Wear behavior of friction stir processed AA7050-SIC composite

Abstract

Friction Stir Processing (FSP) has emerged as an advanced solid-state processing technique to enhance the mechanical andtribological properties of aluminum matrix composites (AMCs). The wear behavior of FSP-processed AA7050-SiC compositesby analyzing the influence of process parameters, SiC reinforcement, and tribological conditions. The composite specimenswere fabricated using varying tool rotational speeds, traverse speeds, and tool tilt angles to achieve optimal microstructuralrefinement and reinforcement dispersion. Wear testing was conducted using a pin-on-disc tribometer under dry slidingconditions, and the wear rate was evaluated based on applied load, sliding speed, and distance. Microstructural characterizationwas performed using Scanning Electron Microscopy (SEM) to examine grain refinement, reinforcement dispersion, and weartrack morphology. The results indicate that the incorporation of SiC significantly enhances hardness and wear resistanceto grain boundary strengthening, load-bearing effects, and formation of a protective tribolayer. Statistical analysis usingAnalysis of Variance (ANOVA) was applied to determine the significance of processing parameters and their effect on wearperformance. FSP conditions improve wear resistance by minimizing material loss, reducing wear debris formation, andenhancing interfacial bonding. This research provides insights into the optimization of FSP parameters for improving thetribological performance of AA7050-SiC composites, making them suitable for aerospace and structural applications.