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This work concentrated on preparation of Al-based composites through stir casting process. Al6082 was chosen as base material that is reinforced with zirconium silicate and titanium carbide. As per Taguchi design L16 orthogonal array, specimens are produced with variation of casting parameters for performing tensile and hardness test. In this process, ZrSiO₄ is kept constant to 10 wt%, whereas TiC concentration varied from 2.5 to 10wt%. For analyzing the properties of optimized stir cast samples for AA6082/ZrSiO4/TiC, three input variables with four levels are taken such as Stir speed (SS) 300-750 rpm, Stir time (ST) 5-20 min, and Reinforcement (RI) 2.5-10 wt%. The Taguchi technique was used as an analyzer to determine optimal parameter on Tensile Strength (TS) and Hardness (HN). The Minitab-17 software is assisting to find analysis of variance (ANOVA), regression equation, and contour plots of the selected parameters. Finally, it is witnessed that SS (65.9%) is the maximum influenced factor that increases TS, followed by RI (23.1%) and ST (11%). The best combinations of parameters on TS and HN were found at SS2-ST1-RI2 (450 rpm, 5 min, and 5wt%) and SS3-ST2-RI4 (600 rpm, 10 min, and 10wt percent), respectively. From the contour plots, the casting variables SS (600-650 Rpm), ST (15-17.5 min), and RI (5-8 wt%) were proposed for achieving excellent mechanical properties.

The friction stir welding (FSW) of steel is a challenging task. Experiments are conducted here, with a tool having a conical pin of 0.4mm clearance. The process parameters are optimized by using the Taguchi technique based on Taguchi's L 9 orthogonal array. Experiments have been conducted based on three process parameters, namely, the tool rotational speed, tool tilt angle and travel speed. Tensile strength has been predicted for the Optimum welding parameters and their percentage of contribution in producing a better joint is calculated, by applying the effect of the signal-to-noise ratio and analysis of variance. Based on the study, the tool tilt angle is found to be the most significant variable over the other process parameters, and it enhances the quality of the weld on steel rather by the tool axis which is perpendicular to the work plate. The optimum tensile strength predicted through the ANOVA is 472 MPa. Confirmation tests have been performed for the resulting optimum parameter and the average tensile strength was found to be 474 MPa. A metallurgical analysis for the optimum parameter was performed on the specimens and typically two distinct Heat affected zones (HAZ) were observed with variation in the micro structure.

The mechanical properties of different polymer matrix composites are discussed in this research study. These composites are multiphase materials in which reinforcing elements and a polymer matrix are suitably combined. The mechanical properties of 18 PMCs, including nylon 66 reinforced with 5, 15, and 25% wt% silicon carbide (SiC) and nylon 66 reinforced with 5, 15, and 25% wt% boron carbide (B4C), were evaluated using an injection moulding technique at three different injection pressures in this study. The optimization of process parameters like reinforcement material, reinforcement quantity, and injection pressure to maximize the tensile and impact strength of nylon 66 composites are the main focus of this study. It is observed that the specimens 25% SiC with an injection pressure of 90 MPa has optimised tensile strength, while the specimen 5% B4C with an injection pressure of 90 MPa has optimised impact strength.

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