Characterisation of Sustainable Aluminium Metal Matrix Composites with Alumina and Fly-ash-Cenosphere Processed by Ultrasonic-Stir-Squeeze Casting
摘要
Aluminium Matrix Composites (AMCs) have significant interest in materials science due to their superior mechanical properties, lightweight nature, and enhanced wear resistance compared to conventional aluminium alloys. This study explores the fabrication and characterisation of AMCs reinforced with alumina (Al2O3) and cenosphere using ultrasonic-assisted stir and squeeze casting techniques. Scrap aluminium alloy wheels were employed as the matrix. Six composite samples were prepared with 2 wt.% alumina and varying wt.% of cenosphere. Detailed characterisation was performed through optical microscopy for morphological studies and x-ray diffraction (XRD) for phase identification. Scanning Electron Microscopy (SEM), Field Emission Scanning Electron Microscope (FESEM) and High-Resolution Transmission Electron Microscopy (HRTEM) were used for microstructural and elemental analysis. Physical characterisation was done, including density and porosity measurements, while mechanical testing comprised tensile strength, compressive strength, hardness, and wear resistance. The composite with 2 wt.% alumina and 1.5 wt.% cenosphere exhibited the highest ultimate tensile strength of 227 MPa and the best wear resistance. The highest compressive strength of 465 MPa was achieved with 1.5 wt.% cenosphere. Microstructural analysis confirmed good dispersion and strong bonding of reinforcements within the matrix. These findings suggest that AMCs reinforced with 2 wt.% alumina and 1.5 wt.% cenosphere offer superior mechanical performance and are suitable for potential industrial applications.