Maximizing machinability at AA8014 joints by hybrid reinforcement in friction stir processing

The research of hybrid composites’ machinability is an intricate modern trend. Industries then evaluate the surface finish of the machined surfaces to ensure they are up to snuff with the needs of the applications. Therefore, the purpose of this research is to examine the machinability performance of AA8014 workpieces (welded by friction stir processing (FSP) with hybrid reinforcement of Titanium diboride and Zirconium dioxide at CNC vertical milling centre, including material removal rate and surface finish (surface roughness). By changing the reinforcement percentage from 4 to 10%, the tool rotational speed from 1000 to 1600 rpm, the traverse speed of the tool head from 4 mm/min setting to 5 mm/min setting, and the axial force from 3 to 4 kN at four levels, we were able to weld the samples with 16 different combinations (L16 orthogonal array) of FSP parameters settings. Taguchi analysis and planning were used to optimize the pace of material removal and smooth out the surface. After milling, the weldment’s maximum material removal rate was measured at 2.48 mm³/min, and its minimum surface roughness was measured at 1.84 m.