Production of AlSi12CuNiMg/Al2O3 Micro/Nanodispersed Surface Composites Using Friction Stir Processing for Automotive Applications

  • L. Tonelli
  • M. RefatEmail author
  • S. Toschi
  • M. M. Z. Ahmed
  • Essam Ahmed
  • A. Morri
  • I. El-Mahallawi
  • L. Ceschini
Conference paper
Part of the The Minerals, Metals & Materials Series book series (MMMS)


The service life of automotive components often depends on their surface properties. Consequently, improved surface properties with the retainment of bulk characteristics are necessary for such components to guarantee enhanced mechanical and tribological properties. In this research, friction stir processing (FSP) is used to produce surface composites characterized by extruded AlSi12CuNiMg matrix and micro and nano-sized Al2O3 particles as reinforcing phase. Multiple passes of FSP using two different strategies were applied to distribute the Al2O3 particles. The effect of the different FSP parameters and sequence of rotation direction for the applied passes was investigated. The processed surface layers were analyzed through optical and scanning electron microscopy, hardness, and wear testing. The properties of the processed composite surface showed to be affected by both the size of reinforcing particles and the processing direction sequence. A comparison between properties of the produced surface composites and the base metal was also carried out. Bench-type test developed to measure the weight loss of samples under sand erosion conditions.


Friction Stir Processing (FSP) Surface Metal Matrix Composite (SMMC) Microstructure Hardness Tribological properties AlSi12CuNiMg 



The Italian Ministry of Foreign Affairs and International Cooperation (MAECI), and The Egyptian Science and Technology Development Fund (STDF) are deeply acknowledged for funding this work under the Executive Programme of Scientific and Technological Cooperation Between Arab Republic of Egypt and Italian Republic.


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Copyright information

© The Minerals, Metals & Materials Society 2019

Authors and Affiliations

  • L. Tonelli
    • 1
  • M. Refat
    • 2
    Email author
  • S. Toschi
    • 1
  • M. M. Z. Ahmed
    • 3
    • 4
  • Essam Ahmed
    • 4
  • A. Morri
    • 1
  • I. El-Mahallawi
    • 5
  • L. Ceschini
    • 6
  1. 1.Department of Industrial EngineeringUniversity of BolognaBolognaItaly
  2. 2.Centre for Simulation Innovation and Advanced ManufacturingThe British University in EgyptEl-ShoroukEgypt
  3. 3.Mechanical Engineering DepartmentThe British University in EgyptEl-ShoroukEgypt
  4. 4.Metallurgical and Materials Engineering DepartmentSuez UniversitySuezEgypt
  5. 5.Metallurgy and Materials Engineering DepartmentCairo UniversityGizaEgypt
  6. 6.Department of Civil, Chemical, Environmental and Materials EngineeringUniversity of BolognaBolognaItaly

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