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<p>Achieving a balanced combination of mechanical and tribological behaviour in hybrid metal–matrix composites remains a serious challenge due to uneven reinforcement dispersion and interfacial unsuitability. This research examines the synergistic effect of dual reinforcement (i.e. red mud and MoS<sub>2</sub>) on the microstructural, mechanical, and tribological performance of AA6061-based hybrid composites developed through stir casting. Composites containing a constant 10 wt% reinforcement with varying red mud–MoS<sub>2</sub> ratios (HC1, HC2, and HC3) were developed and compared with the matrix alloy. Microstructural and phase analyses by OM, SEM-EDS, and XRD revealed the refined interdendritic structures and the formation of Al<sub>2</sub>O<sub>3</sub>, Mg<sub>2</sub>Si, MgAl<sub>2</sub>O<sub>4</sub>, and MoS<sub>2</sub> phases without adverse reactions. Mechanical testing showed significant improvements for the HC2 case, exhibiting maximum hardness (~ 95 VHN, + 61), tensile strength (~ 310 MPa, + 42%), and impact energy (~ 5.1 J, + 45.7%). Due to enhanced, stable tribofilm growth and load-bearing capacity, the tribological results showed a substantial decrease in wear loss, wear rate, and coefficient of friction. Severe adhesion and ploughing wear gave way to a minimal, lubrication-assisted abrasive state as the main wear mechanism. Nevertheless, third-body abrasion and decreased performance were observed due to the formation of particle clusters at a higher red mud proportion (HC3). In order to achieve a balanced combination of toughness, strength, and wear behaviour and make these composites appropriate for novel structural applications, the reinforcement must be optimized.</p>

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Synergistic Impact of Red Mud and MoS2 Addition on the Microstructure and Tribological Behaviour of AA6061 Hybrid Composites Developed Via Stir Casting

  • 期刊论文

  • 发表日期：

    2026年7月18日

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  • Ajay Kumar Singh,
  • Chetan Kumar Hirwani

摘要

Achieving a balanced combination of mechanical and tribological behaviour in hybrid metal–matrix composites remains a serious challenge due to uneven reinforcement dispersion and interfacial unsuitability. This research examines the synergistic effect of dual reinforcement (i.e. red mud and MoS2) on the microstructural, mechanical, and tribological performance of AA6061-based hybrid composites developed through stir casting. Composites containing a constant 10 wt% reinforcement with varying red mud–MoS2 ratios (HC1, HC2, and HC3) were developed and compared with the matrix alloy. Microstructural and phase analyses by OM, SEM-EDS, and XRD revealed the refined interdendritic structures and the formation of Al2O3, Mg2Si, MgAl2O4, and MoS2 phases without adverse reactions. Mechanical testing showed significant improvements for the HC2 case, exhibiting maximum hardness (~ 95 VHN, + 61), tensile strength (~ 310 MPa, + 42%), and impact energy (~ 5.1 J, + 45.7%). Due to enhanced, stable tribofilm growth and load-bearing capacity, the tribological results showed a substantial decrease in wear loss, wear rate, and coefficient of friction. Severe adhesion and ploughing wear gave way to a minimal, lubrication-assisted abrasive state as the main wear mechanism. Nevertheless, third-body abrasion and decreased performance were observed due to the formation of particle clusters at a higher red mud proportion (HC3). In order to achieve a balanced combination of toughness, strength, and wear behaviour and make these composites appropriate for novel structural applications, the reinforcement must be optimized.