1. Multiresponse optimization applied to friction-stir processing to enhance wear and corrosion performance in Al–Si alloys
- Author
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Denner Traiano, Silvia do Nascimento Rosa, Luciano Augusto Lourençato, Angel Sánchez Roca, Mario César Sánchez Orozco, and Hipólito Domingo Carvajal Fals
- Subjects
Friction-stir processing ,Optimization ,Al‒Si alloys ,Microhardness ,Wear and corrosion ,Science (General) ,Q1-390 - Abstract
Abstract In this study, friction stir processing (FSP) parameters were optimized using the response surface method (RSM) to enhance hardness, reduce the friction coefficient and minimize the corrosion rate in cast Al12Si and Al14Si alloys. The FSP tool, made of AISI H13 tool steel, features a concave shoulder and conical pin designed to induce severe plastic deformation. Microstructural analysis was performed via optical microscopy and SEM–EDS, and the particle size and distribution were assessed via ImageJ software. Microhardness profiles were measured across the Nugget, TMAZ, HAZ, and substrate zones. The corrosion resistance was evaluated using an AutoLab potentiostat/galvanostat following ASTM G59-97 standards, whereas the wear performance was assessed using a reciprocating linear tribometer (ASTM G133). FSP led to the fragmentation and uniform distribution of silicon and Fe-rich intermetallic phases within the aluminum matrix. The multiresponse optimization identified the optimal FSP parameters for Al12Si alloys at a tool rotation speed of 1100 rpm and a travel speed of 16 mm/min. Under these conditions, the Al12Si samples presented the highest microhardness (93 Hv), significant fragmentation of silicon particles (2.82 μm) and Fe-rich intermetallic phases (2.07 μm), reduced friction coefficient (0.60) and low corrosion rate (1.28 × 10⁻4 mm/y). The proposed model offers a reliable method to optimize FSP, leading to aluminum surfaces with superior microstructure, hardness, wear resistance and corrosion resistance.
- Published
- 2024
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