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<p>ZE41 magnesium alloy was processed by friction stir processing (FSP), ball burnishing (BB), and duplex processing (FSP + BB) to evaluate its microstructure, microhardness, and wear characteristics. FSP produced fine grains of size 5 ± 2.3&#xa0;µm and the intermetallic phase was broken and distributed in the stir zone. The BB flattened the surface asperities and irregularities due to plastic deformation that induced strain hardening and a layer of materials from the top surface was affected. The FSP + BB sample also exhibited strain-hardened layers up to a thickness of 125&#xa0;µm. No change in grain size was observed in BBed and FSP + BB alloys. The microhardness was increased by 23%, 32%, and 83% in FSPed, BBed, and FSP + BB alloy respectively. The tribological study exhibited a reduction in wear rate by 21% and 30% in FSPed and BBed samples compared to as-cast alloy respectively. FSP + BB alloy exhibited a low wear rate with a reduction of 47% due to grain refinement and strain hardening. A lower coefficient of friction of 0.14 was achieved in the FSP + BB sample. The worn surface and debris morphology exhibited abrasion, oxidation, and severe plastic deformation as dominant wear mechanisms in the as-cast sample, whereas mild delamination was seen in FSPed alloy. The FSP + BB alloy exhibited only abrasion and oxidation as the main wear mechanisms. The duplex-processed ZE41 alloy can be used in light weight structural applications to improve the surface hardness and wear resistance of components used in the field of automobiles, aviation, and defence sectors.</p>

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Synergetic Effect of Ball Burnishing and Friction Stir Processing on the Sliding Wear Behavior of ZE41 Magnesium Alloy

  • 期刊论文

  • 发表日期：

    2025年8月25日

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  • Subrat Kumar Baral,
  • Manjusha M. Thawre,
  • B. Ratna Sunil,
  • Ravikumar Dumpala

摘要

ZE41 magnesium alloy was processed by friction stir processing (FSP), ball burnishing (BB), and duplex processing (FSP + BB) to evaluate its microstructure, microhardness, and wear characteristics. FSP produced fine grains of size 5 ± 2.3 µm and the intermetallic phase was broken and distributed in the stir zone. The BB flattened the surface asperities and irregularities due to plastic deformation that induced strain hardening and a layer of materials from the top surface was affected. The FSP + BB sample also exhibited strain-hardened layers up to a thickness of 125 µm. No change in grain size was observed in BBed and FSP + BB alloys. The microhardness was increased by 23%, 32%, and 83% in FSPed, BBed, and FSP + BB alloy respectively. The tribological study exhibited a reduction in wear rate by 21% and 30% in FSPed and BBed samples compared to as-cast alloy respectively. FSP + BB alloy exhibited a low wear rate with a reduction of 47% due to grain refinement and strain hardening. A lower coefficient of friction of 0.14 was achieved in the FSP + BB sample. The worn surface and debris morphology exhibited abrasion, oxidation, and severe plastic deformation as dominant wear mechanisms in the as-cast sample, whereas mild delamination was seen in FSPed alloy. The FSP + BB alloy exhibited only abrasion and oxidation as the main wear mechanisms. The duplex-processed ZE41 alloy can be used in light weight structural applications to improve the surface hardness and wear resistance of components used in the field of automobiles, aviation, and defence sectors.