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A clear understanding of heat transmission and material course during the friction stir processed (FSP) ZK60 magnesium alloy (Mg) can help eliminate flaws like cracks, voids, and flash. It enhanced the mechanical properties of the FSP of ZK60 Mg alloy. It is mainly controlled by process parameters like axial force, plunge depth, tilt angle, shoulder diameter, traverse speed, and rotational speed. Our investigation focuses on the influence of advanced factors such as tool tilt angle (TTA-deg), rotational tool speed (TRS-rpm), and tool traverse speed (TTS-mm/min), with the aid of the design of experiment technique by Box Behnken method to enhance the hardness. It is necessary to develop finite element models to support experimental results. And is further preceded by transient temperature dispersion throughout FSPed ZK60 Mg alloy fabricated through the Finite Element process. The temperature fields determined numerically engage well by trial data and the highest temperature throughout the FSPed at the stir zone. The temperature distribution is simulated by TRS and TTS in which higher temperature is relative to TRS and indirectly close to TTS. From the model, the highest temperature was determined to be 462°C, which is particularly fewer than the plate’s melting temperature.

Process factors optimisation for friction stir process of ZK 60 magnesium alloy employing Box Behnken approach