Prediction of mechanical and wear properties of copper surface composites fabricated using friction stir processing

•Fabrication of Cu/B4C surface composite by friction stir processing.•Development of empirical relationships to predict the properties of surface composite.•Analyzing the effect of FSP parameters on the properties of surface composite.•Explaining the effect of FSP parameters using microstructural characterization.

Friction stir processing (FSP) has evolved as a novel solid state method to prepare surface composites. In this work, FSP technique has been successfully applied to prepare copper surface composites reinforced with variety of ceramic particles such as SiC, TiC, B4C, WC and Al2O3. Empirical relationships are developed to predict the effect of FSP parameters on the properties of copper surface composites such as the area of the surface composite, microhardness and wear rate. A central composite rotatable design consisting of four factors and five levels is used to minimize the number of experiments. The factors considered are tool rotational speed, traverse speed, groove width and type of ceramic particle. The effect of those factors on the properties of copper surface composites is analyzed using the developed empirical relationships and explained in this paper taking into account the microstructural characterization of the prepared copper surface composites. B4C reinforced composites have higher microhardness and lower wear rate.

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