View in EDS

Ultrafine-Grained Al/Al2Cu Composite Formation via Friction Stir Processing of Cold-Sprayed Coatings.

Saved in:
Bibliographic Details
Title: Ultrafine-Grained Al/Al2Cu Composite Formation via Friction Stir Processing of Cold-Sprayed Coatings.
Authors: Rizvi, Syed Muhammad Mujtaba1 (AUTHOR), Uddin, Md Jasim2 (AUTHOR), McRobie, Chris1 (AUTHOR), Hartmann, Josephine1 (AUTHOR), Malakar, Aniruddha2 (AUTHOR), Yano, Kayla3 (AUTHOR), Barton, Dallin3 (AUTHOR), Tsai, Fu-Yun2 (AUTHOR), Laggner, Florian1 (AUTHOR), Gwalani, Bharat2 (AUTHOR) bgwalan@ncsu.edu, Kautz, Elizabeth1,3 (AUTHOR) ekautz@ncsu.edu
Source: JOM: The Journal of The Minerals, Metals & Materials Society (TMS). Jun2026, Vol. 78 Issue 6, p5357-5368. 12p.
Subjects: Aluminum alloys, Solid-state phase transformations, Microstructure, Material plasticity, Surface coatings, Nanocomposite materials, Mechanical behavior of materials
Abstract: We demonstrate a shear-deformation-driven, solid-state phase transformation pathway for the formation of an ultrafine-grained Al/Al 2 Cu composite via friction stir processing of a Cu cold-sprayed coating on an AA6061 aluminum substrate. This approach leverages the severe plastic deformation and high strain-rate environment inherent to friction stir processing to drive localized interdiffusion and solid-state reactions between the Cu coating and the Al alloy substrate. The processed surface exhibits a significant increase in hardness (≈ 250 HV), compared to both the AA6061 substrate (≈ 100 HV) and the as-deposited Cu coating (≈ 132 HV); these measured hardness values represent an increase of 1.8-times and 2.4-times relative to the Cu CS coating and AA6061 substrate, respectively. This hardness enhancement is attributed to the uniform distribution of fine-grained Al 2 Cu reinforcement within an Al(Cu) matrix, as confirmed by transmission electron microscopy and atom probe tomography. Unlike conventional precipitation hardening, here, discrete Al 2 Cu grains are directly formed and dispersed among Al grains, resulting in a hetero-grained microstructure that transitions into a single-phase matrix below the processed zone. Our results demonstrate the potential of integrating solid-state deposition with high-speed mechanical mixing to generate unique, non-equilibrium microstructures that bypass equilibrium melting constraints and exceed the performance of conventional thermomechanical processing routes. [ABSTRACT FROM AUTHOR]
Copyright of JOM: The Journal of The Minerals, Metals & Materials Society (TMS) is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
Database: Engineering Source
Description
Abstract:We demonstrate a shear-deformation-driven, solid-state phase transformation pathway for the formation of an ultrafine-grained Al/Al 2 Cu composite via friction stir processing of a Cu cold-sprayed coating on an AA6061 aluminum substrate. This approach leverages the severe plastic deformation and high strain-rate environment inherent to friction stir processing to drive localized interdiffusion and solid-state reactions between the Cu coating and the Al alloy substrate. The processed surface exhibits a significant increase in hardness (≈ 250 HV), compared to both the AA6061 substrate (≈ 100 HV) and the as-deposited Cu coating (≈ 132 HV); these measured hardness values represent an increase of 1.8-times and 2.4-times relative to the Cu CS coating and AA6061 substrate, respectively. This hardness enhancement is attributed to the uniform distribution of fine-grained Al 2 Cu reinforcement within an Al(Cu) matrix, as confirmed by transmission electron microscopy and atom probe tomography. Unlike conventional precipitation hardening, here, discrete Al 2 Cu grains are directly formed and dispersed among Al grains, resulting in a hetero-grained microstructure that transitions into a single-phase matrix below the processed zone. Our results demonstrate the potential of integrating solid-state deposition with high-speed mechanical mixing to generate unique, non-equilibrium microstructures that bypass equilibrium melting constraints and exceed the performance of conventional thermomechanical processing routes. [ABSTRACT FROM AUTHOR]
ISSN:10474838
DOI:10.1007/s11837-025-07741-0