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<p>In this work, the effects of multi-pass friction stir processing (FSP) on the microstructural evolution, mechanical properties, tribological behavior, corrosion resistance, and wettability of AZ61 magnesium alloy reinforced with FeCoCrMnTi high-entropy alloy (HEA) particles were systematically investigated. Multi-pass FSP produced significant grain refinement and uniform dispersion of HEA particles within the magnesium matrix. The three-pass FSP (3PFSP) composite exhibited the finest grain size (~2.35&#xa0;<i>μ</i>m), yielding a superior combination of strength and ductility, with an ultimate tensile strength of 336.45&#xa0;MPa and elongation of 15.38%, compared with 280&#xa0;MPa and 6.82% for the base metal. Tribological testing revealed marked improvements in wear resistance, with the lowest wear rate of 1.98 × 10<sup>−2</sup> mm<sup>3</sup>/m and a reduced coefficient of friction of 0.381 for the 3PFSP sample. Electrochemical corrosion studies showed a significant reduction in corrosion rate from 11.98 mpy for the base alloy to 2.16 mpy for the 3PFSP composite. Additionally, wettability measurements indicated enhanced surface hydrophilicity, with the lowest contact angle (~46.5°) and highest surface energy (~51.66&#xa0;mJ/m<sup>2</sup>) observed for the 3PFSP sample. These results demonstrate that three-pass FSP provides an optimal processing route for simultaneously enhancing mechanical performance and functional surface properties, making AZ61/HEA composites promising candidates for lightweight structural components in the aerospace and automotive industries, as well as for biomedical implant applications requiring improved corrosion resistance and surface bioactivity.</p>

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Enhancement of Mechanical, Wear, Corrosion, and Wettability Properties of AZ61/FeCoCrMnNi High-Entropy Alloy Surface Composites through Multi-Pass Friction Stir Processing

  • 期刊论文

  • 发表日期：

    2026年3月9日

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  • Dhanalakshmi Shanmuga Sundaram,
  • Lavanya Dhanapalan,
  • K Kavitha,
  • N Ravikumar

摘要

In this work, the effects of multi-pass friction stir processing (FSP) on the microstructural evolution, mechanical properties, tribological behavior, corrosion resistance, and wettability of AZ61 magnesium alloy reinforced with FeCoCrMnTi high-entropy alloy (HEA) particles were systematically investigated. Multi-pass FSP produced significant grain refinement and uniform dispersion of HEA particles within the magnesium matrix. The three-pass FSP (3PFSP) composite exhibited the finest grain size (~2.35 μm), yielding a superior combination of strength and ductility, with an ultimate tensile strength of 336.45 MPa and elongation of 15.38%, compared with 280 MPa and 6.82% for the base metal. Tribological testing revealed marked improvements in wear resistance, with the lowest wear rate of 1.98 × 10−2 mm3/m and a reduced coefficient of friction of 0.381 for the 3PFSP sample. Electrochemical corrosion studies showed a significant reduction in corrosion rate from 11.98 mpy for the base alloy to 2.16 mpy for the 3PFSP composite. Additionally, wettability measurements indicated enhanced surface hydrophilicity, with the lowest contact angle (~46.5°) and highest surface energy (~51.66 mJ/m2) observed for the 3PFSP sample. These results demonstrate that three-pass FSP provides an optimal processing route for simultaneously enhancing mechanical performance and functional surface properties, making AZ61/HEA composites promising candidates for lightweight structural components in the aerospace and automotive industries, as well as for biomedical implant applications requiring improved corrosion resistance and surface bioactivity.