Optimization of FSP process parameters for hardness and tensile strength of cerium oxide reinforced copper composite using TOPSIS and Taguchi approach

Abstract In this study, a metal matrix composite is fabricated by mixing cerium oxide nanoparticles the copper metal via Friction Stir Processing (FSP). This research primarily attempts to analyse the impact of process parameters of FSP on the mechanical characteristics of the formed composite. Rotational speed, number of passes and transverse speed varied from 1000–1200 rpm, 1–3 and 25–45 mm min −1 respectively to explore the mechanical behaviour of composite in terms of tensile strength and hardness. Taguchi was utilized for designing the experimental matrix and thereafter integrated with TOPSIS technique for optimizing the output responses. Rotation speed 1200 rpm, transverse speed 25 mm min −1 and no of passes 2, turned out as optimum parametric setting. The maximum value of tensile strength and hardness were recorded as 442.854 MPa and 142.50 HV respectively Scanning electron microscopy (SEM) analysis was done for fracture surface which indicates ductile fracture. Further, Analysis of variance highlighted the dominance of rotational speed over other input variables in affecting the hardness as well as tensile strength of the composite. The study not only demonstrates the effectiveness of FSP in producing high-performance Cu-based composites but also provides a framework for tailoring properties through parameter optimization. The fabricated composite demonstrated superior mechanical properties. These insights can be directly applied to the development of durable structural components, electrical contacts, and thermal management systems where strength, hardness and reliability are critical.