Wear behavior optimization of friction stir processed Mg-TiC composites through response surface methodology

Abstract This work examined the behavior of Mg-TiC composites fabricated using a stir casting process followed by a single-pass friction stir process (FSP). Morphological analysis revealed a uniform distribution of TiC reinforcement, effectively mitigating the reinforcement agglomeration issues. The composites processed at 1400 rpm (FSP) exhibited a 26% improvement in microhardness compared to cast Mg-TiC composites and 60% compared to pure Mg processed at the same parameters. The wear behavior was optimized using response surface methodology (RSM), considering load, sliding distance and sliding velocity as key parameters. The results exhibit an increase in the volumetric wear rate. The morphological examination of worn surfaces using scanning electron microscope (SEM), highlighted abrasive, adhesive, and oxidative wear mechanisms. The findings reveal the refined microstructure, enhanced microhardness, and superior wear behaviour of the processed magnesium matrix composites.