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

Abstract

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.