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<p>This study presents the fabrication and characterization of AA6061-based hybrid nanocomposites reinforced with silicon carbide (SiC) and graphite (Gr) nanoparticles via a novel stir-ultrasonic-squeeze casting method. Composites were synthesized with 0, 2, and 3 wt.% SiC, while Gr was kept constant at 2 wt.%. Microstructural analysis using optical microscopy, FESEM-EDS, and XRD confirmed a refined grain structures and uniform dispersion of reinforcements. The addition of nanoparticles transformed the dendritic microstructure of as-cast AA6061 into fine, equiaxed grains, improving mechanical properties. The composite with 2 wt.% SiC and 2 wt.% Gr showed a 28.48% increase in Brinell hardness and a 15.9% rise in ultimate tensile strength (UTS) over the unreinforced alloy. Tribological testing under dry sliding revealed a 63.5% reduction in the coefficient of friction and significantly reduced wear rate. Increasing SiC to 3 wt.% enhanced hardness but also increased porosity and wear rate, highlighting a hardness–wear trade-off. Worn surface analysis indicated reduced wear in the nanocomposites due to higher hardness and presence of Gr. The findings confirm that this hybrid casting approach effectively enhances microstructure, mechanical performance, and wear resistance in aluminium nanocomposites.</p>

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Mechanical and Tribological Performance of AA6061 Hybrid Nanocomposites Produced by Stir-Ultrasonic-Squeeze Casting Method

  • 期刊论文

  • 发表日期：

    2025年9月23日

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  • Utkarsh Pandey,
  • Joyjeet Ghose,
  • Bappa Acherjee,
  • Gayatri Paul

摘要

This study presents the fabrication and characterization of AA6061-based hybrid nanocomposites reinforced with silicon carbide (SiC) and graphite (Gr) nanoparticles via a novel stir-ultrasonic-squeeze casting method. Composites were synthesized with 0, 2, and 3 wt.% SiC, while Gr was kept constant at 2 wt.%. Microstructural analysis using optical microscopy, FESEM-EDS, and XRD confirmed a refined grain structures and uniform dispersion of reinforcements. The addition of nanoparticles transformed the dendritic microstructure of as-cast AA6061 into fine, equiaxed grains, improving mechanical properties. The composite with 2 wt.% SiC and 2 wt.% Gr showed a 28.48% increase in Brinell hardness and a 15.9% rise in ultimate tensile strength (UTS) over the unreinforced alloy. Tribological testing under dry sliding revealed a 63.5% reduction in the coefficient of friction and significantly reduced wear rate. Increasing SiC to 3 wt.% enhanced hardness but also increased porosity and wear rate, highlighting a hardness–wear trade-off. Worn surface analysis indicated reduced wear in the nanocomposites due to higher hardness and presence of Gr. The findings confirm that this hybrid casting approach effectively enhances microstructure, mechanical performance, and wear resistance in aluminium nanocomposites.