Abstract
Dual phase brass was reinforced with industrial residue fly ash particles (0–18 vol%) to produce surface composites through friction stir processing (FSP). Micrographs revealed uniformly dispersed fly ash particles. The interface made a strong bond with the brass matrix because of the absence of pores or any undesirable compounds. Fracture of fly ash particles during processing was not evident. FSP and fly ash particles led to the formation of fine grained structure. There was no evaporation of Zn and the dual phase was retained. TEM micrographs showed evidence for interrupted dynamic recrystallization. Fly ash particles helped to slow down the material removal during sliding wear. The composite specimen produced smaller debris and wore in abrasive manner.
•The large density difference did not play a role to disturb the distribution.•The uniform distribution was repeatable over the entire stir zone.•The size distribution of fly ash particles remained same before and after processing.•There was no loss of Zn element during processing and the dual phase was retained.•Incorporation of fly ash particles reduced the coefficient of friction remarkably.