Parametric Study for Improved Mechanical Performance of AA1050 Aluminum Alloy using Friction Stir Surface Treatment | ||
| Port-Said Engineering Research Journal | ||
| Articles in Press, Accepted Manuscript, Available Online from 19 November 2025 | ||
| Document Type: Original Article | ||
| DOI: 10.21608/pserj.2025.414551.1435 | ||
| Authors | ||
| Yasmine El-Taybany* 1; Ghada Elhendawy2 | ||
| 1Production Engineering and Mechanical Design Department, Faculty of Engineering, Port Said University, Port Said, Egypt. | ||
| 2Mechanical Engineering Department, Faculty of Engineering, Damietta University, Damietta, Egypt | ||
| Abstract | ||
| This work investigates the efficacy of Friction Stir Surface Treatment (FSST), as an innovative surface modification technique, in enhancing the surface mechanical properties of AA1050 aluminum alloy. A comprehensive experimental study was employed to systematically evaluate the influence of key FSST processing parameters: rotational spindle speed (N), feed rate (f), tool design (pinless vs. single pin), and number of passes. Taguchi L16 orthogonal array was utilized for the determination of the most important parameters affecting FSST process. The improvement in the surface characteristics was evaluated specifically focusing on surface microhardness and mechanical wear resistance compared with the base material. Results revealed that rotational spindle speed and tool design emerged as the most dominant factors influencing both properties. Notably, FSST conditions leading to higher microhardness consistently resulted in reduced material weight loss. Optimization of the FSST parameters identified that a pinless tool with a single pass, processed at a rotational speed of 280 rpm and a feed rate of 100 mm/min. Under these conditions, microhardness was maximized to ≈ 128 HRV, while weight loss was minimized to ≈ 0.0011 g, demonstrating significant enhancement compared to the base material. This research provides valuable insights for tailoring FSST parameters to achieve superior surface characteristics in AA1050 for various industrial applications. | ||
| Keywords | ||
| Friction stir surface treatment; aluminum alloy; surface microhardness; mechanical wear; Taguchi method | ||
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