Fabrication and Characterization of Hybrid Surface Composite Al5083/(SiC + TiO₂) Using Cooling-Assisted Friction Stir Processing

Friction stir processing (FSP) was used to produce surface composites (SCs) while maintaining the base material properties. This study incorporated SiC and TiO₂ nanoparticles into the Al5083 alloy matrix using cooling-assisted FSP, forming monolithic and hybrid SCs. The treated sections were analyzed using SEM, EDS, and XRD. Mechanical properties were evaluated through microhardness and tensile tests, while erosion wear resistance was assessed via air jet erosion wear testing. The results showed substantial improvements in mechanical and wear resistance properties. The Al5083/TiO₂ composites demonstrated the highest tensile strength and microhardness, while the hybrid Al5083/(SiC + TiO₂) composites exhibited significant wear resistance enhancements compared to the base alloy. SEM analysis of worn surfaces provided insights into the wear mechanisms.