Impact of FSP Tool Probe Shape on Reinforcing Particles Dispersion in the Piston Alloy Using CEL Approach

In this study, the distribution of boron carbide in the stir zone of the FSPed specimens was examined experimentally and numerically about probe shape, including circular, square, and hexagonal shapes. First, composites were created using different tools. Then, using an optical microscope, the microstructural properties of the samples, such as the size and shape of the silicon particles, were examined. To simulate the procedure and further explore particle distribution, the coupled Eulerian-Lagrangian (CEL) method is employed. The tool was also modeled using a Lagrangian formulation while the material was characterized using an Eulerian formulation. The model predicted the changes in strain and temperature in composites created with different probe shapes. The outcome demonstrated that the circular probe was not suitable for the production of composites because it could not disperse particles in the parent alloy. Tools with flat surfaces, such as square and hexagonal tools, have more evenly distributed metal particles. Square probes can be employed in the FSP process to create composites and offer the best performance in terms of reinforcing particle distribution in the metal matrix. Due to the greater distribution of reinforcing particles, the sample made with a square tool had the highest hardness. Using a tool with a square pin improves the average hardness by 8 and 21%, respectively, compared to hexagonal and circular tools.