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<p>Over the past two decades, Friction Stir Additive Manufacturing (FSAM) has been widely adopted to enhance the surface properties of lightweight alloys. In this work, AA7075 alloy was selected as the matrix material and reinforced with 9.4 wt.% ZrO₂ and 0.6 wt.% Gr to develop a surface composite with improved mechanical and tribological performance. The key FSAM parameters tool rotational speed, traverse speed, and tilt angle were considered as independent variables, while tool geometry, axial force, and reinforcement quantity were kept constant. Response Surface Methodology with a Central Composite Design (20 experimental runs) was employed to study the effects of these parameters on tensile strength and micro hardness. ANOVA results confirmed the developed models to be statistically significant, and the optimized parameters were identified as a rotational speed of 1500&#xa0;rpm, traverse speed of 55&#xa0;mm/min, and a tilt angle of 3°. Under these conditions, the composite achieved a maximum tensile strength of 289.8&#xa0;MPa and a micro hardness of 89.9 HV. Optical microscopy and SEM analyses confirmed uniform dispersion of ZrO₂ and Gr particles, grain refinement, and defect-free bonding in the stirred zone. The fabricated composite also exhibited enhanced corrosion and wear resistance compared to the base AA7075 alloy, owing to the synergistic effect of the hard ceramic (ZrO₂) and solid lubricant (Gr) reinforcements.</p>

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Optimization of FSAM parameters for tensile strength and hardness of AA7075/9.4% ZrO2/0.6% Gr composite using RSM Technique

  • 期刊论文

  • 发表日期：

    2026年1月12日

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  • Abdhesh Kumar,
  • Yogesh Kumar,
  • Kuntal Maji,
  • Santosh Kumar

摘要

Over the past two decades, Friction Stir Additive Manufacturing (FSAM) has been widely adopted to enhance the surface properties of lightweight alloys. In this work, AA7075 alloy was selected as the matrix material and reinforced with 9.4 wt.% ZrO₂ and 0.6 wt.% Gr to develop a surface composite with improved mechanical and tribological performance. The key FSAM parameters tool rotational speed, traverse speed, and tilt angle were considered as independent variables, while tool geometry, axial force, and reinforcement quantity were kept constant. Response Surface Methodology with a Central Composite Design (20 experimental runs) was employed to study the effects of these parameters on tensile strength and micro hardness. ANOVA results confirmed the developed models to be statistically significant, and the optimized parameters were identified as a rotational speed of 1500 rpm, traverse speed of 55 mm/min, and a tilt angle of 3°. Under these conditions, the composite achieved a maximum tensile strength of 289.8 MPa and a micro hardness of 89.9 HV. Optical microscopy and SEM analyses confirmed uniform dispersion of ZrO₂ and Gr particles, grain refinement, and defect-free bonding in the stirred zone. The fabricated composite also exhibited enhanced corrosion and wear resistance compared to the base AA7075 alloy, owing to the synergistic effect of the hard ceramic (ZrO₂) and solid lubricant (Gr) reinforcements.