Mechanical and wear properties of AA7075-T6 reinforced with SiC and Aloevera ash, fabricated using Friction stir processing (FSP) are investigated in this study. Due to less density, easy availability, and cost-effectiveness, aloevera ash is considered as one of the reinforcements. FSP is done using a square tool pin profile, at different tool rotational speeds. To study wear behaviour, pin on disc test is carried out on High Temperature Rotary Tribometer at 20N, 30N and 40N applied load. Wear increases on increasing the applied load and at 20N load Al+SiC/Aloevera ash composite, processed at 600 tool rpm gave the best results due to the formation of oxide tribolayer. At 30N and 40N applied load Al+SiC composite, processed at 900 tool rpm showed the least wear because of proper scattering of ceramic particles due to high tool rotational speed. Coefficient of friction increases on increasing the applied load and all fabricated composite samples showed a lesser coefficient of friction than the base metal. Microhardness, ductility and Ultimate tensile strength increases on the addition of reinforcement and had a direct relation with tool rpm. Wear morphology was analysed using Scanning Electron Microscope (SEM). Energy Dispersive Spectroscopy (EDS) analysis after wear shows the presence of C, Fe, O, Mg, Zn, Si, Al elements and confirms the formation of an oxide layer which is responsible for decreasing wear loss.

Among several methods to fabricate Aluminium metal matrix composites, stir-casting technique is used for large-scale production due to its being less expensive. This research is concerned with the fabrication of Aluminium composites with SiC and Jute Ash Particles, for sake of producing a cost-effective composite with enhanced properties. Wear behaviour was studied using pin on disc tribometer and it was found that wear resistance increases with-addition of reinforcement particles. Fabricated composite samples showed almost 4 times better wear resistance compared to base material. Matrix metal reinforced with SiC showed the best wear resistance of all fabricated samples. Coefficient of friction significantly decreased with the presence of reinforcement due to formation of mechanical mixed layer. Tensile Strength was escalated with the introduction of reinforcement as load is transferred to strongly bonded reinforcement particles. Microhardness was enhanced with the introduction of reinforcement and Sample 2 with SiC as reinforcement showed the best microhardness. Microstructure and fractography of the base metal and fabricated composites was analyzed by Scanning Electron Microscope (SEM).

In the present research work, AA7075 composite reinforced with silicon carbide particles has been fabricated using Friction stir processing (FSP). The silicon carbide particles having a size of 40 μm were placed in grooves of length 160 mm, width 2 mm, depth 3.5 mm, that were generated on the AA7075 plate. The square pin tool is utilized for fabricating the composite at two different rotational speed i.e. 700 and 1000 rpm. Effect of processing, particle addition and tool rotational speed is analyzed on mechanical and wear properties of the material. On friction stir processing the microhardness value and elongation of the material increased. Reinforcement addition contributed to decrease in ductility and tensile strength while on the contrary microhardness and wear resistance of the material improved. Tool rotational speed showed a direct relation with the tested mechanical and wear properties. Adhesive wear was the prominent wear mechanism and Fe layer formation was observed on the worn surface, contributing to increased wear resistance. These fabricated composites can find vast application in industries like automotive, defence and aerospace.

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