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<p>Magnesium alloys are utilized in the aerospace, marine, and medical industries because of their low density and favourable mechanical properties. However, their hexagonal close-packed (HCP) crystal structure results in poor wear resistance and formability, which limits their large-scale applications. Enhancing the surface quality is an effective strategy to overcome these limitations. Friction Stir Processing (FSP) has emerged as a promising technique for microstructural refinement and surface modification. In this study, a novel hybrid surface composite of AZ91D reinforced with TiO<sub>2</sub> and silver nanoparticles (AgNPs) was fabricated using FSP. The experimental design was carried out using a Box–Behnken Design (BBD) based on Response Surface Methodology (RSM). Multi-objective optimization was performed using desirability function analysis (DFA) to achieve enhanced surface characteristics. The optimal process parameters were identified as a tool rotation speed (TRS) of 900&#xa0;rpm, tool traverse speed (TTS) of 70&#xa0;mm/min, number of passes (NoP) of 4, and reinforcement fraction (Rf) of 2 wt.%. Under these conditions, the microhardness of the composite increased by ~ 200% (from 60 to 70 Hv for the base material to 141.41 Hv).also wear rate was decreased by ~ 42% (from 5.6 × 10⁻<sup>3</sup> to 3.26 × 10⁻<sup>3</sup>&#xa0;mg/m). Scanning Electron Microscopy (SEM) analysis of the worn surfaces was conducted to investigate the prevailing wear mechanisms.</p>

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Optimizing Surface Quality of TiO2/Ag Reinforced Magnesium Composites Using RSM-based Desirability–Function Analysis Fabricated by FSP Process

  • 期刊论文

  • 发表日期：

    2026年7月9日

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  • Ram Niwas,
  • Vikas Kumar

摘要

Magnesium alloys are utilized in the aerospace, marine, and medical industries because of their low density and favourable mechanical properties. However, their hexagonal close-packed (HCP) crystal structure results in poor wear resistance and formability, which limits their large-scale applications. Enhancing the surface quality is an effective strategy to overcome these limitations. Friction Stir Processing (FSP) has emerged as a promising technique for microstructural refinement and surface modification. In this study, a novel hybrid surface composite of AZ91D reinforced with TiO2 and silver nanoparticles (AgNPs) was fabricated using FSP. The experimental design was carried out using a Box–Behnken Design (BBD) based on Response Surface Methodology (RSM). Multi-objective optimization was performed using desirability function analysis (DFA) to achieve enhanced surface characteristics. The optimal process parameters were identified as a tool rotation speed (TRS) of 900 rpm, tool traverse speed (TTS) of 70 mm/min, number of passes (NoP) of 4, and reinforcement fraction (Rf) of 2 wt.%. Under these conditions, the microhardness of the composite increased by ~ 200% (from 60 to 70 Hv for the base material to 141.41 Hv).also wear rate was decreased by ~ 42% (from 5.6 × 10⁻3 to 3.26 × 10⁻3 mg/m). Scanning Electron Microscopy (SEM) analysis of the worn surfaces was conducted to investigate the prevailing wear mechanisms.