Stir Cast Composites Research Articles

Hybrid Treatment and Natural Aging Behavior of Peak-Aged Eutectoid Steel Powder-Reinforced Al 7075 Matrix Composites

The current work focuses on the natural aging phenomenon of a eutectoid steel powder-(0.8 wt.%) reinforced Al-Zn-Mg (Al 7075) alloy, which was subjected to a hybrid heat treatment. The hybrid treatment comprises the aging treatment of a matrix and the conventional treatment of a steel reinforcement in a single stretch on the stir cast composite. This material finds uses in space and transportation applications. The hybrid treatment consists of a conventional heat treatment cycle to obtain pearlite, bainite, and martensite phases in steel powder, followed by an age-hardening treatment for the Al 7075 matrix. This hybrid heat treatment resulted in improvements in the hardness and strength over the conventional aging treatment. The peak-aged hybrid specimens were subjected to natural aging in an open atmosphere for a continuous duration of 25 weeks to study the stability of the properties after peak aging. Tests of the mechanical properties such as the hardness and tensile strength along with microstructure analysis were carried out. During natural aging, the hardness of composites decreases irrespective of the quantity of the reinforcement in the composites and the type of reinforcement phase alteration during hybrid heat treatment. Also, the composites subjected to hybrid heat treatment show better resistance to natural aging compared to the conventionally aged samples. Within the group, the hybrid-treated martensite formed into a composite with 6 wt.% reinforcement showed only a 4% reduction in hardness during natural aging, which is an indication of a decent level of resistance to natural aging.

Comparison of Tribological Characteristics of LM13/B4C and LM13/Ilmenite Composites at High-Temperature Conditions

Abstract In this work, high-temperature tribological characteristics of ilmenite-reinforced LM13 aluminum alloy–based matrix composites (AMCs) and boron carbide–reinforced AMCs are compared. Stir-cast composites were processed using boron carbide (covalently bonded discontinuous particles (CDP)) and ilmenite (natural discontinuous particles (NDP)) particles separately as reinforcements. The particle size range was 106–125 µm, and reinforcement levels were 5, 10, and 15 wt% for both types of composites. Both composites exhibited a uniform distribution of reinforced particles and grain refinement. Compared to the LM13 base alloy, NDP composite containing 15 wt% reinforcement showed significant improvement in hardness (57%), coefficient of friction (57%), mild-to-severe wear transition temperature, average steady-state wear-rate (49%), and coefficient of thermal expansion (55%). CDP-15 composite showed slightly better properties than NDP-15 composite. Microstructure refinement, increased dimensional stability, formation of the oxide layer, and formation of tribolayer due to reinforcement of the ceramic fillers were the main reasons for the improvement in properties of processed AMCs. Scanning electron microscope (SEM)-energy dispersive spectroscopy (EDS) of wear tracks-debris showed abrasive/delamination wear as the main mechanism for materials loss. The research showed that the low-cost ilmenite particles can substitute for the very costly boron carbide particles as reinforcements in AMCs used for dry sliding wear applications under high operating temperatures–applied load conditions of the order of 300 °C–49 N.

Enhancing wear resistance in Al-7075 composites through conventional mixing and casting techniques

Aluminium 7075 alloy composite are highly sought after materials because of their superior strength, light weight and exhibiting enhanced tribological characteristics. An electric resistance furnace and the metal die process were used to develop this aluminium (Al 7075) alloy hybrid composites, with reinforcing provided by E-glass short fibres and aluminium oxide (Al2O3) particulates. The Al 7075 alloy composites have been cast by employing stirring technique at various weight percentages of E-glass short fibres (2 %, 4 %, 6 %, and 8 %) and Al2O3 particles (3 %, 6 %, 9 %, and 12 %). Microscopic examination demonstrates that Al2O3 particle distribution within Aluminium matrix has been uniform. Hardness of the in-situ Al–Al2O3-E-glass-based composites rose by 10.58 %, 22.35 %, 50.58 %, and 41.17 % in comparison to its base alloy. Tensile strength of the 2 to 8 wt% E-glass with 3–12 wt% Al2O3 stir-cast composites increased by 9.08 %, 15.91 %, 19.09 %, and 7.27 % when compared with the aluminium matrix, whereas ductility reduced by 8.9 %, 12.5 %, 18.75 %, and 25 %. An experiment on wear rate was carried out using a pin-on-disk benchtop test equipment. The examination was performed at varying weights and sliding speeds, and the resulted demonstrated that composite materials exhibit higher wear resistance than Al matrix. Furthermore, the presence of Al2O3 and E-glass resulted in lower wear loss across all applied loads and sliding velocities. Lower wear rates in these composites were attributed to hardness and the interfacial bonding between the Al alloy and the in-situ reinforcement.

Study on Mechanical Behaviour of Al-15Si-10Zn/x ZrO2 Composites Synthesized by Stir Cast Method

In this research, the microstructure and mechanical properties of Al-15Si-10Zn-xZrO2 (x = 5, 7 and 10 wt.%) composites synthesized by the stir-casting process have been investigated. The matrix and composite samples were characterized using an X-ray diffraction test (XRD) and their microstructures were studied using optical microscopy and scanning electron microscopy (SEM). The microstructure of different phases was analyzed using energy-dispersive spectroscopy (EDS). The microstructure of the Al-15Si-10Zn/ZrO2 composites consisted of coarse primary Si, needlelike eutectic Si, and Zn-rich phases, with ZrO2 reinforcement particles distributed homogeneously in the composites. The micro-hardness and tensile properties of the matrix and composites were determined at room temperature. The results show significant improvements in the micro-hardness and tensile strength of the composites compared to the matrix alloy. The micro-hardness of the stir-cast composites increased by 24%, 44%, and 58% in the 5, 7, and 10 wt% ZrO2 reinforcement composites, respectively. The ultimate tensile strength (UTS) of the 5, 7, and 10 wt% ZrO2 composites increased by 17%, 30%, and 44%, respectively, compared to the matrix alloy. The increased content of ZrO2 resulted in an increase in hardness, ultimate tensile and yield strengths and a decrease in ductility.

Effect of fabrication techniques on mechanical and microstructural behavior of AA7075/SiC/ZrC hybrid composite

Aluminum composites are highly sought-after in the industrial sector due to their improved mechanical properties compared to their parent metals. The choice of fabrication technique has a significant impact on the mechanical behavior of the composite. This study investigated the mechanical behavior of an optimized weight-fractioned AA7075/SiC/ZrC hybrid composite using different fabrication techniques. Stir casting, conventional sintering, and microwave sintering methods were employed to produce the composites. By optimizing the ball milling parameters, a uniform distribution of reinforcement particles was achieved throughout the matrix material. XRD, porosity, microstructural, and mechanical tests were conducted on all three composites to analyze the major changes during fabrication. Remarkably, the composites fabricated through microwave sintering exhibited significantly higher strength than the other fabrication methods. Specifically, the microwave-sintered composites displayed a compressive strength of 389 MPa, a tensile strength of 321 MPa, and a strain-to-fracture value of 26%. In contrast, the stir-cast composites showed a larger scale of secondary phases, poor mechanical performance, and elevated porosity. Moreover, when considering the overall production cost associated with the different fabrication techniques investigated in this study, microwave sintering was the most cost-effective method for large-scale production. This suggests that microwave sintering offers superior mechanical properties and economic advantages regarding manufacturing expenses.

Influence of Si3N4 on micro structural, mechanical and physical features of Al-7175 based vacuum assisted bottom stir cast composites

Influence of Si3N4 on micro structural, mechanical and physical features of Al-7175 based vacuum assisted bottom stir cast composites

Microstructural, Mechanical and Wear behaviour of in-situ Al-TiB2 composites

ABSTRACT In this study, mechanical and wear properties of in-situ stir cast Al-TiB2 composites were investigated. The composites were prepared by a metal salt reaction with different (3.0, 5.0 and 7.0 wt %) TiB2 contents. The microstructure of the composites were examined through an optical and scanning electron microscopy (SEM/EDS). The microstructures clearly revealed the uniform distribution of TiB2 particles in the Al matrix. The hardness of the in-situ Al-TiB2 based composites increased by 42%, 55%, and 58% compared to the matrix with the addition of 3, 5, and 7 wt% TiB2 reinforcements, respectively. The tensile strength of the 3, 5, and 7 wt% TiB2 stir-cast composites increased by 25%, 33%, and 45%, respectively, compared to the matrix, whereas the ductility decreased by 4.9%, 24.3%, and 41.3%, respectively. A pin-on-disk tester was used to perform a dry sliding wear test at different loads and sliding speeds. In comparison to the Al matrix, the composite materials showed improved wear resistance. Furthermore, in the entire applied loads and sliding velocities, the wear rate decreased with the increase in TiB2 content. The composites displayed lower wear rates due to their high hardness and strong interfacial bonding between the in-situ reinforcement and the matrix alloy.

Experimental analysis of hardness and tensile characteristics of copper reinforced AA6061 stir cast composites subjected to thermal and deformation assisted heat treatments

Aluminium alloy 6061 based composites reinforced with a varied weight percentage of copper particulates are fabricated utilizing a liquid metal stir casting technique. The collective influence of copper reinforcement, age hardening and low temperature thermomechanical treatment on AA6061 was investigated. The age hardened composites displayed better hardness and ultimate tensile strength than as cast composites. Thermomechanical treatment of the composites further enhanced the mechanical properties and hence showed better results over age hardened composites. The study revealed that an increase in the deformation enhanced the hardness and strength of the composite while the aging time to achieve the peak hardness was reduced. Both age hardened and thermomechanically treated composites with 6 wt.% copper reinforcement indicated the best peak hardness and UTS values at the lower aging temperature of 100 °C. The thermomechanically treated composite with 6 wt.% Cu, 15% deformation aged at 100 °C showed 80 and 69% increase in hardness and UTS, respectively, over as cast composite. Fracture surface analysis of the as cast, age hardened, and thermomechanical treated composites showed a mixed mode of fracture dominant with the brittle failure.

Online acoustic emission measurement of tensile strength and wear rate for AA8011-TiC- ZrB2 hybrid composite

In current scenario the aircraft industry in need of a lightweight connecting material that persuade the technical and technological standards, but also need superior mechanical qualities. In this work the major objective is to enhance the strength behaviour of stir cast composites. Aluminum 8011 (Al 8011) titanium carbide (TiC) and zirconium boron (ZrB2) hybrid composites are stir cast in this work, and their microstructure, mechanical, and tribological properties are investigated. The matrix material was Al 8011, which was supplemented with stronger TiC to boost mechanical strength and softer ZrB2 to improve thermal and corrosion resistance without significantly changing electrical properties. According to the findings, the reinforced alloy’s mechanical qualities outperform those of the unreinforced alloy. Acoustic energy generated during deformation of composite materials has been monitored and early fracture measurements has been achieved using the Acoustic emission (AE) approach in tensile test specimens. As a result of the experiment, Al8011 + 10% TiC + 2% ZrB2 composites outperform the Al8011 matrix alloy in terms of wear resistance, coefficient of friction, and surface smoothness, as well as other characteristics. The AFM representation of Al8011 + 10% TiC + 2% ZrB2 matrix reveals that the wear surface smoothness of the AMMC is significantly improved as compared to the Al8011 matrix alloys.

Processing, Mechanical Characterization, and Electric Discharge Machining of Stir Cast and Spray Forming-Based Al-Si Alloy Reinforced with ZrO2 Particulate Composites

High performance lightweight structures made of metal matrix composites (MMCs) are in demand for application in variety of industries such as aircraft, spacecraft, automobile, marine, sports equipment, etc. However, uniform distribution of the reinforcement phase to improve the mechanical properties and quality of MMCs has been the challenge for the manufacturing industries. Hence, researchers are focusing on the development of traditional low-cost method of producing metal matrix composites. In the view of above facts, an attempt is made to study the processing and characterization of Si-Al alloy reinforced with zirconium dioxide particulate composites in this paper. Hence, this paper concentrates on experimentally identifying the effect of stir cast and spray forming processing techniques followed by hot pressing on micro hardness, compressive strength, and tensile strength using Taguchi’s design of experiments for aluminum silicon matrix alloy reinforced with zirconium dioxide particulates. From the extensive experimentation on aluminum and silicon reinforced with the ZrO2 powder particulates, it was observed that there was an improvement in selected mechanical properties as the percentage of ZrO2 increased with 13 wt.% of silicon under spray forming processing technique compared to stir cast composites. This may be due to uniform distribution homogenous dispersion, larger work hardening rate, and structure of dislocation tangles around the ZrO2 particulates that occurred during spray forming processing technique. Further, results obtained from the interaction plot, contour plot, main effects plot, and analysis of variance (ANOVA) proved to be successful for identifying the optimum processing parameters for Si-Al alloy reinforced with zirconium dioxide particulate composites. Further, this paper also discusses wear study using pin on disc wear testing apparatus on spray forming processed aluminum and silicon (13.0 wt.%) alloy reinforced with the ZrO2 powder particulates based on Taguchi’s design of experiments followed by second order model generation for wear using response surface methodology. Finally, electrode wear study of spray forming processed aluminum and silicon alloy reinforced with the ZrO2 powder particulates using electric discharge machining by varying peak current (A), pulse on time (μs), and pulse off time (μs) using brass, copper, and graphite as electrode material based on L27orthogonal array. The understanding gained from the design of experiments in this paper can be used to develop future guidelines for processing and characterization of Si-Al alloy reinforced with zirconium dioxide particulate composites.

Investigation on microstructure and tribological performance of zirconium boride reinforced AZ91D magnesium alloy: Effect of processing routes

The present research explored the effects of spatially dispersed ZrB2 particles on mechanical characteristics, surface-modified tribo layer and the dry sliding wear of the AZ91D alloy composite. The objective of this study was to reduce the porosity and improve the tribo performance of the AZ91D/ZrB2 composite by a squeeze casting, and the results were compared with those of a stir-cast composite. The influence of ZrB2 on mechanical properties such as hardness, tensile strength, and wear analysis of composites by the pin-on-disk technique was studied. The squeeze cast composite showed a higher hardness of 115 HV and ultimate tensile strength of 275 MPa than the stir cast composite. Stir-cast composite reduces particle rearrangement due to cluster formation, resulting in higher porosity and lower mechanical strength, reducing tribo performance. The refinement of grain structure and porosity reduction of up to 31.61% improves strength, leading to better tribological properties for the squeeze cast composites. The squeeze cast composite containing 12 wt% of ZrB2 showed a minimum wear of 0.024 mm3/m, which is 25.14% less than the stir cast composite. The improved wear resistance resulted from a lubricating boron oxide layer (B2O3), confirmed through Raman spectroscopy. Tribo layer, delamination, and plastic deformation were found to be the primary wear mechanisms for the AZ91D/ZrB2 composite that were active throughout the sliding period.

Effect of Friction stir processing parameters on microstructure and microhardness of aluminium based Metal matrix composites

The present article demonstrates the Friction Stir Processing (FSP) of the stir cast Aluminium Alloy based Metal Matrix Composites (MMC). Generally, composites manufactured using the stir casting process tends to have several casting defects along with some agglomeration of reinforcement particles. These defects in stir cast composites can be resolved by implementing FSP. MMC was manufactured using the matrix of aluminium alloy 2014, which was reinforced with different weight percent of Silicon Carbide (SiC) particles (5%, 10% and 15%). FSP was performed by considering two different combinations of rotational speed and transverse speed i.e. (i) 270 rpm and 78 mm/min (First Combination) and (ii) 190 rpm and 50 mm/min (Second Combination). The article discusses the variation in microstructure and microhardness of all the friction stir processed composites and the effects of process parameters were examined. Lastly, the conclusion of the article suggests the best combination of processes parameters for performing FSP of manufactured composites.

Application of ultrasounds to improve the dispersion of nanoparticulates in a Al-Si7Mg0.6 alloy reinforced with 0.5 wt. % of nanodiamonds

One of the most important technical barriers that hinders the development and implementation of nanoparticulate reinforced aluminium alloys is the difficulty to avoid the formation of clusters and to obtain their homogeneous distribution. The present work summarises the results obtained with the use of an ultrasound probe that was immersed into the melt alloy containing nanodiamond particulates just before the casting step. The microstructure and tensile properties of the obtained specimens are compared with nanoreinforced samples obtained with conventional stir cast process. The materials used in the study are the Al-Si7Mg0.6 casting alloy and nanodiamond particulates obtained by detonation synthesis. Samples containing up to 0.5 wt.% of nanodiamonds have been obtained. The use of the ultrasound probe results in the elimination of nanoparticulate clusters and provides an improvement of mechanical properties in comparison to properties measure with the unreinforced alloy and also with the conventionally stir cast composite.

Mechanical and microstructure evaluation of stir cast Al-4.5%Cu alloy reinforced fly ash/boron carbide hybrid metal matrix composites

Metal matrix composites (MMCs) have risen to prominence as a structural material in the aerospace and automotive industries. When compared to traditional materials, MMCs have higher specific strength, wear resistance, reduced part weight, less thermal shock, and strength conservation at high temperatures. In this study, it was established that components should be cast using Aluminium Copper as the base matrix, with fly ash and B4C as reinforcement. A composite of 3 wt% and 5 wt% fly ash with 2, 4, and 6 wt% B4C was reinforced in an Al-4.5 wt% Cu matrix for three different diameters of 25, 50, and 75 mm casting. Stir cast composites were tested for hardness, tensile, compression, and impact strength. The results showed that stir casting composites with a 25 mm diameter had better mechanical qualities than those with a 50 mm or 75 mm diameter. For a 25 mm diameter stir casting, the increase in percentage of reinforcements enhanced 20% hardness, 29% tensile strength, 30% compression, and 38%impact strength. Microstructure analysis reveals better bonding between matrix and reinforcement for 25 mm diameter casting compared to 50 and 75 mm castings.

Abrasive waterjet machining studies on Al6061/15%LaPO4 composite

To the Al6061 matrix composite, the monazite structure Lanthanum Phosphate with a weight ratio of 15% is added as the reinforcement. The machinability characteristics of the stir cast composite is predicted using Abrasive Waterjet Machine. Jet Pressure, Stand-Off Distance, and Cutting Speed are taken as independent parameters. Material Removal Rate, Kerf taper Angle, and Surface Profile Roughness are taken as the dependent responses. The influence of the machining parameters is investigated using the Taguchi's L27 orthogonal array through ANOVA table for both single response and multi responses problems by Gray Relational Approach. From the single response study, the jet pressure has significant impact on material removal and kerf angle whereas, the surface finish depends on the cutting speed. For the multi-response problems, stand-off distance shows the superior influences on the output responses followed by jet pressure and cutting speed.

A Study on Particle Weight Fraction and Extrusion on the Mechanical Properties and Microstructural Evaluation of Al-Cu/Fly Ash Composite

Fly ash is the waste product coming out from thermal power plant is an increasingly urgent problem due to its storage and disposal. At the same time Metal Matrix composites (MMCs) reinforced with ceramic particles such as SiC, Al2O3 and B4C has their partial use in engineering application due to higher cost. The study focuses on the Al-Cu alloy reinforced fly ash particles produced by stir casting followed by hot extrusion. The composites produced by incorporation of fly ash reinforcements by varying 2%, 4%, 6%, 8% and 10wt% is hot extruded with an extrusion temperature of 400°C, extrusion rate of 5mm/s and extrusion ratio of 1.77:1. The extrusion composites have been evaluated based on the investigation of mechanical properties and microstructure. The results showed that, the amount of porosity increased with increasing the percentage of fly ash reinforcements in stir cast and the extruded composites is almost gratis from porosity. Hardness and tensile strength of composites increases with increases in percentage of reinforcement by stir and extruded composites. But extruded composites show better mechanical properties than stir cast composites. Wear test under different loads and for 45 minutes duration have been conducted on both cast and extruded composites. The worn surfaces have been observed under Scanning electron microscope (SEM) to understand the mechanism of wear. Extruded composites possess lower wear rates under all studied loads with constant sliding velocities when compared with cast composites. Microstructural study using SEM shows that the fly ash particulates in the molten matrix forms strong matrix reinforcement interface and their distribution might have led to the increase in mechanical properties of the composites due to fine grain structure during extrusion and dislocation density in the matrix.

Optimization of CNC-WEDM Parameters for AA2024/ZrB2 in situ Stir Cast Composites Using Response Surface Methodology with Desirability Function Technique

In recent years, application of aluminum materials in aircraft structures with output responses like maximum material removal rate and minimal surface roughness is at great necessity. This performance is attained during the wire cut electrical discharge machining and is influenced by the extent of ceramic inclusions in the aluminum matrix. The current research focuses on improving the machining performance of as-prepared aluminum zirconium diboride AA2024–ZrB2 prepared at different weight ratios of ZrB2 particles as 0, 2.5, 5, 7.5 and 10 wt%. The as-prepared samples are investigated for different characterizations like phase identification using X-ray diffraction technique; microstructure analysis using both optical microscope and field emission scanning electron microscope; and analysis of mechanical properties using tensile strength and micro-hardness tests. During the machining process, four input parameters like pulse on time Ton (μs), pulse off time Toff (μs), gap voltage GV (V) and ZrB2 wt% are considered for optimization and obtains 23 μs, 41 μs and GV 100 V at 2.5 wt% ZrB2. During machining, multi-response optimization, using response surface methodology with desirability function is performed. The output responses as of maximum material removal rate (MRR) of 0.0765 g/min and minimum surface roughness (SR) of 3.618 μm are obtained. The addition of different wt% ZrB2 in the base matrix has greatly influenced the output response like MRR and SR in the aluminum matrix.

Process parameters, development and applications of stir cast composite: A review

AbstractIn the current environment, aluminum metal matrix composites are in enormous demand due to notable improvement in mechanical and wear characteristics. Several manufacturing techniques have been developed among which traditional stir casting is preferred due to simple processing techniques other than available methods like compocasting, in situ fabrication, powder metallurgy or friction stir processing. Nanoparticles seem appealing to researchers for manufacturing nanocomposites due to their improved microstructural, mechanical and tribological properties. Parameters like weight or volume fraction, stirrer design, number of blades, stirring speed, stirring time, reinforcement feed rate and melting temperature required to prepare a composite are discussed in great detail. The innovation of this assessment effort lie in the fact that few such review works have been published for the stircasting technique to prepare aluminum metal matrix composites/nano composites reinforced with SiC, TiO2, Al2O3, B4C and TiC.

Influence of ceramic Al2O3 particulates on performance measures and surface characteristics during sinker EDM of stir cast AMMCs

PurposeAA2014 is a copper-based alloy and is typically used for production of complex machined components, given its better machinability. The purpose of this paper was to study the effects of variation in weight percentage of ceramic Al2O3 particulates during electrical discharge machining (EDM) of stir cast AA2014 composites. Scanning electron microscopy (SEM) examination was carried out to study characteristics of EDMed surface of Al2O3/AA2014 composites.Design/methodology/approachThe effect of machining parameters on performance measures during sinker EDM of stir cast Al2O3/AA2014 composites was examined by “one factor at a time” (OFAT) method. The stir cast samples were obtained by using three levels of weight percentage of Al2O3 particulates, i.e. 0 Wt.%, 10 Wt.% and 20 Wt.% with density 1.87 g/cc, 2.35 g/cc and 2.98 g/cc respectively. Machining parameters varied were peak current (1-30 amp), discharge voltage (30-100 V), pulse on time (15-300 µs) and pulse off time (15-450 µs) to study their influence on material removal rate (MRR), tool wear rate (TWR) and surface roughness (SR).FindingsMRR and SR decreased with an increase in weight percentage of ceramic Al2O3 particulates at the expense of TWR. This was attributed to increased microhardness for reinforced stir cast composites. However, microhardness of EDMed samples at fixed values of machining parameters, i.e. 9 amp current, 60 V voltage, 90 µs pulse off time and 90 µs pulse on time reduced by 58.34, 52.25 and 46.85 per cent for stir cast AA2014, 10 Wt.% Al2O3/AA2014 and 20 Wt.% Al2O3/AA2014, respectively. SEM and quantitative energy dispersive spectroscopy (EDS) analysis revealed ceramic Al2O3 particulate thermal spalling in 20 Wt.% Al2O3/AA2014 composite. This was because of increased particulate weight percentage leading to steep temperature gradients in between layers of base material and heat affected zone.Originality/valueThis work was an essential step to assess the machinability for material design of Al2O3 reinforced aluminium metal matrix composites (AMMCs). Experimental investigation on sinker EDM of high weight fraction of particulates in AA2014, i.e. 10 Wt.% Al2O3 and 20 Wt.% Al2O3, has not been reported in archival literature. The AMMCs were EDMed at variable peak currents, voltages, pulse on and pulse off times. The effects of process parameters on MRR, TWR and SR were analysed with comparisons made to show the effect of Al2O3 particulate contents.

Influence of processing route on microstructure and wear resistance of fly ash reinforced AZ31 magnesium matrix composites

Abstract Utilizing fly ash (FA) as reinforcement for magnesium matrix composites (MMCs) brings down the production cost and the land pollution. Magnesium alloy AZ31 was reinforced with FA particles (10 vol.%) successfully by two different processing methods namely conventional stir casting and friction stir processing (FSP). The microstructural features were observed using optical microscope, scanning electron microscope and electron backscatter diffraction. The sliding wear behavior was tested using a pin-on-disc wear apparatus. The stir cast composite showed inhomogeneous particle dispersion and coarse grain structure. Some of the FA particles decomposed and reacted with the matrix alloy to produce undesirable compounds. Conversely, FSP composite showed superior particle dispersion and fine, equiaxed grains by dynamic recrystallization. FA particles encountered disintegration but there was no interfacial reaction. FSP composite demonstrated higher strengthening and wear resistance to that of stir cast composite. The morphology of the worn surface and the wear debris were studied in detail.