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September 5, 2026Rapid Prototyping Journal

Taguchi-based optimization of friction stir additive manufacturing for AA6061 eggshell-graphene hybrid composites

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Authors

SKSanjay KumarPKPramod KumarMKManoj Kumar

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Overview

Experimental optimization reveals enhanced tensile strength in AA6061 eggshell-graphene composites, indicating the viability of eco-friendly solid-state additive manufacturing.

Key Points

  • To optimize the friction stir additive manufacturing process parameters for developing high-strength AA6061 hybrid metal matrix composites reinforced with eggshell powder and graphene nanoplatelets.
  • Implemented a Taguchi L16 orthogonal array on a vertical machining center to assess the impact of tool rotational speed, traverse speed, and reinforcement weight percentage.
  • Evaluated parameter significance using signal-to-noise ratio and ANOVA, and characterized reinforcement dispersion and microstructure via optical microscopy, FESEM, and energy-dispersive X-ray spectroscopy.
  • Tool rotational speed served as the dominant parameter influencing tensile strength, accounting for approximately 78% of the total variation.
  • Fabrication using optimal conditions (4000 rpm rotational speed, 20 mm/s traverse speed, and 10 W%R reinforcement) yielded a peak tensile strength of approximately 387 MPa.
  • Microstructural analysis confirmed refined grains, uniform reinforcement dispersion, robust interlayer bonding, and dimpled ductile fracture features.

Cite This Study

Kumar et al. (2026) studied this question.

synapsesocial.com/papers/6a9bd4436b95aff0620ebd63https://doi.org/10.1108/rpj-03-2026-0159
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Also Consider

Synapse has enriched 5 closely related papers on similar clinical questions. Consider them for comparative context:

  1. 1Fabrication and Characterization of AA7075/Al 2 O 3 /Graphene Hybrid Composites via Friction Stir Additive Manufacturing2026
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  3. 3Evaluation of mechanical properties of recycled stainless-steel chips and glass waste particle reinforced AA6061 composites via friction stir processing2026
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  5. 5Fabrication, mechanical characterization, and wear optimization of Al6061-CSAp metal matrix composites using hybrid Taguchi-ARAS-Sunflower Algorithm Approach2026 · 1 citations