The friction stir process (FSP) is becoming a highly utilized method to manufacture composites since it refines the microstructure and improves the physical characteristics like hardness, strength, and wear resistance of their surfaces. In this study, the hardness and wear behaviours of Al6061-based surface composites prepared by the FSP were investigated and compared for the influences of various parameters-FSP tool geometry, reinforcement composition, number of FSP passes, pin load, etc. The Taguchi design with an L27 orthogonal array was developed to analyze the influence of five input parameters on the output parameter, i.e., wear rate during wear tests. The hardness of the composite samples for different reinforcement compositions was investigated, and the results were statistically compared with the obtained wear rates. It was concluded from the results that various parameters influenced the surface wear and hardness of the composites. Tool geometries cylindrical pin and square pin had the maximum and minimum wear rates, respectively. Additionally, the optimal composition of the reinforcements copper and graphene as 1:3 possessed the maximum wear rate and minimum hardness. However, the reinforcement composition 3:3 (Cu:Gr) by weight had the minimum wear rate and maximum hardness. The higher the FSP pass numbers, the lesser the wear rate and the higher the hardness, and vice-versa. This work helps identify the influence of numerous factors on the wear and hardness aspects of surface composites prepared by the FSP. In the future, this study can be modified by combining it with thermal analysis, sensor data analysis of the composites, and optimization of the parameters for desirable microstructure and physical properties.
Keywords: Al6061; friction stir process; hardness; surface composite; wear.