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<p>Friction stir processing (FSP) provides a key for enhancing the strength of aluminium-based metal matrix composites (MMCs), particularly when silicon carbide (SiC) uses as the reinforcement. The resultant MMCs find extensive industrial applications like in manufacturing of lightweight components, contributing to advancements in fuel economy. Al–SiC MMCs are cost-effective, wear-resistant, thermally stable, and high-strength composites that perform better to other reinforcements in real-world, especially when a balance of mechanical and economic performance is needed. In this study, RSM design the experiment and examine the process parameters, including Tool Traveling Speed (TTS), Tool Rotational Speed (TRS) and Tool Depth (TD). FSP had conducted on 20 samples with varying process parameters, aiming to optimize output parameters such as Ultimate Tensile Strength (UTS) and Vickers Hardness (HV). The results indicate that tool rotational speed (TRS) has the greatest effect on ultimate tensile strength (UTS) and vicker hardness (HV), followed by tool depth (TD) and tool traverse speed (TTS). Fractography analysis revealed ductile fracture characteristics in the MMC region. This study highlights the role of regression analysis in improving the mechanical performance of Al-SiC advanced MMCs. The multi-objective optimization carried out through the desirability function approach (DFA) identified an optimal parameter set of 1100&#xa0;rpm, 25&#xa0;mm/min, and 5&#xa0;mm. This optimized combination minimizes the need for extensive trial experiments while ensuring better suitability for subsequent fabrication.</p>

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Friction stir processing of Al-SiC composites: a pathway to high-performance surfaces

  • 期刊论文

  • 发表日期：

    2025年11月29日

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  • Pooja Singh,
  • Audhesh Narayan,
  • Yengatigadu George Bala

摘要

Friction stir processing (FSP) provides a key for enhancing the strength of aluminium-based metal matrix composites (MMCs), particularly when silicon carbide (SiC) uses as the reinforcement. The resultant MMCs find extensive industrial applications like in manufacturing of lightweight components, contributing to advancements in fuel economy. Al–SiC MMCs are cost-effective, wear-resistant, thermally stable, and high-strength composites that perform better to other reinforcements in real-world, especially when a balance of mechanical and economic performance is needed. In this study, RSM design the experiment and examine the process parameters, including Tool Traveling Speed (TTS), Tool Rotational Speed (TRS) and Tool Depth (TD). FSP had conducted on 20 samples with varying process parameters, aiming to optimize output parameters such as Ultimate Tensile Strength (UTS) and Vickers Hardness (HV). The results indicate that tool rotational speed (TRS) has the greatest effect on ultimate tensile strength (UTS) and vicker hardness (HV), followed by tool depth (TD) and tool traverse speed (TTS). Fractography analysis revealed ductile fracture characteristics in the MMC region. This study highlights the role of regression analysis in improving the mechanical performance of Al-SiC advanced MMCs. The multi-objective optimization carried out through the desirability function approach (DFA) identified an optimal parameter set of 1100 rpm, 25 mm/min, and 5 mm. This optimized combination minimizes the need for extensive trial experiments while ensuring better suitability for subsequent fabrication.