Optimizing the Mechanical and Microstructure Characteristics of Stir Casting and Hot-Pressed AA 7075/ZnO/ZrO2 Composites

The composite was made using the stir cast manufacturing method. Many parameters, like stirring speed, stirring time, ZrO2% reinforcement, and cast temperature, are evaluated in a Taguchi experimental design to see how they affected the composite properties. In terms of composite properties, ZrO2% reinforcement and the stir speed have the most significant impact. There were 25.02% gains in ultimate tensile strength and hardness, as well as a decrease in composite wear loss, when the optimal stir casting parameters were used compared to the initial stir casting settings. To get insight into the process and the qualities of the composite, the hot-pressing parameters were studied. Pressure, followed by temperature, is the most critical factor in determining the properties of composites. When a hot-pressing setting was determined to reduce the wear loss by a significant 39.3%, it was deemed perfect by the superranking concept. Under ideal conditions, hot-pressing procedures reduced wear loss by 40.8% while boosting ultimate tensile strength and hardness by 19.83% and 9.6%, respectively. The resulting microstructures and worn surface morphologies from stir casting and hot pressing show vastly different properties.