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Optimization of Friction Stir Process Parameters for Micro-Hardness and Wear Characteristics of Silicon Carbide-Reinforced Al-7075 Surface Composite

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Abstract

Friction stir processing is a newly emerged manufacturing method for modifying the surface of materials by localized plastic deformation for enhancing their surface characteristics. This research focuses on the optimization of process parameters for silicon carbide-reinforced 7075 aluminum alloy surface composite produced by friction stir processing. For placing silicon carbide particles, an array of 2 × 2 mm blind holes of size 2 mm with a spacing of 4 mm was machined on the AA7075 base plate. A tool with a square pin of 6 mm size having a shoulder diameter of 25 mm was utilized for the fabrication of composites. Process parameters such as tool rotational speed, travel speed and tilt angle were selected in this study and the effects of these parameters on micro-hardness and wear properties were analyzed. These parameters were varied in four levels and surface composites were manufactured according to the Taguchi’s L16 experiment. Optimization of process parameters for enhancing the micro-hardness and wear resistance was performed with grey relational analysis. Experimental results showed that the micro-hardness and wear rate of the composites were most significantly affected by tool travel speed followed by the tool rotation and tilt angle, respectively. Both responses were optimized when the AA7075/SiC surface composite was manufactured with 1120 rpm as tool rotational speed, 50 mm/min as tool travel speed and 3° as tilt angle. The surface composite developed in this research work can be used as a viable alternative material for applications that require superior surface characteristics.

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Authors and Affiliations

  1. Department of Mechanical Engineering, JNTUK, Kakinada, Andhrapradesh, 533005, India

    D. S. Chandra Mouli

  2. Department of Mechanical Engineering, MREC(A), Hyderabad, Telangana, 500100, India

    D. S. Chandra Mouli

  3. Department of Mechanical Engineering, CEC, Visakhapatnam, Andhrapradesh, 530048, India

    R. Umamaheswara Rao

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Correspondence to D. S. Chandra Mouli.

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Mouli, D.S.C., Rao, R.U. Optimization of Friction Stir Process Parameters for Micro-Hardness and Wear Characteristics of Silicon Carbide-Reinforced Al-7075 Surface Composite. Trans Indian Inst Met 74, 3135–3143 (2021). https://doi.org/10.1007/s12666-021-02394-4

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