Tribological and Hardness Analyses of Friction-Stir-Processed Composites Using the Taguchi Approach

Area of Science:

• Materials Science and Engineering
• Surface Engineering
• Composite Materials Manufacturing

Background:

• Friction stir processing (FSP) is a key technique for refining composite microstructures and enhancing surface properties like hardness and wear resistance.
• Aluminum alloy-based surface composites are gaining importance in various industrial applications due to their improved physical characteristics.

Purpose of the Study:

• To investigate the hardness and wear behavior of Al6061-based surface composites manufactured using FSP.
• To analyze the influence of FSP parameters, including tool geometry, reinforcement composition (Cu:Gr), and number of passes, on wear rate and hardness.

Main Methods:

• Utilized the Taguchi design methodology with an L27 orthogonal array to systematically study the effects of five input parameters.
• Prepared Al6061-based surface composites via FSP, varying tool geometries, reinforcement ratios (Cu:Gr), and number of processing passes.
• Conducted wear tests to determine wear rates and hardness measurements for all prepared composite samples.

Main Results:

• Cylindrical pin tool geometry resulted in the highest wear rate, while the square pin tool showed the minimum wear rate.
• A reinforcement composition of 3:3 (Cu:Gr) by weight exhibited the minimum wear rate and maximum hardness.
• Increased FSP passes led to reduced wear rates and enhanced hardness, with the opposite effect observed for fewer passes.

Conclusions:

• FSP parameters significantly influence the surface wear and hardness of Al6061-based composites.
• The study identified optimal processing conditions for improved wear resistance and hardness, providing valuable insights for composite manufacturing.
• Further research could integrate thermal analysis and sensor data for comprehensive understanding and optimization.