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<p>Aluminium alloys are widely used in automotive and aerospace industries due to their low density, corrosion resistance, durability, and ease of processing. This study presents a novel and cost-effective surface modification technique for enhancing the wear resistance of Al7075 alloy through in-situ formation of Al₂O₃-reinforced surface composites using Gas Tungsten Arc Welding (GTAW). Alumina particles (625 mesh) were introduced between Al7075 substrate and cover sheet and dispersed into the molten pool through controlled arc stirring. A two-level half-factorial design (2⁴⁻¹) was employed to systematically investigate the effects of welding current (90–110&#xa0;A), welding speed (10–20&#xa0;cm/min), electrode diameter (4–6&#xa0;mm), and gas flow rate (7.5–10&#xa0;l/min). Surface composites exhibited significant improvement over base metal, with hardness reaching up to 301 HV and mass loss reduced by nearly threefold (minimum 0.007&#xa0;g). Regression models demonstrated high predictive capability, explaining 95.34% variability in hardness and 96.09% in mass loss (R² &gt; 0.95). SEM confirmed uniform alumina dispersion and EDX validated reinforcement presence. The study establishes a statistically optimized, scalable GTAW-based surfacing route for developing high-performance wear-resistant aluminium surface composites without bulk composite processing.</p>

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Experimental and statistical optimization of process parameters for wear-resistant Al7075 surface composites

  • 期刊论文

  • 发表日期：

    2026年4月6日

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  • Neha Bhadauria,
  • Prashant Vashishtha,
  • Sunil Pandey,
  • Pulak Mohan Pandey

摘要

Aluminium alloys are widely used in automotive and aerospace industries due to their low density, corrosion resistance, durability, and ease of processing. This study presents a novel and cost-effective surface modification technique for enhancing the wear resistance of Al7075 alloy through in-situ formation of Al₂O₃-reinforced surface composites using Gas Tungsten Arc Welding (GTAW). Alumina particles (625 mesh) were introduced between Al7075 substrate and cover sheet and dispersed into the molten pool through controlled arc stirring. A two-level half-factorial design (2⁴⁻¹) was employed to systematically investigate the effects of welding current (90–110 A), welding speed (10–20 cm/min), electrode diameter (4–6 mm), and gas flow rate (7.5–10 l/min). Surface composites exhibited significant improvement over base metal, with hardness reaching up to 301 HV and mass loss reduced by nearly threefold (minimum 0.007 g). Regression models demonstrated high predictive capability, explaining 95.34% variability in hardness and 96.09% in mass loss (R² > 0.95). SEM confirmed uniform alumina dispersion and EDX validated reinforcement presence. The study establishes a statistically optimized, scalable GTAW-based surfacing route for developing high-performance wear-resistant aluminium surface composites without bulk composite processing.