Surface Modification and Parametric Optimization of Tensile Strength of Al6082/SiC/Waste Material Surface Composite Produced by Friction Stir Processing

Friction stir processing (FSP) is one of the promising tools to enhance the mechanical and microstructural features of any engineering material due to its excellence in grain refinement. Further, the successful utilization of waste material into a useful product instigates the use of chicken bone powder (CBP), walnut shell powder (WSP), and rice husk powder (RHP) as secondary reinforcement to develop surface composites and metal matrix composites to enhance the mechanical properties. In the present work, a surface composite of base alloy Al6082 is developed through the utilization of SiC as primary reinforcement and CBP, WSP, and RHP as secondary reinforcement. The experiments were performed as per Taguchi’s L9 orthogonal array and the analysis of variance (ANOVA) response is discussed in detail. The process parameters taken for the study are the type of tool pin profile such as hexagonal, square, and cylindrical threaded along with rotational speed and tool tilt angle. The result revealed the microstructural characterization through field emission scanning electron microscopy (FESEM) images equipped with energy-dispersive X-ray spectroscopy (EDS) phase mapping and elemental spectrum. The tensile strength of each specimen was tested through a horizontal tensometer and further studied to get the optimized value of the process parameter to achieve a larger value. The use of a hexagonal pin profile with the optimized value of the rotational speed of 1500 rpm and 3° tilt angle gives the higher tensile strength of 250.64 MPa.