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<p>Friction stir processing (FSP) is an emerging solid-state technique used to modify the surface characteristics of metallic materials without altering their bulk properties. It has shown great potential for enhancing the mechanical and tribological performance. This study explores the mechanical behaviour of AZ91 magnesium alloy subjected to surface modification via FSP, incorporating reinforcements such as silicon carbide (SiC), silicon nitride (Si<sub>3</sub>N<sub>4</sub>), and a hybrid combination of both. The fabricated composites were evaluated through Vickers hardness testing, tensile testing, and wear analysis to determine the improvements in hardness, strength, and wear resistance. Microstructural characterisation was performed using scanning electron microscopy (SEM) to examine the thermomechanically affected zone (TMAZ) and establish correlations between microstructural changes and mechanical performance. The results showed enhancements in the tensile strength, surface hardness, and wear resistance owing to the presence of ceramic reinforcements. This study provides valuable insights into the development of high-performance Mg-based surface composites using FSP for potential applications in lightweight and wear-critical engineering.</p>

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Friction stir processing of AZ91 magnesium alloy using SiC and Si3N4 with hybrid ceramic reinforcements: Enhanced mechanical properties

  • 期刊论文

  • 发表日期：

    2026年2月9日

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  • Rameshkannan C.,
  • Saravanan P.,
  • Veera Manikandan P.

摘要

Friction stir processing (FSP) is an emerging solid-state technique used to modify the surface characteristics of metallic materials without altering their bulk properties. It has shown great potential for enhancing the mechanical and tribological performance. This study explores the mechanical behaviour of AZ91 magnesium alloy subjected to surface modification via FSP, incorporating reinforcements such as silicon carbide (SiC), silicon nitride (Si3N4), and a hybrid combination of both. The fabricated composites were evaluated through Vickers hardness testing, tensile testing, and wear analysis to determine the improvements in hardness, strength, and wear resistance. Microstructural characterisation was performed using scanning electron microscopy (SEM) to examine the thermomechanically affected zone (TMAZ) and establish correlations between microstructural changes and mechanical performance. The results showed enhancements in the tensile strength, surface hardness, and wear resistance owing to the presence of ceramic reinforcements. This study provides valuable insights into the development of high-performance Mg-based surface composites using FSP for potential applications in lightweight and wear-critical engineering.