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The aluminum (Al) alloy AA7075 is widely used in various industries due to its high strength-to-weight ratio, which is comparable and replaceable to steel in many applications. However, it has poor resistance to wear and corrosion compared to other Al alloys. The conventional pressure die coating with Cr and cadmium has led to premature failure while the load is applied. It is indeed to develop a novel coating method to improve the mechanical, wear, and corrosion properties of AA7075 Al alloy. In the present investigation, the binary and ternary metals such as zinc–nickel (Zn–Ni), zinc–cobalt (Zn–Co), and nickel–chromium–cobalt (Ni–Cr–Co) are electroplated on the substrate material (AA7075). In order to ensure optimal coating adhesion, the surface of the substrate material was pre-treated with laser surface treatment (LST). The mechanical and corrosion studies have been carried out on the uncoated and coated materials. It is observed from the findings that the ternary coating has higher wear resistance than the binary-coated material. The ternary coating has 64% higher resistance in the non-heat-treated status and 67% higher resistance in the heat-treated condition compared to the uncoated specimens. The tensile strength (MPa) of Ni–Cr–Co on AA7075 pressure die casting (PDC) is higher than the other deposits (582.24 of Ni–Cr–Co > 566.07 of Zn–Co > 560.05 of Zn–Ni > 553.64 of uncoated condition). The presence of a crystalline structure with the high alignment of Co and Ni atoms could significantly improve the corrosion resistance of Ni–Cr–Co coatings on AA 7075 PDC substrates when compared to binary coatings. The scanning electron microscopy (SEM) images, X-ray diffraction (XRD), and X-ray photoelectron spectroscopy findings on the coated materials have been corroborated with the analyses on mechanical and corrosion properties. The XRD analysis of the Zn–Ni binary coating has reported that the diffraction peaks of γ-NiZn3 (831), γ -Ni2Zn11 (330), and 631 with 2θ values 38, 43, and 73° are confirming the presence of Zn–Ni binary deposit on AA7075 PDC substrate. The XRD pattern of Zn–Co-coated material has revealed that the presence of three strong peaks such as Zn (110), Co (111), and CoZn (211) and two feeble peaks such as ε-CoZn3 (220) and ε-CoZn3 (301) are clearly visible. The XRD pattern of Ni–Cr–Co ternary coating has exhibited that the Ni–Cr–Co ternary deposit is a solid solution with a body-centered cubic structure due to the formation peaks at lattice plane such as (110), (220), and (210) with a crystal lattice constant of 2.88 A°. The SEM image for both the binary- and ternary-coated materials has exhibited that the deposited surface has displayed many shallow pits due to hitting by progressive particles. The SEM image has illustrated the presence of Zn–Ni atoms with smaller globular structure. The surface morphology of binary Zn–Co coating on the PDC AA7075 substrate has unveiled the evenly distributed dot-like structure and submerged Co particles in the galaxy of Zn atoms. To understand the effectiveness of bonding by laser texturing, cross-section SEM has been carried out which furthermore revealed the effective adhesion of Ni–Cr–Co on AA7075 PDC; this could also be the reason for the enhancement of microhardness, wear, and corrosion resistance of the said coating.

Exploring high strength materials with a higher concentration of reinforcements in the alloy proves to be a challenging task. This research has explored magnesium-based composites (AZ31B alloy) with tungsten carbide reinforcements, enhancing strength for medical joint replacements via league championship optimisation. The primary objective is to enhance medical joint replacement biomaterials employing magnesium-based composites, emphasising the AZ31B alloy with tungsten carbide reinforcements. The stir casting method is utilised in the manufacture of magnesium matrix composites (MMCs), including varied percentages of tungsten carbide (WC). The mechanical characteristics, such as micro-hardness, tensile strength, and yield strength, have been assessed and compared with computational simulations. The wear studies have been carried out to analyse the tribological behaviour of the composites. Additionally, this study investigates the prediction of stress and the distribution of forces inside bone and joint structures, therefore offering significant contributions to the field of biomedical research. This research contemplates the use of magnesium-based MMCs for the discovery of biomaterials suitable for medical joint replacement. The study focuses on the magnesium alloy AZ31B, with particles ranging in size from 40 to 60 microns used as the matrix material. Moreover, the outcomes have revealed that when combined with MMCs based on AZ31B-magnesium matrix, the WC particle emerges as highly effective reinforcements for the fabrication of lightweight, high-strength biomedical composites. This study uses the league championship optimisation (LCO) approach to identify critical variables impacting the synthesis of Mg MMCs from an AZ31B-based magnesium alloy. The scanning electron microscopy (SEM) images are meticulously analysed to depict the dispersion of WC particulates and the interface among the magnesium (Mg) matrix and WC reinforcement. The SEM analysis has explored the mechanisms underlying particle pull-out, the characteristics of inter-particle zones, and the influence of the AZ31B matrix on the enhancement of the mechanical characteristics of the composites. The application of finite element analysis (FEA) is being used in order to make predictions regarding the distribution of stress and the interactions of forces within the model of the hip joint. This study has compared the physico-mechanical and tribological characteristics of WC to distinct combinations of 0%, 5%, 10% and 15%, and its impact on the performance improvements. SEM analysis has confirmed the findings' improved strength and hardness, particularly when 10%–15% of WC was incorporated. Following the incorporation of 10% of WC particles within Mg-alloy matrix, the outcomes of the study has exhibited enhanced strength and hardness, which furthermore has been evident by utilising SEM analysis. Using ANSYS, structural deformation and stress levels are predicted, along with strength characteristics such as additional hardness of 71 HRC, tensile strength of 140–150 MPa, and yield strength closer to 100–110 MPa. The simulations yield significant insights into the behaviour of the joint under various loading conditions, thus enhancing the study's significance in biomedical environments. [ABSTRACT FROM AUTHOR]