Advancements in Aluminum-Based Composite Manufacturing: Leveraging ZrO2 Reinforcement through Friction Stir Process

Abstract

This paper explores advancements in aluminum-based composite manufacturing by leveraging ZrO2 reinforcement through the Friction Stir Process (FSP). The FSP method, utilizing an electric field to enhance sintering, ensures a highly uniform dispersion of nanoparticles within the material matrix, crucial for optimizing mechanical strength, thermal conductivity, and electrical performance. Micrograph analysis reveals the homogeneous distribution of ZrO2 particles, indicating the effectiveness of FSP. Tensile strength improves by 19.26%, hardness by 34.56%, fatigue strength by 22.45%, and wear resistance by 28.45% after integrating ZrO2 nanoparticles via FSP. These enhancements underscore the significance of nanoparticle reinforcement in fortifying aluminum alloys against various mechanical stresses and wear mechanisms. The findings highlight the potential of FSP-based techniques in tailoring the properties of aluminum-based composites for applications in aerospace, automotive, and manufacturing industries, where superior performance and durability are essential.