Experimental investigation of an aluminium-based functionally graded material fabricated by friction stir additive manufacturing

Abstract Advanced engineering materials that provide better mechanical performance via small changes in composition and microstructure are called Functionally Graded Materials (FGMs These materials are dominant in the aerospace and automotive industries when property gradients are a crucial factor. This research paper explores Aluminium-based functional graded materials (AFGMs) fabricated utilizing the friction stir additive manufacturing (FSAM). It is designed to determine the influence of tool rotational speed (TRS) on the mechanical properties and the microstructure formation. Layers of increasingly strong alloys AA1100, AA5083, AA6061, AA2024, and AA7075 were produced to form a five-layer AFGM system. The TRS range of 400 to 800 RPM was used for processing. The finest mechanical parameters, including a microhardness of 139 HV, a tensile strength of 310 MPa, a yield strength of 252 MPa, and an elongation of 18%, were obtained by using field emission scanning electron microscopy, which showed that 600 RPM created the finest grain structure. Grain coarsening and reduced mechanical performance were seen at both low and high rotating speeds. To fabricate AFGMs for industrial use using FSAM, these results provide realistic recommendations for parameter selection.