Development and characterization of fly ash-reinforced aluminium matrix composites using stir casting
Sahil Duggal1, Jatinder Kumar2 and Santosh Kumar3
Department of Mechanical Engineering,Ramgarhia Institute of Engineering and Technology, Phagwara, 144402, Punjab,India1
Department of Mechanical Engineering,Modern Group of Colleges, Mukerian, 144211, Punjab,India2
Department of Mechanical Engineering,Chandigarh Group of Colleges, Landran, Mohali, 140307, Punjab ,India3
Department of Mechanical Engineering,Modern Group of Colleges, Mukerian, 144211, Punjab,India2
Department of Mechanical Engineering,Chandigarh Group of Colleges, Landran, Mohali, 140307, Punjab ,India3
Corresponding Author : Santosh Kumar
Recieved : 01-January-2024; Revised : 25-April-2025; Accepted : 10-May-2025
Abstract
Aluminium (Al) is well known for its advantageous combination of low density and a high strength-to-weight ratio. Nevertheless, ongoing research aims to further enhance its properties. This study investigates the potential of incorporating fly ash (FA)—a byproduct of coal combustion—into aluminium to develop a composite material. Due to its lightweight nature and fine particle size, FA presents a promising option for reducing the overall density of the composite while potentially maintaining or improving its mechanical strength. This research contributes to the development of lightweight and durable materials for various industrial applications. In this study, a stir-casting technique was employed to integrate varying weight percentages (5% to 20%) of FA particulates into a pure aluminium matrix. The resulting composite materials were evaluated using standard characterization techniques, including scanning electron microscopy (SEM), optical microscopy, hardness testing, tensile strength testing, and wear analysis. The findings revealed that increasing the FA content from 5% to 20% led to a progressive reduction in the overall density of the composite material. However, the influence of FA on mechanical properties such as hardness and tensile strength varied. These variations were attributed to factors such as particle size, distribution, and interfacial bonding of FA within the Al matrix. Notably, in certain cases, the incorporation of FA resulted in enhanced strength and hardness, indicating the feasibility of producing a more robust aluminium-based composite. Moreover, the study highlights that the addition of elements such as silicon (Si) and magnesium (Mg) to the Al-FA composite may further improve mechanical and wear properties. However, the extent of these enhancements depends on the specific composition, processing conditions, and the intended application of the composite material.
Keywords
Aluminium matrix composite, Fly ash reinforcement, Stir casting, Mechanical properties, Wear resistance, Density reduction.
Cite this article
Duggal S, Kumar J, Kumar S. Development and characterization of fly ash-reinforced aluminium matrix composites using stir casting. International Journal of Advanced Technology and Engineering Exploration. 2025;12(126):748-767. DOI : 10.19101/IJATEE.2024.111100006
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