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This paper seeks to investigate the effect of roller burnishing on the surface roughness and hardness of Zn−5% Al alloyed by copper at varied percentages.

Copper was added to molten Zn−5%Al cast alloy at different percentages, then the roller burnishing process with different parameters was carried out on the five Zamac5−Cu alloys, however the effect on the surface roughness and hardness was investigated.

It was found that there is an enhancement on the hardness and the maximum is 18 per cent in Zamac5−10% Cu alloy. The best surfaces result was 0.05 μm that obtained at 0.04 mm rev ⁻¹ burnishing feed rate in Zamac5−10% Cu alloy.

The addition of copper is recommended to be added to Zamac5 up to percentage of maximum solubility of copper in Zamac5 alloy.

The purpose of this paper is to review, analyze and present the effects of the roller burnishing process on pure aluminum alloyed by pure copper at 3%, 6% and 9% percentages. Roller burnishing is one of the effective finishing treatment methods in terms of stabilization of surface layers properties along the depth, Roller burnishing is one of the effective methods used to improve the surface layer properties such as microhardness and average surface roughness.

Three different Al‐Cu alloys of 3%, 6% and 9% copper additions were prepared and microstructure, micro hardness and mechanical properties investigated. Then the roller burnishing mechanism was applied on Al‐Cu alloys on cylindrical work pieces, different conditions were used, and the results were obtained and discussed.

The best enhancement in hardness was 46.4% which was achieved at 9% Cu addition, whereas the best enhancement in the flow stress was 101.8% which was achieved at 9% Cu addition. Applying burnishing force 100 and 150 N resulted in an enhancement in the micro hardness of 80% and 102.8%, respectively, in the Al‐Cu% alloy, where the maximum enhancement on the surface roughness was 61% that resulted in pure Al when applying 150 N burnishing forces. Finally it was found that pure aluminum has the highest wear resistance.

This is new work on Al‐Cu alloys, thus the results after implementation of roller burnishing process are of great value and add an extra enhancement in the surface quality.