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Abstract
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In the realm of advanced materials engineering, the development of hybrid nanocomposites has
garnered significant attention due to their superior mechanical properties and potential applications.
The primary aim of this research is to develop a surface hybrid nanocomposite using Al1050
aluminium alloy (5 mm thickness) as the base material through friction stir processing. B 2O 3 nano-
powder, averaging 100 nm in size, and Cu micro-powder, averaging 5 μm in size, were incorporated
into the aluminium surface in various volume ratios using the Friction Stir Processing (FSP). The
processing parameters included a tool rotational speed of 1250 rpm, a feed rate of 50 mm min−1
, and a tilt angle of 3°. The number of passes was set at two levels: 1 and 3 passes. The influence of the volume
ratio of constituents and the number of passes on the microstructure and mechanical properties of the
resulting composite was thoroughly explored. The samples underwent tensile tests, microhardness
tests, and metallographic examinations using both Optical Microscopy (OM) and Field Emission
Scanning Electron Microscopy (FE-SEM). The composite with 25%-B2 O 3-75%-Cu composition
exhibited the highest stress and hardness values, measuring 139 MPa and 58.14 HV, respectively. The
enhanced strength of this sample is attributed to the presence of additives and the resultant grain size.
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