Enhancing wear resistance of aluminum 6061 composites with fly ash: A sustainable approach for industrial applications

This study investigated the benefits of adding fly ash as a reinforcement material. The benefits included cost-effectiveness, improved quality, isotropic behavior, and environmental advantages. To improve self-lubrication and wettability behavior, Al6061 alloy composites were fabricated with differe...

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Bibliographic Details
Published in:Advances in mechanical engineering 2024-10, Vol.16 (10)
Main Authors: Kumar, Raj, Bairwa, Kedar Narayan, Vemanaboina, Harinadh, Naidu, BoyaVishnu Vardhana, Shoush, Kamel A, Pushkarna, Mukesh, Tuka, Milkias Berhanu, Ghoneim, Sherif SM
Format: Article
Language:English
Subjects:
Aluminum base alloys
Composite materials
Composition
Cost effectiveness
Deformation effects
Deformation wear
Design of experiments
Fly ash
Graphite
Image enhancement
Industrial applications
Industrial development
Magnesium
Mechanical properties
Parameter identification
Scratch resistance
Self lubrication
Sliding
Sustainable materials
Variance analysis
Wear rate
Wear resistance
Wear tests
Wettability
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Summary:This study investigated the benefits of adding fly ash as a reinforcement material. The benefits included cost-effectiveness, improved quality, isotropic behavior, and environmental advantages. To improve self-lubrication and wettability behavior, Al6061 alloy composites were fabricated with different amounts of fly ash (0%, 2%, 4%, 6%, and 8% by weight), along with a fixed amount of graphite (3wt.%) and magnesium (2wt.%). Wear tests were conducted using Taguchi’s Design of Experiment (DoE) approach on the composites. The optimized composition with 6% fly ash exhibited the least wear rate under the test conditions of load = 10 N, sliding velocity = 3 m/s, and sliding distance = 2 km. SEM images revealed a uniform distribution of fly ash and graphite reinforcement in the matrix, contributing to enhanced wear resistance. The composites exhibited fewer scratches and plastically deformed surfaces, indicating a decrease in wear rate and increased wear resistance with higher fly ash content. ANOVA were used, and four parameters were identified to be critical, Composition at 34%, Sliding Distance at 27%, load at 23%, and Sliding Velocity at 12% contribution with a statistical confidence of 95%. This research contributes to developing cost-effective and environmentally sustainable materials with improved mechanical properties. It makes them suitable for various industrial applications, such as the automotive industry, where wear resistance is essential.
ISSN:1687-8132
1687-8140
DOI:10.1177/16878132241290913