Process–structure–property relationships in AA5083/CeO2/B4C nanocomposites fabricated by modified friction stir deposition – additive manufacturing

Purpose This study aims to print additive products using a modified friction stir deposition – additive manufacturing (MFSD-AM) technique. Design/methodology/approach MFSD-AM uses a consumable rod instead of the conventional non-consumable hollow tool. Nano-sized boron carbide and cerium oxide reinforcements were mixed with a 50/50 volume ratio and were inserted into the Al–Mg rods to fabricate hybrid aluminum matrix composites (AMCs). One reference product was also printed to survey the outcomes of inserting reinforcements. The effects of MFSD-AM parameters on microstructure, hardness, corrosion and wear were examined in this survey. Findings Energy dispersive X-ray spectroscopy indicated that no agglomerates were established inside AMCs. Optical microscopy revealed that up to 91.8% grain refinement was observed for AMCs compared to the rod. Pin-on-disc test demonstrated up to a 25% drop in specific wear rate compared to the rod. Scanning electron microscopy of worn-out surfaces exhibited severe adhesive wear for the rod and abrasive wear with delamination sites for AMCs. AMCs displayed up to 30.4% growth in hardness compared to the rod. Tafel curves revealed that the corrosion resistance of AMCs increased compared to the rod. AMCs also displayed up to 423 mV passivation range. Originality/value MFSD-AM represents a key breakthrough in additive manufacturing, offering new possibilities for the fabrication of hybrid composites.