Abstract
In this paper, optimization of the fabrication parameters of an aluminum surface composite with respect to tensile strength and tool wear rate is reported. The surface layer was reinforced with SiC particles to improve the tribological properties of AA-5052. The Taguchi design with orthogonal array L8 was used for the experimental design, which included three processing parameters: the number of passes, rotational speed, and traversal speed. The experiment used optimal fabrication parameter searching to produce a multi-response prediction of both the tensile strength and tool wear rate. The experimental result was determined by grey relational analysis for multi-performance characteristics. Afterward, the prediction result of the optimal fabrication parameters was confirmed by repeated experiments to confirm the selection of optimal process parameters. The results revealed that the optimal fabrication parameters for multi-performance characteristics are two passes, rotational speed of 1000 revolutions per minute (RPM), and traversal speed of 30 mm/min (condition N2R1T2). These showed high tensile strength (229.90 MPa), low tool wear rate (0.0851), and a uniform distribution of SiC particles in the matrix. In addition, grey relational analysis showed that the parameter priority was 51.68% for rotational speed (the most significant process parameter), 36.18% for transversal speed, and 7.05% for the number of passes. Therefore, the grey-based orthogonal array Taguchi method can optimize multi-performance characteristics through the setting of process parameters for friction stir processing of an aluminum surface composite.
Highlights
Aluminum surface composites (ASC) have a large variety of application in the transportation, food, and aerospace industries due to their characteristics of being lightweight and having good wear resistance, hardness, and good performance at high temperatures. These properties are good mechanical and physical properties for ASC, which are formed by the reinforcement of hard ceramic particles in an aluminum matrix layer
Both the mechanical and physical properties of ASC are very important for their continued usability [1,2,3,4]
The cooling temperature of the casting process is a difficult-to-control parameter that affects the quality of the structure in the surface matrix
Summary
Aluminum surface composites (ASC) have a large variety of application in the transportation, food, and aerospace industries due to their characteristics of being lightweight and having good wear resistance, hardness, and good performance at high temperatures. These properties are good mechanical and physical properties for ASC, which are formed by the reinforcement of hard ceramic particles in an aluminum matrix layer. There are several techniques for composite surface fabrication including high energy laser treatment, plasma sprayed coating, cast sintering, and casting, which are techniques for improving the properties of materials These techniques can improve the property of many materials such as composite fiber fabrication by dissolving the coating process for producing the conductive polymer composite material. The internal structure engenders surface interfacial reactions between reinforcement particles in the aluminum matrix [9,10]
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