In this study, mechanical behaviour and microstructural evolution in friction stir processing (FSP) of casting hypereutectic A390 aluminium alloy have been investigated. The mechanical behaviour of FSP samples was investigated by measuring the strain rate sensitivity using shear punch testing. The room-temperature shear punch tests were conducted at shear strain rates in the range of 10−4–10−1 s−1. The results indicate that the strain rate sensitivity index increases from about 0.015 to 0.120 for as-cast A390 after third FSP pass and then experiences a further growth in FSP passes. The increase in the grain size and CuAl2 intermetallic particle size result in a reduction in strain sensitivity index as well as shear strength after third FSP pass.
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