Fabrication of Billet from Aluminum Alloys AA 2011-T3/7075 Chips through Friction Stir Consolidation

Recently evolving Solid-State Recycling (SSR) techniques have shown promising features to recycle metals scraps more efficiently compared to remelting-based approaches. Among these SSR methods, Friction Stir Consolidation (FSC) has been successfully tested to transform metals chips directly into semi or final solid products. Therefore, researchers explored FSC critical process parameters and their subsequent effects on quality in terms of the mechanical and metallurgical properties of the billet. All the previous studies of FSC were limited to developing billet of mono materials. Therefore, in this research, an attempt was made to go beyond the idea of recycling; in fact, a billet of two dissimilar aluminum alloys AA 7075 and AA 2011-T3 out of chips was obtained. The mechanical and metallurgical properties were assessed through the Vickers hardness measurements and microstructure analysis. The experimental results of this research illustrate that the FSC process is a feasible approach to develop a billet of dissimilar materials with achieving quality closer to the corresponding billet of mono-material.