Physical, Mechanical and Tribological Behavior of Metal Matrix Hybrid Composite Fabricated via Friction Stir Consolidation Process

Abstract

Metal Matrix Composite Materials Are Becoming A Growing Trend In The Automotive And AerospaceIndustries Because Of Their Mechanical, Physical, Tribological And Fundamentally Desirable Strength ToWeight Ratio Properties. However, Their Availability In Use Is Limited Because Of Their Manufacturing Method Difficulty And Process Extravagancy. The Main Aim Of This Research Was To Fabricate Metal MatrixHybrid Composite (Mmhcs) Through Friction Stir Consolidation (Fsc) Process Which Is Composed OfAz61 Reinforced With Sic And Zro2. The Investigation Integrated Discrete Element Method (Dem)Simulation, Optimization Using Response Surface Methodology (Rsm), Artificial Neural Network (Ann)Model Validation, Genetic Algorithm (Ga), And Experimental Validations. The Dem Simulation ProvidesInsight Into The Fsc Process, Offering A Virtual Platform To Analyze Material?�?S Porosity Behavior And Optimize Process Parameters. Rsm And Ga Were Employed To Optimize Key Parameters, Including Die Rotational Speed, Applied Load, Thickness, Consolidation Time, And Reinforcement Composition Of The Mmhc. Rsm Predicted An Optimal Configuration At 800 Rpm Rotation Speed, 500 N Applied Load, 12 MmThickness, 6 Minutes Of Consolidation Time, And 5%Wt (2.5 %Wt Of Sic And 2.5 %Wt Of Zro2) Composition Of The Metal Matrix. This Combination Was Projected To Yield A Minimum Porosity Response Of 0.62%. In Contrast, Ga Suggested An Optimal Configuration With Identical Rotation Speed, Applied Load, Thickness,And Consolidation Time, But A Higher 15%Wt (7.5 %Wt Of Sic And 7.5 %Wt Of Zro2) Composition Of TheMetal Matrix. This Prediction Gave A Lower Minimum Porosity Response Of 0.469%. In Contrast,Optimization Through Ga Showed A Better Predicting Accuracy. Experimental Validation Of The GaPredicted Optimal Process Parameter Combination For Minimum Porosity Was Successfully Carried Out.The Results Of The Fabricated Samples Showed Hardness, Compressive Yield Strength And Wear RateProperties Of 339??1.5hv (3324.6??14.7mpa), 170??2.6mpa And 0.0054mg/M Respectively. Furthermore,Following Fsc Synthesis, A New Phase Of Zno Emerged Upon Characterization With Xrd And Thermogravimetric Analysis Revealed That The Thermal Stability Ranged From 375 To 480 Oc. In Conclusion,Based On The Findings Of This Study And The Properties Of Manufactured Mmhcs, Fsc May Generally BeTaken Into Consideration For An Alternative Approach For Fabricating Mmhcs.