Influence of tool rotational speed on microstructure and sliding wear behavior of Cu/B₄C surface composite synthesized by friction stir processing

An attempt was made to synthesize Cu/B₄C surface composite using friction stir processing (FSP) and to analyze the influence of tool rotational speed on microstructure and sliding wear behavior of the composite. The tool rotational speed was varied from 800 to 1200 r/min in step of 200 r/min. The traverse speed, axial force, groove width and tool pin profile were kept constant. Optical microscopy and scanning electron microscopy were used to study the microstructure of the fabricated surface composites. The sliding wear behavior was evaluated using a pin-on-disc apparatus. The results indicate that the tool rotational speed significantly influences the area of the surface composite and the distribution of B₄C particles. Higher rotational speed exhibits homogenous distribution of B₄C particles, while lower rotational speed causes poor distribution of B₄C particles in the surface composite. The effects of tool rotational speed on the grain size, microhardness, wear rate, worn surface and wear debris were reported.