Marble Dust-Enhanced Friction Stir Processing of AA7075: Impacts on Mechanical and Material Characteristics

Abstract

The study investigated the effect of adding Marble dust particles as reinforcement in different weight percentages (Wt.%) to AA7075 aluminum-based surface composites manufactured by Friction Stir Processing (FSP). The composites were produced by evenly distributing the Marble dust particles in the aluminum matrix through FSP, with a fixed set of input variables including a tool rotational speed (TRS) of 1250 rpm, a tool traverse speed (TTS) of 45 mm/min, and a tool tilt angle (TTA) of 1º. The output response was analyzed, that the addition of marble dust particles resulted in increased ultimate tensile strength (UTS) in the aluminum matrix. However, the impact strength was reduced. To understand the surface morphology of the wear samples, scanning electron microscopy (SEM) was used. From the SEM observations, it was evident that the Marble dust particles were evenly distributed in the aluminum matrix, indicating good particle incorporation during the FSP process. Overall, the results suggest that the addition of Marble dust particles can significantly enhance the impact strength and UTS of aluminum-based surface composites produced through FSP.