Rokkala, U.Gudala, S.Ramesh, M.R.2026-02-042024Journal of Materials Engineering and Performance, 2024, 33, 4, pp. 1578-158710599495https://doi.org/10.1007/s11665-023-08087-xhttps://idr.nitk.ac.in/handle/123456789/21317Mg alloys are becoming increasingly popular as lightweight materials in recent years. Wear resistance, on the other hand, is a severe issue with Mg alloys. Plasma spray and friction stir processing (FSP) are being investigated in this context for developing composite surfaces with improved surface characteristics. Scanning electron microscopy (SEM), energy dispersive spectroscopy, and x-ray diffraction are used to examine the microstructural changes and phase changes of all materials. After FSP, SEM analysis indicated that the coated particles were equally dispersed throughout the Mg matrix. The composite samples had the lowest wear rate as compared to other samples, according to the wear tests. In comparison to AC, the F-1 sample surface has much higher wear resistance. As a consequence, the findings of this investigation for the F-1 sample appear encouraging for biological wear resistant applications. © ASM International 2023.Energy dispersive spectroscopyFrictionFriction stir weldingMagnesium alloysPlasma jetsPlasma sprayingScanning electron microscopyWear of materialsWear resistanceZinc alloysComparatives studiesComposite surfaceFriction stir processingLightweight materialsMg alloyMicrostructural changesMicrostructural phasisSurface characteristicsWear behaviorsWear propertiesTernary alloys