In this study, copper/ZrO2 surface composites were produced using nano-particles via friction stir processing in order to enhance surface tribological properties. The present research aimed to generate copper matrix composites and analyze the effect of processing parameters on the evolving microstructure, microhardness, and wear-resistance behavior. It is worth noting that the processed composite layer had more homogeneity in the four-pass process. In comparison to the base metal and non-powder samples, it had higher mechanical characteristics. Based on the results, the highest recorded hardness, approximately 288 HV, was found in a four-pass state with powder. Remarkably, it showed a double peak compared to 80 HV in the base metal. The lowest friction coefficient of four-passes with the powder sample was about 0.47, which showed a significant efficiency in comparison to the friction coefficient of base metal that was about 0.81.
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