An investigation has been carried out of the effects of tool probe shape and size on the formation of surface composite by uniformly distributing SiC particles into a surface layer of an A1050-H24 aluminium plate through friction stir processing (FSP). Tool probes of three different diameters (3, 5 and 7 mm) and four different shapes (circular with threads, circular without threads, square and triangular) have been used to fabricate the surface layers at rotation speeds of 1500–2250 rev min⁻¹ and a travelling speed of 1·66 mm s⁻¹. The SiC particles were packed into a groove of 3 mm width and 1·5 mm depth cut on the aluminium plate and covered by an aluminium sheet of 2 mm thickness. A rotating tool was plunged into the plate through the cover sheet so that the tip of the probe reached beyond the bottom of the groove. As a result, it was found that the square probe dispersed the SiC particles homogeneously in the nugget zone compared with other probe shapes regardless of the rotation speeds. Furthermore, the distributed particles and also the aluminium matrix grain size became finer by the use of square probe than those of the other shapes. On the other hand, the wear rates of the square and triangular probes were higher than that of circular shape. The worn iron debris from the tool reacted with aluminium matrix and form fine iron aluminides compound dispersed in the nugget zone. The probe size had limited effects on the homogeneity of the SiC particles distribution in the nugget zone; the distribution of SiC particles obtained by triple FSP passes was less homogeneous when the probe size was smaller. Microhardness of the nugget zone was homogeneously increased to a level as high as 60 HV with tool of square probe shape after three passes to be compared with 23 HV of the aluminium matrix beside the nugget zone.

A feasibility investigation has been carried out of the formation of surface composite by uniformly distributing SiC particles 1˙25 µm in size into a surface layer of an A 1050-H24 Al plate through friction stir processing (FSP). The SiC particle was filled into a groove cut on the Al plate, covered by an Al sheet 2 mm thick, and a rotating tool was penetrated from the cover sheet so that the probe tip reached a depth beyond the groove bottom. The effects of process parameters (rotation speed and travelling speed) and applying multiple passes on the distribution of SiC particle in the nugget zone were investigated. The effects of groove size and its position relative to the tool probe were also investigated. Applying multiple passes had a great effect on the homogeneity of the SiC particle distribution. At rotation speeds of 2000–3000 rev min⁻¹, the SiC particles tended to cluster in some places in the nugget zone. By decreasing the rotation speed to 1000–1500 rev min⁻¹, the SiC particle was distributed in almost all the nugget zone area when the groove was 2–3 mm wide and 1˙5 mm deep. On the other hand, the stirring action of FSP was insufficient to distribute homogenously the SiC particles when the groove size was increased to 3×2 mm. By shifting the groove position towards the advancing side of the tool probe, the distribution of the SiC particles in the nugget zone became better. The defect free nugget zone with homogenously distributed SiC particles was obtained in a sample produced by FSP at rotation speeds of 1500 rev min⁻¹ for the first pass and 1250 rev min⁻¹ for the second and third passes. Microhardness of the nugget zone was increased to a level as high as 55 HV when the groove size was 3×1˙5 mm. The effect of the rotation speed on the particles dispersion was discussed with particular reference to the vertical material flow in the nugget zone.

This paper presents a modified re-entrant honeycomb auxetic structure. The structure is constructed by adding an additional horizontal member between the vertical and re-entrant member of the semi-re-entrant honeycomb model to increase the overall compliance of the structure in order to obtain higher values of negative Poisson’s ratio (NPR). An analytical model of the structure is presented, taking into account the bending, shear, and axial deformations. The model is verified using finite element analysis (FEA) and tensile testing. The results of FEA and tensile testing corroborate the results of the presented mathematical model. The structure is also compared to the existing re-entrant honeycomb structure. The newly added strut has shown a direct effect on the directional properties of the overall structure. With an increase in the newly added strut to re-entrant lengths, NPR was significantly enhanced in the x-direction and reduced in the y-direction loadings. The structure shows an improved Young’s modulus compared to solid material in both loading directions, especially for the low values of the new strut and re-entrant lengths ratio. The structure also shows that high NPR can be achieved for low relative density compared to semi re-entrant honeycomb structure.