Surface composites (SCs) of aluminium-magnesium (Al–Mg) alloys reinforced with nano and micro silicon carbide (SiC) particles were fabricated using friction stir processing (FSP). The SCs were fabricated by multi-pass (five passes) FSP using a H13 steel tool. An investigation of the microstructural evolution, mechanical properties, wear behaviour, and corrosion resistance was conducted. The study revealed that nano-SiC reinforced SCs outclassed the micro-SiC reinforced as well as base metal (BM) counterparts in all domains. The ultimate tensile strength (337 MPa) and yield strength (315 MPa) of nano-SiC reinforced were 25.2% and 26.5% higher than BM (269 MPa and 249 MPa) and 13.5% and 11.3% higher than micro-SiC reinforced SC (287 MPa and 263 MPa), respectively. The wear rate in nano-SiC reinforced SC reduced significantly by about 16.67%, 14.73%, and 14.43% compared to BM and by 4.76%, 7.4%, and 7.78% compared to micro-SiC reinforced SC at 15N, 20N, and 25N loads, respectively. The nano-SiC reinforced SC showed 60% better corrosion resistance compared to BM and 50% better than micro-SiC reinforced SC. These improvements in reinforced SCs are attributed to various reasons: grain refinement due to FSP, uniform distribution of hard ceramic particles within the Al matrix, and the reduction in wear and corrosion-prone sites due to multiple FSP passes that minimise the agglomeration of reinforcement particles. This enhancement in the properties of nano-SiC-reinforced Al–Mg SCs makes them suitable for various applications in marine, automobile, and aerospace engineering domains.
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