Repetitive Corrugation and Straightening (RCS) on sheet geometries causes Cyclic Plastic Deformation, resulting in potential improvements of mechanical characteristics in metals and alloys. In this study, sample sheets of Al 2024 are subjected to severe plastic deformation with specially designed corrugated rollers to generate heterogeneous repeated plastic deformation at room temperature. The material shows enhanced properties under severe plastic deformation, with 5.07% increase in tensile strength, compared to unprocessed material. Maximum tensile strength was observed at annealed temperature of 150 °C is of about 3.49% increase in tensile strength over other temperature conditions. A wear study was carried out by considering the processed sheet that yields high tensile strength (annealed at 150 °C) by varying process parameters like sliding distance, load and sliding velocity as per design of experiments. In comparison to all other combinations, the wear resistance was shown to be better with a sliding distance of 6000 m, a load of 9.81 N, and a sliding velocity of 1.45 m s−1. The Response Surface Methodology (RSM) approach was adopted for comparing purpose, the experimental findings are found to be more similar to the RSM approach’s outcomes.

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