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<p>Friction stir back extrusion (FSBE) is employed for producing wires of brass, with process parameters optimized using central composite design of experiments. Parameters including tool rotating speed (TRS), feed rate (FR), and temperature are fine-tuned based on the ultimate tensile strength of the samples. Confirmation tests are conducted using projected optimal parameters to validate output parameter values. Analysis of variance reveals that tool rotational speed has the greatest influence on tensile load, while feed rate has the least influence. The highest tensile load of 676&#xa0;MPa is achieved using 2400&#xa0;rpm tool rotational speed, 0.7&#xa0;mm/min feed rate, and 340&#xa0;°C temperature. Despite the large number of optimization studies published for W/methods such as friction stir welding, friction stir processing, and friction stir extrusion, there have not been many systematic investigations into the optimization of process parameters for friction stir back extrusion (FSBE). The main goal of this project is to use a response surface methodology (RSM)-based optimization framework to fill this gap by establishing quantitative process–structure–property relationships that can be used to produce seamless brass tub using FSBE method. The microstructural analysis is also conducted on the samples exhibiting higher UTS possessed refined grains, whereas coarser grain structures correlated with reduced tensile strength, confirming the strengthening effect of grain refinement achieved through controlled FSBE process. Fractographic analysis further substantiated these findings, showing a ductile fracture mode with uniformly distributed fine dimples on the fracture surface of maximum UTS specimen while low UTS samples displayed a mixed failure mode combining ductile dimples and quasi-cleavage patterns. Hardness measurements supported the tensile strength results, with TRS again exerting the most significant influence and FR the least. The maximum hardness value of 162&#xa0;HV1 was observed in the sample processed with higher TRS.</p>

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Process Optimization and Microstructural Characteristics Correlation in Brass Tube Fabrication by Friction Stir Back Extrusion

  • 期刊论文

  • 发表日期：

    2026年3月2日

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  • V. Abhilash,
  • R. Sasi Lakshmikhanth,
  • A. R. Vignesh,
  • S. Suresh Kumar

摘要

Friction stir back extrusion (FSBE) is employed for producing wires of brass, with process parameters optimized using central composite design of experiments. Parameters including tool rotating speed (TRS), feed rate (FR), and temperature are fine-tuned based on the ultimate tensile strength of the samples. Confirmation tests are conducted using projected optimal parameters to validate output parameter values. Analysis of variance reveals that tool rotational speed has the greatest influence on tensile load, while feed rate has the least influence. The highest tensile load of 676 MPa is achieved using 2400 rpm tool rotational speed, 0.7 mm/min feed rate, and 340 °C temperature. Despite the large number of optimization studies published for W/methods such as friction stir welding, friction stir processing, and friction stir extrusion, there have not been many systematic investigations into the optimization of process parameters for friction stir back extrusion (FSBE). The main goal of this project is to use a response surface methodology (RSM)-based optimization framework to fill this gap by establishing quantitative process–structure–property relationships that can be used to produce seamless brass tub using FSBE method. The microstructural analysis is also conducted on the samples exhibiting higher UTS possessed refined grains, whereas coarser grain structures correlated with reduced tensile strength, confirming the strengthening effect of grain refinement achieved through controlled FSBE process. Fractographic analysis further substantiated these findings, showing a ductile fracture mode with uniformly distributed fine dimples on the fracture surface of maximum UTS specimen while low UTS samples displayed a mixed failure mode combining ductile dimples and quasi-cleavage patterns. Hardness measurements supported the tensile strength results, with TRS again exerting the most significant influence and FR the least. The maximum hardness value of 162 HV1 was observed in the sample processed with higher TRS.