The primary objective of this study is to investigate the microstructural, mechanical, and wear behaviour of AZ31/TiC surface composites fabricated through friction stir processing (FSP). TiC particles are reinforced onto the surface of AZ31 magnesium alloy to enhance its mechanical properties for demanding industrial applications. The FSP technique is employed to achieve a uniform dispersion of TiC particles and grain refinement in the surface composite. Microstructural characterization, mechanical testing (hardness and tensile strength), and wear behaviour evaluation under different operating conditions are performed. Response surface methodology (RSM) is utilized to optimize the wear rate by considering the effects of process parameters. The results reveal a significant improvement in hardness (41.3%) and tensile strength (39.1%) of the FSP-TiC composite compared to the base alloy, attributed to the refined grain structure (6-10 μm) and uniform distribution of TiC particles. The proposed regression model accurately predicts the wear rate, with a confirmation test validating an error percentage within ± 4%. Worn surface analysis elucidates the wear mechanisms, such as shallow grooves, delamination, and oxide layer formation, influenced by the applied load, sliding distance, and sliding velocity. The enhanced mechanical properties and wear resistance are attributed to the synergistic effects of grain refinement, particle-accelerated nucleation, the barrier effect of TiC particles, and improved interfacial bonding achieved through FSP. The optimized FSP-TiC composites exhibit potential for applications in industries demanding high strength, hardness, and wear resistance.

Department of Machining Assembly and Engineering Metrology Faculty of Mechanical Engineering VSB Technical University of Ostrava 70800 Ostrava Czech Republic

Department of Mechanical Engineering Amrita School of Engineering Amrita Vishwa Vidyapeetham Coimbatore 641112 India

Department of Mechanical Engineering Coimbatore Institute of Technology Coimbatore India

Department of Mechanical Engineering Sri Ramakrishna Engineering College Coimbatore Tamil Nadu India

Department of Mechanical Engineering Vel Tech Rangarajan Dr Sagunthala R and D Institute of Science and Technology Avadi 600062 India

University Centre for Research and Development Chandigarh University Mohali 140413 India

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Sci Rep. 2024 Sep 25;14(1):22019. doi: 10.1038/s41598-024-73292-0. PubMed

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