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<p>Friction stir processing (FSP) is an advanced surface modification technique utilized to enhance the surface properties of Mg alloys through grain refinement and reinforcement particle incorporation. However, challenges such as achieving uniform particle dispersion, maintaining mechanical integrity, and improving corrosion resistance remain significant concerns. The present study investigates the fabrication of Mg alloy-based surface composites reinforced with hydroxyapatite (HA) and ZrO<sub>2</sub> via multi-pass friction stir processing (MPFSP), focusing on the influence of varying number of FSP passes and powder concentration on microstructure, mechanical properties, and in-vitro degradation behavior. Before MPFSP, reinforcement powders (HA and ZrO<sub>2</sub>) were compacted into pre-machined micro-grooves on Mg alloy plates. The FSP experiments were systematically conducted at a tool rotation speed of 1120&#xa0;rpm, traverse speed of 25&#xa0;mm/min, and tool tilt angle of 2.5°, with varying FSP passes (1, 2, and 3) and micro-grooves (1, 2, and 3). Results demonstrated significant grain refinement in 2–3&#xa0;Mg–Zr composites from an initial average size of 63.23&#xa0;µm down to 5.83&#xa0;µm. Consequently, notable enhancements in mechanical performance were achieved, with ultimate tensile strength (UTS) increasing from 163.68&#xa0;MPa to 257.5&#xa0;MPa and microhardness rising from 47 to 86 HV. Meanwhile, the 2–3&#xa0;Mg–HA composite displayed the lowest corrosion rate and most stable apatite-layer formation, demonstrating superior in-vitro corrosion resistance. Overall, the 2–3&#xa0;Mg–Zr and 2–3&#xa0;Mg–HA composites collectively represent the optimal balance between mechanical strength and corrosion protection. The findings of the current study underscores the potential of MPFSP-fabricated Mg alloy composites for bio-degradable implant applications.</p>

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Evaluation of in-vitro degradation and mechanical integrity of Mg-ZrO2/HA surface composites processed via friction stir additive manufacturing

  • 期刊论文

  • 发表日期：

    2026年3月12日

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  • Gaurav Kumar Sharma,
  • Navdeep Singh Grewal,
  • Kamal Kumar

摘要

Friction stir processing (FSP) is an advanced surface modification technique utilized to enhance the surface properties of Mg alloys through grain refinement and reinforcement particle incorporation. However, challenges such as achieving uniform particle dispersion, maintaining mechanical integrity, and improving corrosion resistance remain significant concerns. The present study investigates the fabrication of Mg alloy-based surface composites reinforced with hydroxyapatite (HA) and ZrO2 via multi-pass friction stir processing (MPFSP), focusing on the influence of varying number of FSP passes and powder concentration on microstructure, mechanical properties, and in-vitro degradation behavior. Before MPFSP, reinforcement powders (HA and ZrO2) were compacted into pre-machined micro-grooves on Mg alloy plates. The FSP experiments were systematically conducted at a tool rotation speed of 1120 rpm, traverse speed of 25 mm/min, and tool tilt angle of 2.5°, with varying FSP passes (1, 2, and 3) and micro-grooves (1, 2, and 3). Results demonstrated significant grain refinement in 2–3 Mg–Zr composites from an initial average size of 63.23 µm down to 5.83 µm. Consequently, notable enhancements in mechanical performance were achieved, with ultimate tensile strength (UTS) increasing from 163.68 MPa to 257.5 MPa and microhardness rising from 47 to 86 HV. Meanwhile, the 2–3 Mg–HA composite displayed the lowest corrosion rate and most stable apatite-layer formation, demonstrating superior in-vitro corrosion resistance. Overall, the 2–3 Mg–Zr and 2–3 Mg–HA composites collectively represent the optimal balance between mechanical strength and corrosion protection. The findings of the current study underscores the potential of MPFSP-fabricated Mg alloy composites for bio-degradable implant applications.