Optimization of friction stir processing to improve the mechanical properties of bone fixation plate inputs made of ZK60 magnesium alloy

New advances in biomedical research have led to the creation of magnesium alloy-based lightweight bone implants that are meant to make implants stronger. Reinforcing particles, such as zirconium (Zr) and calcium (Ca), have been added to make the material stronger and more biocompatible. The main goal of this study is to find the best sources for the friction stir process (FSP), which is used to make a bone fixation plate out of magnesium alloy (ZK60) that is strengthened with zirconium and calcium. The Taguchi L16 Orthogonal Array (OA) was used to find the best settings for the FSP process. These included tool speed (600, 800, 1000, and 1200 rpm), reinforcement content (4%, 8%, 12%, and 16%), welding speed (20, 30, 40, and 50 mm/min), and axial force (5, 10, 15, and 20 kN). After undergoing a thorough examination, the manufactured bone plate was determined to have a microhardness of 106 HV, a tensile strength of 205.38 MPa, and minimal attrition at 0.042 mm³/m. The axial force had significant impacts on tensile and microhardness tests, while reinforcement % had a major influence on wear. This study successfully makes a bone fixation plate that is biocompatible and long-lasting by using the optimized FSP settings. The mechanical properties and resistance to wear are also strong.