Investigation on Fractographic and Microstructure Evolution in AA7075/ZrO2/G Multilayer Laminated Composite Fabricated Using Friction Stir Additive Manufacturing Process

This research aims to enhance the mechanical and physical properties of AA 7075 aluminum alloy by using friction stir additive manufacturing (FSAM) to develop a multilayered laminated composite reinforced with zirconium dioxide (ZrO2) and graphene (G). An octagonal high-speed steel tool was employed to fabricate the composite, with varying weight percentages of ZrO2 and G. The composite's properties were analyzed through wear, corrosion resistance, hardness, and tensile strength tests. Advanced characterization techniques, including fractography analysis, energy-dispersive x-ray spectroscopy (EDS), x-ray diffraction (XRD), optical microscopy, and field emission scanning electron microscopy (FESEM), were utilized to evaluate the microstructural details and elemental distribution. The results showed that the AA7075/4 wt.% ZrO2 /0.6 wt.% G composite achieved the highest hardness and tensile strength among the samples. Additionally, wear and corrosion resistance improved significantly compared to the base alloy. Fractographic analysis confirmed the quality of the tensile test specimens, while EDS and spectral mapping verified the uniform distribution of elements. These findings demonstrate the effectiveness of FSAM in developing AA7075 composites with enhanced mechanical properties and durability, suitable for high-performance applications.