Development of Mg-Zn-Mn Surface Composites Reinforced with ZnO Through Friction Stir Processing and Investigation of Corrosion and Wear Behavior

Abstract Magnesium (Mg) composites exhibit exceptional properties, making them ideal for diverse applications in the medical, aerospace, and energy industries. The extensive use of Mg-based composites has driven ongoing efforts to enhance their properties and performance. Therefore, the present work focused on the fabrication of Mg-Zn-Mn surface composites reinforced with Zinc oxide (ZnO) through friction stir processing (FSP). The effect of the addition of ZnO on microstructure, mechanical properties, corrosion, and wear behavior was investigated. The development of the microstructure is analyzed using a scanning electron microscope (SEM) and X-ray diffraction analysis. Surface topography and roughness are analyzed using atomic force microscopy (AFM) and revealed a Ra value of 68.4 nm. The mechanical properties of the friction stir processed samples are investigated using Vickers microhardness equipment. The FSP/ZnO-Mg-Zn-Mn surface nanocomposites demonstrated a microhardness of 152.7 Hv, which is 2.4 times greater than that of the H-Mg-Zn-Mn base materials. The enhancement in the corrosion resistance of the FSP/ZnO-Mg-Zn-Mn surface nanocomposites is primarily due to the combined effect of the refined grains and the uniform dispersion of ZnO particles. Furthermore, this surface composite had the best wear resistance as a result of significant grain refinement and higher hardness.