Advancement and mechanical performance of friction stir additive manufactured Al7075/ZrO₂/Gr composite

Purpose This study explores using friction stir additive manufacturing (FSAM) to develop high-performance laminated composites from AA 7075 alloy, incorporating zirconium oxide (ZrO 2 ) powder and graphene (Gr) reinforcements. It aims to report the limitations of traditional methods by enhancing hardness, compressive and tensile strength, and to show FSAM’s development for manufacturing durable, high-strength aluminium materials. Design/methodology/approach AA 7075 sheets were layered with ZrO 2 and Gr powders and joined using a tapered HSS triangular pin tool in the FSAM process. The composite was analyzed with scanning electron microscopy (SEM) and EDS for particle distribution, and its mechanical properties (hardness, compressive and tensile strength) were measured. Fractographic and corrosion resistance tests were also conducted. Findings FSAM effectively dispersed ZrO 2 and Gr in AA 7075 composites, resulting in improved mechanical properties: hardness of 88.64 HV, compressive strength of 249.56 MPa and tensile strength of 288.73 MPa. The tests confirmed better durability and performance compared to the base alloy. Originality/value This study introduces a novel FSAM approach for developing laminated AA 7075 composites with ZrO 2 and Gr reinforcements. This innovative reinforcement for wear resistance and flexibility respectively, produces novel possibilities for advancing materials processing and enhancing performance.