Friction Stir Processing (FSP) has emerged as an advanced solid-state processing technique to enhance the mechanical and tribological properties of aluminum matrix composites (AMCs). The wear behavior of FSP-processed AA7050-SiC composites by analyzing the influence of process parameters, SiC reinforcement, and tribological conditions. The composite specimens were fabricated using varying tool rotational speeds, traverse speeds, and tool tilt angles to achieve optimal microstructural refinement and reinforcement dispersion. Wear testing was conducted using a pin-on-disc tribometer under dry sliding conditions, and the wear rate was evaluated based on applied load, sliding speed, and distance. Microstructural characterization was performed using Scanning Electron Microscopy (SEM) to examine grain refinement, reinforcement dispersion, and wear track morphology. The results indicate that the incorporation of SiC significantly enhances hardness and wear resistance to grain boundary strengthening, load-bearing effects, and formation of a protective tribolayer. Statistical analysis using Analysis of Variance (ANOVA) was applied to determine the significance of processing parameters and their effect on wear performance. FSP conditions improve wear resistance by minimizing material loss, reducing wear debris formation, and enhancing interfacial bonding. This research provides insights into the optimization of FSP parameters for improving the tribological performance of AA7050-SiC composites, making them suitable for aerospace and structural applications.

Keywords: Friction stir process, AA7050-SIC, ANOVA