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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.

Roller burnishing (RB) is a finishing treatment method that is used to impart certain physical and mechanical properties, such as surface roughness, improved visual appearance, or increased corrosion, friction, wear, and fatigue resistance. The purpose of this paper is to study, the influence of RB on corrosion resistance in A53 steel in HCl solution.

Microhardness (MH), microstructure, weight loss, and potentiostatic polarization are investigated at pressing forces of 40, 60, 80, 100 and 120 N.

MH increases with increasing the applied force and the percentage improvements are found to be 12, 24, 28, 35 and 65 percent for 40, 60, 80, 100 and 120 N RB pressing forces, respectively. Weight losses, in general, showed an optimum value at about 80 N. Corrosion potential and corrosion current decrease with increasing pressing force and reached a minimum at about 80 N, then begin to increase with increasing RB force.

The results present in this paper are important to the understanding of the effect of the surface plastic deformation methods on surface properties and corrosion resistance in steel.