Advancements in Surface Reinforcement of AA2024 Alloy Using Hybridized Niobium Carbide and Ceramics Particles via FSP Technique

Niobium carbide (NbC) is a ceramic material that enhances the mechanical properties of advanced composites by restricting grain growth during recrystallization. This study aimed to improve the properties of aluminum-AA2024 hybrid composites by hybridizing NbC with three nanoceramic reinforcement particles (Al 2 O 3 , BN, and SiC). Friction stir processing (FSP) was used to fabricate the hybrid composites. This technique produces a hybrid composite with a better homogeneous distribution than other methods. The mechanical properties and microstructure of the hybrid composites were studied. The results showed that the static modulus of elasticity and compressive stress improved by ~ 23.6% and ~ 24% more for the AA2024/NbC + SiC hybrid composite than the base alloy. The microhardness of the fabricated hybrid surface composites is improved by an average of 41.5% more than the base alloy. The relationship between strain hardening and grain size showed that a grain size reduction reduced strain hardening and increased yield strength. The bulk density of AA2024/NbC + Al 2 O 3 has the highest value of (3.04 g/cm 3 ), while AA2024/NbC + SiC and AA2024/NbC + BN have 2.97 g/cm 3 and 2.88 g/cm 3 , respectively. Furthermore, the electrical conductivity of the AA2024/NbC + SiC has the highest value among hybrid composites; however, it was still less than the AA2024 base alloy by 13.8%. The results showed that the hybrid composites fabricated by FSP have improved mechanical properties and microstructure compared to the base alloy; hence, the AA2024/NbC + SiC hybrid composite has the best overall properties. Graphical Abstract