Optimization of Effective Parameters in the Stir Friction Extrusion Process on Porosity and Tensile Strength of SiC Ceramic Particles Reinforced AA1050 Aluminum Matrix Composite

This research, involved dynamic optimization of process parameters on the porosity and tensile strength of AA1050/SiC aluminum composite wires produced by friction stir extrusion (FSE) was carried out. In this regard, SiC ceramic particles reinforced AA1050 composite samples were produced using the FSE process. Also, response surface methodology (RSM) was used to design of experiment. The rotational speed of the punch, extrusion force, and reinforcement percentage weight were determined as input variables of the process. The porosity and tensile strength of produced composite samples were determined as response variables. Analysis of variance (ANOVA) and regression analysis were used to analyze the obtained data. The results showed that rotational speed, extrusion force with second-order effects, and reinforcement percentage with linear effects were effective on the tensile strength and porosity of composite samples. Also, the optimization of FSE process parameters to reach the minimum percentage of porosity and maximum tensile strength was performed using the desirability method. Finally, the optimization results were evaluated based on the validation test. Also, by achieving the maximum value of the desirability function (0.9852), the optimal conditions of process input variables were a rotational speed of 787 rpm, an extrusion force of 11.7 kN, and a reinforcement percentage of 3.86% to simultaneously achieve the maximum ultimate tensile strength (155.4 MPa) and minimum porosity percentage (0.45%). Also, the values obtained from the optimization were compared with the experimental values and the accuracy of the results in tensile strength and porosity were confirmed with 2.57% and 6.78% errors, respectively.