Abstract
Friction stir alloying (FSA) of commercially pure Cu with Ni, Zn, and Mg is implemented in the current study. Mechanical and microstructural aspects of the successfully fabricated alloy structure have been examined. Energy dispersive X-ray spectroscopy revealed a uniform distribution of alloying elements and coalescence at the atomic level. The compositional and grain size heterogeneity is managed in the stir zone, allowing for microstructural control with FSA. Thus, the present study is essential for the development of novel materials whose fabrication requires temperature well below the melting point of base metals. The alloying process is found to be accompanied by ultra-refined grains, with the smallest grain size being similar to 0.44 mu m. The fabricated alloy managed to retain the FCC phase, and no brittle intermetallic compounds formed, according to X-ray diffraction. The fabricated alloy exhibits maximum and average microhardness enhancements of 18.4% and 6%, respectively. Tensile properties have also been investigated and correlated with microstructural morphology. A shift toward grain bimodality has also been documented, which is a highly sought-after property nowadays, especially to overcome the strength-ductility trade-off.