction stir processing: Microstructure characterization, mechanical performance and strengthening mechanisms. J. Alloy. Compd. 2018, 736, 115\u0026ndash;123.\u003c/li\u003e\n \u003cli\u003eShashi Prakash Dwivedi, Praveen Pachauri, Manish Maurya, Ambuj Saxena, Ravi Butola, Rohit Sahu and Shubham Sharma, \u0026ldquo;Alumina catalyst waste utilization for aluminumbased composites using the friction stir process\u0026rdquo;, Materials Testing 2022; 64(4): 533\u0026ndash;540.\u003c/li\u003e\n \u003cli\u003eAnas Islam, Vijay K. Dwivedi, Shashi Prakash Dwivedi, \u0026ldquo;Effect of Friction Stir Process Parameters on Mechanical Properties of Al/Eggshell/SiC Composite Material\u0026rdquo;, Annales de Chimie - Science des Mat\u0026eacute;riaux, Vol. 45, No. 1, February, 2021, pp. 51-57.\u003c/li\u003e\n \u003cli\u003eShashi Prakash Dwivedi (2021): Extraction of Cr from CCLW and its utilization in the development of composite by friction stir process, Australian Journal of Mechanical Engineering, DOI: 10.1080/14484846.2021.1953265\u003c/li\u003e\n \u003cli\u003eAnas Islam, Shashi Prakash Dwivedi, Vijay Kumar Dwivedi, Rajat Yadav, \u0026ldquo;Extraction of Chromium Oxide from CCLW to Develop the Aluminium Based Composite by FSP as Reinforcement alongwith Alumina\u0026rdquo;, EVERGREEN Joint Journal of Novel Carbon Resource Sciences \u0026amp; Green Asia Strategy, Vol. 09, Issue 04, pp993-1002\u003c/li\u003e\n\u003c/ol\u003e"}],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":true,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":true,"highlight":"","institution":"","isAcceptedByJournal":false,"isAuthorSuppliedPdf":false,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":false,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true},"keywords":"FSP technique, nano-TiC, Interfacial layer, Mechanical Properties, Wear","lastPublishedDoi":"10.21203/rs.3.rs-2893732/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-2893732/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eIn the present study, dissimilar aluminum alloys AA2014 and AA2024 alloys have been taken as a base matrix material to develop the composite material by using nano-TiC particles as reinforcement. The friction stir process (FSP) technique was employed to develop the composite. The number of tool passes on the workpiece surface i.e. single, double, triple, and fourth were varied in this experiment. Nono-TiC particles were encapsulated in the groove. Homogeneous distribution and proper interfacial reaction layer of nano-TiC particles were observed in the processed surface of AA2014 and AA2024 alloy for the composite fabricated after the triple tool pass. XRD analysis illustrated the occurrence of Al, TiC, and Al\u003csub\u003e2\u003c/sub\u003eCu phases inside the composite. The average tensile strength of aluminum alloys (average of AA2014 and AA2024) was found to be 225 MPa. The tensile strength of the nano-TiC reinforced AA2014 and AA2024-based composite material after the triple tool pass was found to be 256 MPa. There was a 20.54% improvement in the hardness after the addition of nano-TiC in the aluminum alloy (AA2014 and AA2024) developed after the triple tool pass. The friction stir process produced a nanocrystalline layer near the surface of the material, which improved the wear resistance of the composite.\u003c/p\u003e","manuscriptTitle":"Development of Dissimilar AA2014 and AA2024 Based Composite by Using nano-TiC as Reinforcement Via FSP Technique to Categorize Microstructure, Interfacial Layer, and Mechanical Properties","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2023-05-12 20:50:51","doi":"10.21203/rs.3.rs-2893732/v1","editorialEvents":[{"type":"communityComments","content":0}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true}}],"origin":"","ownerIdentity":"e823796d-b1aa-445a-8fd2-953a45e75b41","owner":[],"postedDate":"May 12th, 2023","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"posted","subjectAreas":[],"tags":[],"updatedAt":"2023-05-15T12:29:30+00:00","versionOfRecord":[],"versionCreatedAt":"2023-05-12 20:50:51","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-2893732","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-2893732","identity":"rs-2893732","version":["v1"]},"buildId":"cBFmMYwuxLRRLfASyISRj","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}