ABSTRACT Zirconia (ZrO2) dispersed aluminum alloy metal matrix composites produced by stir casting techniques. Using stir casting techniques, aluminium based composites with varying amounts of 3%, 6%, 9%, and 12% of zirconia by weight are fabricated. The prepared samples were subjected to physical, mechanical,tribiology and microstructure investigation. The extraordinary performance of Aluminium MMCs was the low density that obtained after alloying. Hardness and ductility were also increased when increase in Zirconia particle. Ultimate tensile strength, compressive strength and impact toughness were slightly increasing with the addition of zirconia particle. Microstructural characteristics shows that a homogeneous distribution of particles with reinforcement in casted composite. The investigations of the metallurgical characterization were carried using optical, scanning electron microscope, X-ray diffraction and Energy Dispersive Spectrometry (EDS) test to understand the metallurgical properties.

ABSTRACT In this paper aluminum (LM25) alloy was chosen as a base matrix metal, and it was reinforced with 0, 3, 6, 9, 12% of Zirconium dioxide (ZrO2) particulates based on weight fraction method. Stir casting method was used to cast LM25/ZrO2 composite material. The cast samples were subjected to physical and mechanical test viz, density, hardness, tensile, compression and impact test. The feasibility trial weld was carried out on the developed composite (similar metals) using Friction welding process (FSW) and then welded sample were prepared for the various test. The welded samples were subjected to various mechanical tests such as tensile, hardness and bend test to evaluate the strength of the friction welded joints. Then welded samples were also subjected to optical microscopy analysis to evaluate microstructures of the base and the weld regions. The tensile, hardness, compression and impact strength increases with increase in the percentage of ZrO2 in LM25 alloy. The tensile, hardness and bending strength were high in the welded zone. The microstructures of the welded tensile tested specimen were analyzed using the Scanning Electron Microscopy (SEM) in a different region of the welded area. From the above results shows weldability of LM25/ZrO2 composites was improved with the increase in weight percentage of ZrO2 reinforcement.