Abstract
Hybrid Al-based surface nanocomposites were manufactured and investigated for industrial applications. The friction stir process (FSP) was successfully utilized to combine and incorporate AA6061 wrought sheets with different reinforcement nanoparticles: silicon carbide (SiC), solid lubricant graphene nanoplates (GNPs), and aluminum oxide (Al2O3). Tribological tests were utilized to assess the friction coefficient and wear resistance of the fabricated nanocomposites. The results showed that the AA6061/SiC_GNPs hybrid nanocomposite exhibited ultra-refined grains inside the processed zone with excellent wear resistance behavior. Hence, during the FSP, there was a 36-fold decrease in grain size. Furthermore, the wear rates by volume and mass losses were reduced by 46% and 90%, respectively, due to the self-lubrication properties of the GNPs combined with the SiC particles. Moreover, the friction coefficient of the hybrid AA6061/SiC_GNPs decreased by 30%. The SiC nanoparticles eliminate the negative effect of the GNPs on the hardness. Thus, achieving a balance between improving wear resistance rates and the surface hardness of the manufactured nanocomposites is one of the essential objectives of the study.