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<p>Friction Stir Processing (FSP) has been utilized to develop metal foam through the precursor foaming technique. The metal precursor is fabricated by incorporating a specific amount of reinforced particles (blowing and stabilizing agents) into the base material. The reinforced particles are mixed in the base material on the Vertical milling machine. Aluminum foam finds extensive applications due to its low density, superior acoustic properties, and excellent mechanical performance. In this study, AA6063 is employed as the base material, titanium hydride (TiH₂) is the blowing agent, and powdered alumina is the stabilizing agent. Three process parameters, each with two levels, are investigated: tool rotational speed (750&#xa0;rpm and 1000&#xa0;rpm), tool traversing speed (40&#xa0;mm/min and 80&#xa0;mm/min), and tilt angle (1° and 1.5°). These parameters are analyzed for their influence on the metal foam’s density, porosity, energy absorption capacity and compressive behavior. The optimization of process parameters and prediction of optimal combinations for achieving the desired properties were carried out 20 runs using the Central Composite Design (CCD) of Response Surface Methodology (RSM). Analysis of Variance (ANOVA) confirms that the process parameters significantly affect the responses, and satisfactory models have been developed for the investigated properties. Additionally, SEM-EDX analysis is conducted to examine the morphological characteristics of the foam. After performing the trial runs, the porosity of AA6063 varies from 41.5 to 60.15%, and compressive strength varies from 11.5 to 31.5&#xa0;MPa.</p>

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Optimization of friction stir processing parameters using RSM and their impact on the mechanical characteristics of AA6063 metal foam

  • 期刊论文

  • 发表日期：

    2025年9月11日

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  • Smriti Mishra,
  • Pradeep Kumar Mouria,
  • Prashant Bhardwaj,
  • Husain Mehdi

摘要

Friction Stir Processing (FSP) has been utilized to develop metal foam through the precursor foaming technique. The metal precursor is fabricated by incorporating a specific amount of reinforced particles (blowing and stabilizing agents) into the base material. The reinforced particles are mixed in the base material on the Vertical milling machine. Aluminum foam finds extensive applications due to its low density, superior acoustic properties, and excellent mechanical performance. In this study, AA6063 is employed as the base material, titanium hydride (TiH₂) is the blowing agent, and powdered alumina is the stabilizing agent. Three process parameters, each with two levels, are investigated: tool rotational speed (750 rpm and 1000 rpm), tool traversing speed (40 mm/min and 80 mm/min), and tilt angle (1° and 1.5°). These parameters are analyzed for their influence on the metal foam’s density, porosity, energy absorption capacity and compressive behavior. The optimization of process parameters and prediction of optimal combinations for achieving the desired properties were carried out 20 runs using the Central Composite Design (CCD) of Response Surface Methodology (RSM). Analysis of Variance (ANOVA) confirms that the process parameters significantly affect the responses, and satisfactory models have been developed for the investigated properties. Additionally, SEM-EDX analysis is conducted to examine the morphological characteristics of the foam. After performing the trial runs, the porosity of AA6063 varies from 41.5 to 60.15%, and compressive strength varies from 11.5 to 31.5 MPa.