A novel real-time auger-driven reinforcement feeding system for fabricating surface metal matrix composites via friction stir processing

The fabrication of metal matrix composites using friction stir processing utilizes solid-state techniques with a dedicated stirring mechanism, significantly reducing the challenges associated with the melting of the material. Utilizing multi-pass FSP can also enhance the particle distribution. However, this process faces certain challenges, like the pre-processing stage, including preparing grooves or blind holes, introducing reinforcement, and sealing the grooves, is very time-consuming and laborious process. Moreover, the repetitive processing over the same zone in the multi-pass FSP further increases the total fabrication time. To overcome these challenges, an in-situ reinforcement deposition friction stir processing (IRDFSP) system has been proposed in which a dedicated powder feeding system along with the FSP tool is utilized that can operate in real time during the processing itself. This approach significantly reduces processing time and associated costs by eliminating the need for pre-processing stages and multi-pass FSP, while still achieving enhanced particle distribution. The fabricated AA6063/SiC composite using the IRDFSP system was compared with the conventional FSP and counter-rotating twin-tool FSP. The results showed around a 62.5 % increase in processing efficiency with homogeneous particle distribution, a 36.78 % improvement in microhardness with consistency, and around 26.07 % improvement in wear properties. • An in-situ reinforcement deposition friction stir processing (IRDFSP) system for surface composites fabrication. • The IRDFSP system incorporates a real-time auger-driven particle feeding mechanism. • Eliminates the need of grooves or blind holes machining before processing. • Achieves significant reduction in manufacturing time along with uniform particle distribution. • Improved microhardness and wear properties are obtained.