Exploring the Metallurgical and Mechanical Characteristics of Magnesium/Silicon Carbide Surface Composites Manufactured via Friction Stir Processing

The proposed research endeavors to enhance the longevity of magnesium alloy materials by employing friction stir processing (FSP) to incorporate metallic particles. The experimental phase encompassed the manipulation of silicon carbide (SiC) particles at varying weights of 0% (neat FSP), 4%, and 8% in conjunction with a magnesium alloy matrix (AZ-91) using the FSP method. Subsequent evaluation focused on both metallurgical and mechanical aspects of the prepared samples. The results obtained highlighted the uniform dispersion of SiC particles within the matrix stir zone, exhibiting an absence of intermetallic reactions as indicated by scanning electron microscopic analysis. Notably, the samples containing 8 wt% SiC exhibited higher levels of hardness, impact and tensile strength, with fracture occurring at the thermo-mechanically affected zone, while also displaying improved ductility. In quantitively 26.13% increase in hardness, 47.88% higher impact strength, and 33.33% greater tensile strength was obtained. This can be attributed to the amalgamation of dispersion strengthening, which significantly influenced the overall strength of the fabricated surface composites. The enhanced strength is due to the pinning effect generated by SiC particles, combined with the utilization of the FSP process. The resulting surface composites, following these processing techniques, hold promising potential for integration into future applications, particularly within the automotive and marine sectors. © 2023, The Institution of Engineers (India).