| Summary: | Friction stir processing (FSP) has emerged as an effective technique for enhancing the mechanical and microstructural properties of metal matrix composites. This study investigates the influence of FSP parameters on the mechanical characteristics and microstructure of AZ31B magnesium alloy reinforced with silicon carbide particles of size APS < 80 nm. The method employed here is a hole method for reinforcement and designed with an L9 orthogonal array to analyze the effects of tool geometry, rotational speed, traverse speed, and hole diameter. The experimental findings indicate that a cylindrical threaded tool pin profile, a 0.8-mm hole diameter, a rotational speed of 765 revolutions per minute, and a traverse speed of 31.5 mm/min resulted in the most optimal combination of mechanical properties, including improved tensile strength, micro-hardness, and elongation. Microstructural analysis revealed a uniform distribution of SiC particles, leading to grain refinement and enhanced material performance. These results demonstrate that FSP is a sustainable approach for fabricating high-performance magnesium-based composites, making them suitable for applications in aerospace, automotive, and biomedical industries.
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