Abstract:The effects of Mn addition (1 wt.%, 2 wt.% and 4 wt.%) and friction stir processing (FSP) on the microstructure and mechanical properties of Al-4Ni alloy were studied. The results showed that Mn promoted the formation of Al₆Mn and Al₆₀Mn₁₁Ni₄ intermetallics. These Mn-rich compounds increased the strength and hardness, but decreased the ductility and fracture toughness of the alloy. To improve the ductility and toughness, the as-cast alloys were then subjected to FSP (rotation speed of 1600 r/min and traverse speed of 12 mm/min). According to the results, FSP greatly improved the mechanical properties. The tensile strength, yield strength, fracture strain, microhardness, and fracture toughness of FSPed Al-4Ni-2Mn increased by 67%, 30%, 230%, 20%, and 1185%, respectively. The fine redistribution of Mn-rich compounds, formation of ultrafine grains, microstructural densification, and the elimination of casting defects such as micropores and oxide bifilms were found to be the most important factors responsible for improving the mechanical properties. The fractographic investigations also revealed that the fracture of as-cast Mn-rich alloys changed from the brittle mode containing micro-facets to a more ductile fracture mode containing fine and equiaxed dimples in FSPed alloys.

Key words: friction stir processing; Al-Ni alloy; manganese; intermetallics; mechanical properties