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<p>This study investigates the tribological behaviour of friction stir processed (FSPed) AA8011 surface composites reinforced with 1–3 wt% nano zirconium oxide nZrO<sub>2</sub>of 40–60&#xa0;nm size under axial load (AL: 10–30&#xa0;N) and sliding velocity (SV: 0.5–1.5&#xa0;m/s) using an L<sub>9</sub>Taguchi’s design. The lowest wear rate (WR) and coefficient of friction (CoF) were obtained at 10&#xa0;N, 1&#xa0;m/s, and 2 wt% nZrO<sub>2</sub>, yielding 0.0031&#xa0;g/min and 0.36, respectively, whereas the highest values, 0.0071&#xa0;g/min and 0.51, occurred at 30&#xa0;N, 1&#xa0;m/s, and 1 wt% nZrO<sub>2</sub>. Analysis of variance (ANOVA) confirmed that AL was the most influential factor for both WR and CoF, followed by nZrO<sub>2</sub> content and SV. The developed models showed high adequacy, with R<sup>2</sup> values of 0.9744 for WR and 0.9766 for CoF. Desirability function analysis predicted optimum conditions at 10&#xa0;N, 0.5&#xa0;m/s, and 2.05 (≈ 2) wt% nZrO<sub>2</sub>, corresponding to WR of 0.00449&#xa0;g/min and CoF of 0.3872 with an overall desirability of 0.730. Confirmation experiments yielded 0.00457&#xa0;g/min and 0.391, with deviations of only 1.7% and 0.98%. Microstructural and worn-surface analyses confirmed that 2 wt% nZrO<sub>2</sub> provided the best particle dispersion, stable tribolayer formation, and superior wear resistance. Wear mechanisms observed were abrasive wear, adhesion, subsurface cracking, and material peeling under different conditions.</p>

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Hybrid Taguchi-RSM optimization of wear response in friction stir processed AA8011/Nano-ZrO2 composites with variable reinforcement

  • 期刊论文

  • 发表日期：

    2026年5月13日

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  • K. Velavan,
  • S. Gopinath,
  • K. Gajalakshmi,
  • S. Sathish,
  • T. Balamurugan,
  • C. Kaviarasu,
  • S. Sundaraselvan

摘要

This study investigates the tribological behaviour of friction stir processed (FSPed) AA8011 surface composites reinforced with 1–3 wt% nano zirconium oxide nZrO2of 40–60 nm size under axial load (AL: 10–30 N) and sliding velocity (SV: 0.5–1.5 m/s) using an L9Taguchi’s design. The lowest wear rate (WR) and coefficient of friction (CoF) were obtained at 10 N, 1 m/s, and 2 wt% nZrO2, yielding 0.0031 g/min and 0.36, respectively, whereas the highest values, 0.0071 g/min and 0.51, occurred at 30 N, 1 m/s, and 1 wt% nZrO2. Analysis of variance (ANOVA) confirmed that AL was the most influential factor for both WR and CoF, followed by nZrO2 content and SV. The developed models showed high adequacy, with R2 values of 0.9744 for WR and 0.9766 for CoF. Desirability function analysis predicted optimum conditions at 10 N, 0.5 m/s, and 2.05 (≈ 2) wt% nZrO2, corresponding to WR of 0.00449 g/min and CoF of 0.3872 with an overall desirability of 0.730. Confirmation experiments yielded 0.00457 g/min and 0.391, with deviations of only 1.7% and 0.98%. Microstructural and worn-surface analyses confirmed that 2 wt% nZrO2 provided the best particle dispersion, stable tribolayer formation, and superior wear resistance. Wear mechanisms observed were abrasive wear, adhesion, subsurface cracking, and material peeling under different conditions.