In-situ fabrication of titanium metal powder incorporated AA3003 /Al3Ti alloy composite by friction stir processing

A rolled AA3003-H14 aluminum alloy sheet and Titanium metal powders were used to fabricate Al-surface composites reinforced by in-situ formed Al3Ti aluminide nanoparticles while applying friction stir processing (FSP). The titanium powder of particle sizes smaller than 45 microns was used as reinforcement. Tensile strength and the hardness of the surface composites were determined after applying 6 passes FSP. Its phase analysis was done by using an X-ray diffraction and the microstructural examinations were performed using an optical microscope and scanning electron microscopy. Microstructural examinations revealed that the large size and elongated grains of the base metal have transformed into a more homogeneous, equiaxed and smaller ones after applying FSP. It was also noticed that the reaction between the titanium powders and the aluminum matrix led to the formation of Al3Ti aluminide at the interface between the two elements. This aluminide formation was in the form of a spherical shell around the aluminum, wherein the later stage of processing fragmented into smaller particles and distributed throughout the matrix. Results showed that tensile strength and the hardness of the base metal were increased by about 30% after applying 6 passes FSP.