FSP for B4C Surface Composite on Copper Plate - Research Report

This report investigates the feasibility of fabricating a Boron Carbide (B4C) particulate-reinforced copper surface matrix composite using friction stir processing (FSP). The study aims to improve the mechanical properties of copper plates by integrating micron-sized B4C particles with varying volume percentages. The research explores the impact of process parameters such as B4C composite volume percentage, tool rotation speed, and traverse speed on the microstructure and mechanical properties of the resulting Cu-B4C surface composite. The report references existing literature, proposes a methodology for further research using secondary data, and discusses the potential for achieving a defect-free interface between the composite layer and the copper matrix. Taguchi method is proposed for optimization. The study highlights the potential of FSP in composite manufacturing and suggests further investigation into process characteristics and parameters for successful technology implementation. Desklib provides a platform for students to access this assignment and other valuable study resources.

Running head: FABRICATION OF B4C SURFACE COMPOSITE ON A COPPER PLATE USING FRICTION STIR PROCESSING
FABRICATION OF B4CSURFACE COMPOSITE ON A COPPER PLATE USING FRICTION STIR PROCESSING
Karthik Reddy Bommareddy
Student ID: 19223849
Written Report - 2

1FABRICATION OF B4C SURFACE COMPOSITE ON A COPPER PLATE USING FRICTION STIR PROCESSING
Abstract
Composites manufacturing could be defined as one of the techniques based on advance level of
manufacturing based within the history of materials. The method of friction stir processing could
be defined as an innovative method for the fabrication of the composites of surface metal matrix.
This paper is able to discuss about the feasibility of making B4C particulate reinforced copper
surface matrix. This paper discusses about the detection free form of interface between the
composite layer and matrix that could be achieved. This paper proposes better methods for the
improvement of the different processes.

2FABRICATION OF B4C SURFACE COMPOSITE ON A COPPER PLATE USING FRICTION STIR PROCESSING
Table of Contents
1. Introduction..................................................................................................................................3
1.1 Background............................................................................................................................3
2. Problem Statement.......................................................................................................................3
3. Research Aims and Objectives....................................................................................................3
4. Research Question.......................................................................................................................4
5. Literature Review........................................................................................................................4
5.1 Discussion from Results........................................................................................................5
6. Methodology................................................................................................................................6
6.1 Proposed Timeline.................................................................................................................7
7. Conclusion...................................................................................................................................8
8. References....................................................................................................................................9

3FABRICATION OF B4C SURFACE COMPOSITE ON A COPPER PLATE USING FRICTION STIR PROCESSING
1. Introduction
1.1 Background
The use of the technique of Friction Stir Processing (FSP) could be defined as an efficient
technique that would be used for the fabrication of surface metal matrix composite (SMMC)
(Azarsa & Mostafapour, 2013). The FSP was primarily designed based on the principles of
friction stir welding (FSW). One of the primary methods of producing SMMC with the help of
FSP would be based on the making of a groove based on required depth. These would be
compacted with ceramic particles, plunging of the tool and traversing them along the groove
(Bahrami, Dehghani & Givi, 2014). The heat produced by friction of the grooves would thus
soften the matrix alloy and the ceramic particles. These would be distributed all over the
plasticized matrix alloy based on the stirring of the tool. Hence the technique followed by FSP
could be effectively used for the performing of different kinds of investigations. These kinds of
investigators would be required for fabricating SMMC based on magnesium, aluminium,
titanium alloys and steel (Sun et al., 2013).
2. Problem Statement
The statement of the problem is based on the following areas of research based on
friction stir processing. One of the statement of the problem would be based on the regulation of
liquid metallurgy as it would be in a process of solid-state.
3. Research Aims and Objectives
Based on the kind of research that would be proceeded in the field of friction stir
processing, the primary aim of the research would be based on the study of the influences based
on volume percentages, rotation of tool and speeds of welds.

4FABRICATION OF B4C SURFACE COMPOSITE ON A COPPER PLATE USING FRICTION STIR PROCESSING
The primary objectives of the research would be as follows:
 The identification of reinforcements and process parameters that have effect on the
mechanical properties on the composites of copper surface based on the use of FSP
 The different kinds of impact based on process parameters that would include speed of
the rotation tool, volume percentage and traverse speed that would play a major role.
4. Research Question
How would the study and evaluation of microstructures based on the co-relation of
mechanical properties of the composites of copper surface would be beneficial for the research?
5. Literature Review
The Copper based ceramic particulate reinforced metal matrix composites (CMMCs) are
one of the primary topic of attention. This has been mainly been possible due to the good form of
thermal, mechanical and tribological properties (Sathiskumar et al., 2013). The use of CMMCs
could be applied in the places where good form of wear resistance without the loss of electrical
and thermal conductivity of the particular matrix would be needed. The life of the different
components would mainly depend on the properties of surface of the various kinds of
applications (Sathiskumar et al., 2014). Hence, it would be appropriate for the modification of
the component surface based on reinforcing of the ceramic particles. The modified form of
surface dispersion has the capability of strengthening the composite layer. They are thus known
as surface metal matrix composite (SMMC). The FSP is one of the technique that could be used
for the fabrication of SMMC. This technique would be able to perform several forms of
investigation based on different alloys of aluminium, steel, titanium and magnesium
(Thankachan, Prakash & Kavimani, 2018).

5FABRICATION OF B4C SURFACE COMPOSITE ON A COPPER PLATE USING FRICTION STIR PROCESSING
Barmouz et al. (2011) have applied the techniques of FSP based on the fabrication of
Cu/SiC SMMC in the present times. They have studies different forms of aspects based on the
processes of FSP on the formation of Cu/SiC SMMC. It could thus be reported that the speed of
processing would thus be significantly increased due to the distribution of SiC particles. Based
on the techniques applied by Barmouz et al (2011), they have prepared the composite of Cu/SiC
surface. They had observed some kinds of factors based on the FSP technique based within the
production of the Cu/SiC composite. Based on the discussion, it could be concluded that the
rotation of tools and speeds of traversing would be able to play a major role based within the
dispersion of SiC particles (Besharati-Givi & Asadi, 2014). The port form of dispersion of the
SiC particles would mainly take place based on the increasing speed of processing. The rate of
dispersion of the SiC particles would be further increased based on the time of processing and
motion of hard stirring within the heat affected zone.
5.1 Discussion from Results
The fabrication of Cu/8vol.% B4C surface dispersion could be able to strengthen the
composites and hence would be successfully strengthen the accomplishment with the use of FSP.
The composite layer would be bonded to the substrate of copper. There would not be any form of
macroscopic defects that includes pinhole, worm hole, tunnel and many others based on the
combination of different forms of chosen parameters. During the techniques of FSP, the heat
generated by friction would be able to plasticize the copper and the particles of B4C would be
distributed and thus embedded within the Cu matrix (Jeon et al., 2014). This could be achieved
due to the stirring action based on the performance of the rotating tool.
The FSP could be defined as an extreme successful process based on the production of
Metal Matrix Composites. The selection of the parameters of FSP is a major form of challenge in

6FABRICATION OF B4C SURFACE COMPOSITE ON A COPPER PLATE USING FRICTION STIR PROCESSING
the recent times. These forms of challenges could be based on the production of sound composite
zone. This would be based on the uniform form of distribution of the reinforced particles within
the matrix. The different forms of fine particles that would be used for the purpose of
reinforcement would be able to improve the structure of the grain (Gibson et al., 2014). The
processes of FSP also have the capability of improving the inclusive properties of the material
within the increased young’s modulus, tensile strength and microhardness. The large form of
plastic strain that would be produced with the aid of FSP have the capability of shearing the
metal powders and thus be able to break the oxide film that would surround the reinforcement
particles. They would be able to cause contact between the reinforcement particles and matrix
that would be able to promote the reaction. The tendency of the agglomeration of the particles
could be reduced based on the proper form of selection of the diameter of the FSP tool shoulder.
This would thus be responsible for generating of the shear forces and frictional forces (Devaraju,
Kumar & Kotiveerachari, 2013).
Pre-treatment of the different kinds of reinforcements based on the improvement of the
wettability along with multi pass FSP would be able to provide a different form of alternative
way based on the uniform form of distribution of the various kinds of reinforcement particles in
the zone of FSP (Aruri et al., 2013).
6. Methodology
The research would be conducted based on the works of different other authors who have
performed an extensive research on the area of the concerned topic. The research would be
further proceeded based on the use of secondary data such as the collection of articles from
different sources such as various journals, books, publication of other authors, books and many

7FABRICATION OF B4C SURFACE COMPOSITE ON A COPPER PLATE USING FRICTION STIR PROCESSING
other kinds of sources. With the help of this form of research, the following research proposal
would further be proceeded in the particular direction.
6.1 Proposed Timeline
Activities
wk 1 wk2 wk3 wk4 wk 5 w k6 wk 7 wk 8 wk 9 wk 10 wk 11 wk 12 wk 13
Selection of the Topic of
Study
Preparation of Proposal
Layout
Design of the research
proposal
Literature Review
Developing of the proper
methodology for research
Collection of the Secondary
Data
Analysis of the Data
Collection of findings from
the analysis
Drawing conclusions from
the study
Preparation of rough draft
for the study
Review and final submission
of the work
Duration
(Fig 1: Description of the Proposed Project)
Task ID Task Description resource
Name Cost
1 Topic Selection Superviser $ 8.00
2 Gather information from secondary sources Researcher $ 7.00
3 Finalize the layout Researcher $ 10.00
4 Review Literature Researcher $ 12.00
5 Develop Plan for Research Researcher $ 13.00
6 Select the correct technique Researcher $ 6.00
7 Collect secondary data Researcher $ 7.00
8 Data analysis and Interpretation Researcher $ 9.00
9 Draw Conclusion Researcher $ 5.00
10 Prepare Rough Draft Researcher $ 9.00
11 Completion of Final Work Researcher $ 15.00
Total cost $ 101.00
(Fig 2: Proposed Budget of the Concerned Project)

8FABRICATION OF B4C SURFACE COMPOSITE ON A COPPER PLATE USING FRICTION STIR PROCESSING
Topic Selection
Gather information from secondary sources
Finalize the layout
Review Literature
Develop Plan for Research
Select the correct technique
Collect secondary data
Data analysis and Interpretation
Draw Conclusion
Prepare Rough Draft
Completion of Final Work
Total cost
1 2 3 4 5 6 7 8 9 10 11
0 20 40 60 80 100 120
Chart Title
resource Name Cost
(Fig 3: Proposed Project Timeline)
7. Conclusion
Based on the discussion from the above topic, the different prospects based on the
fabrication of the B4C surface composition based on a copper plate with the help of friction could
be understood. The proper form of application based on the technique of FSP within the
generating surface and bulk composites could be able to firmly establish within the field of
Composite manufacturing. Further form of research within the particular area and better form of
understanding of the characteristics of the process and parameters would be able to provide
general insights on the ways of the success of the technology of FSP.

9FABRICATION OF B4C SURFACE COMPOSITE ON A COPPER PLATE USING FRICTION STIR PROCESSING
8. References
Aruri, D., Adepu, K., Adepu, K., & Bazavada, K. (2013). Wear and mechanical properties of
6061-T6 aluminum alloy surface hybrid composites [(SiC+ Gr) and (SiC+ Al2O3)]
fabricated by friction stir processing. Journal of Materials research and technology, 2(4),
362-369.
Azarsa, E., & Mostafapour, A. (2013). On the feasibility of producing polymer–metal
composites via novel variant of friction stir processing. Journal of Manufacturing
Processes, 15(4), 682-688.
Bahrami, M., Dehghani, K., & Givi, M. K. B. (2014). A novel approach to develop aluminum
matrix nano-composite employing friction stir welding technique. Materials &
Design, 53, 217-225.
Barmouz, M., Asadi, P., Givi, M. B., & Taherishargh, M. (2011). Investigation of mechanical
properties of Cu/SiC composite fabricated by FSP: Effect of SiC particles’ size and
volume fraction. Materials Science and Engineering: A, 528(3), 1740-1749.
Besharati-Givi, M. K., & Asadi, P. (2014). Advances in friction-stir welding and processing.
Elsevier.
Devaraju, A., Kumar, A., & Kotiveerachari, B. (2013). Influence of addition of Grp/Al2O3p with
SiCp on wear properties of aluminum alloy 6061-T6 hybrid composites via friction stir
processing. Transactions of Nonferrous Metals Society of China, 23(5), 1275-1280.

10FABRICATION OF B4C SURFACE COMPOSITE ON A COPPER PLATE USING FRICTION STIR PROCESSING
Gibson, B. T., Lammlein, D. H., Prater, T. J., Longhurst, W. R., Cox, C. D., Ballun, M. C., ... &
Strauss, A. M. (2014). Friction stir welding: process, automation, and control. Journal of
Manufacturing Processes, 16(1), 56-73.
Jeon, C. H., Jeong, Y. H., Seo, J. J., Tien, H. N., Hong, S. T., Yum, Y. J., ... & Lee, K. J. (2014).
Material properties of graphene/aluminum metal matrix composites fabricated by friction
stir processing. International journal of precision engineering and manufacturing, 15(6),
1235-1239.
Sathiskumar, R., Murugan, N., Dinaharan, I., & Vijay, S. J. (2013). Characterization of boron
carbide particulate reinforced in situ copper surface composites synthesized using friction
stir processing. Materials characterization, 84, 16-27.
Sathiskumar, R., Murugan, N., Dinaharan, I., & Vijay, S. J. (2014). Fabrication and
characterization of Cu/B4C surface dispersion strengthened composite using friction stir
processing. Archives of metallurgy and materials, 59(1), 83-87.
Sun, Y. F., Fujii, H., Takaki, N., & Okitsu, Y. (2013). Microstructure and mechanical properties
of dissimilar Al alloy/steel joints prepared by a flat spot friction stir welding
technique. Materials & Design, 47, 350-357.
Thankachan, T., Prakash, K. S., & Kavimani, V. (2018). Investigations on the effect of friction
stir processing on Cu-BN surface composites. Materials and Manufacturing
Processes, 33(3), 299-307.