International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056 Volume: 04 Issue: 04 | Apr -2017 www.irjet.net p-ISSN: 2395-0072 © 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 3608 INVESTIGATION ON THE PROPERTIES OF Al6063/Al2O3 SURFACE COMPOSITE FABRICATED BY FRICTION STIR PROCESSING M. Appas Muthu 1 , V. Sritharan 2 ,R. Surendran 3 Aby Kurian 4 14 PG Scholar, Government college of Technology, Coimbatore 2 Professor of Production Engineering, Government College of Technology, Coimbatore 3 Assistant Professor Mechanical Engineering, Government College of Technology, Coimbatore ---------------------------------------------------------------------***--------------------------------------------------------------------- Abstract - Friction stir processing (FSP), a solid state technique based on the principle of friction stir welding, is used for material processing in order to modify the microstructures and mechanical properties of surface composites. In this investigation, the influence of tool rotational speed, traverse speed and volume percentage (10%, 17% and 22%) of Al2O3 reinforcement particles on wear characterization and hardness of aluminium alloy (Al 6063) based surface composites fabricated via Friction stir processing (FSP) was studied. For various combinations of rotational speed and traverse speed, the average hardness on top surface of processed samples was evaluated. It was found that maximum hardness has been obtained at rotational speed of 1400 rpm and traverse speed of 80 mm/min. The wear rate decreases with increase in the volume fraction of Al2O3 particles. Key Words: Friction Stir Processing, Surface composite, Hardness, Microstructure, Wear Resistance 1.INTRODUCTION Friction stir processing (FSP), a solid state technique based on the principle of friction stir welding, is used for material processing in order to modify the microstructures and mechanical properties of surface composites and to fabricate the surface composites. Firstly the tool without pin is used and traverses along the groove consisting of reinforcement particles thus forging it. Later the tool with pin is used and moves along the desired line to cover the region underneath the shoulder. Friction between the tool and work piece results in localized heating that softens and plasticizes the work piece. During this process, the material undergoes plastic deformation, thus resulting in grain refinement to improve its mechanical properties. Fig-1 Principle of Friction Stir Processing 1.1 ALUMINIUM ALLOY MATERIALS Aluminium is not just a single material, but a family of a variety of alloys grouped according to the alloy elements added and that provide the best combination of properties for a particular application. Alloy requirements may include strength, corrosion resistance enhancement and ductility, ease of welding, formability or combinations of some of these properties. Aluminium 6 series contains additions of silicon and manganese up to 1.7% and 1.2% respectively. Used extensively for extruded sections of all shapes and sizes. Common alloys are 6063, 6082 and 6061. Al6063 is an aluminium alloy, with magnesium and silicon as the alloying elements. The standard controlling its composition is maintained by the association. It’s generally good mechanical properties and is heat treatable and weldable. 6063 is the most common used alloy used for aluminium extrusion. It allows complex shapes to form with very smooth surfaces fit for anoidizing and so is popular for