Optimization of friction stir processing parameters to produce AA2014/SiC surface composites using response surface methodology

Abstract In this study, Friction Stir Processing (FSP) was applied to produce surface composites of AA2014 by using SiC as a reinforcement. The main aim of the investigation is to study the influence of FSP on the microhardness of AA2014/SiC surface composites. A mathematical model was created by employing the Response Surface Methodology (RSM) to predict the microhardness properties by optimizing FSP parameters like tool rotating speed, tool tilt angle, tool traverse speed, and the number of FSP passes. It was observed that the tool traverse speed of 50 mm min −1 , 1000 rpm tool rotating speed, and tool tilt angle of 1° with 2 FSP passes produce surface composites with uniformly dispersed SiC particles. The grain size of the produced surface composites decreased from 26.9 μm in the base matrix to 16.7 μm in the FSPed specimens, enhancing microhardness by 6.25% in the cross-section and 15.36% in the top surface of the FSPed specimens. The dynamic recrystallization and generation of fine-grain microstructure played an essential role in enhancing the microhardness of the material. These results show the effectiveness of the RSM technique in optimizing the FSP parameters and producing the AA2014/SiC for enhanced microhardness applications in aerospace and automobile applications.