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.

References

[1] Mallik M, Saha M. Carbon-based nanocomposites: processing, electronic properties and applications. In carbon nanomaterial electronics: devices and applications 2021 (pp. 97-122). Singapore: Springer Singapore.

[2] Yashas GTG, Sanjay MR, Subrahmanya BK, Madhu P, Senthamaraikannan P, Yogesha B. Polymer matrix-natural fiber composites: an overview. Cogent Engineering. 2018; 5(1):1-13.

[3] Binner J, Porter M, Baker B, Zou J, Venkatachalam V, Diaz VR, et al. Selection, processing, properties and applications of ultra-high temperature ceramic matrix composites, UHTCMCs–a review. International Materials Reviews. 2020; 65(7):389-444.

[4] Desai AM, Paul TR, Mallik M. Mechanical properties and wear behavior of fly ash particle reinforced Al matrix composites. Materials Research Express. 2020; 7(1):1-14.

[5] Lloyd DJ. Particle reinforced aluminium and magnesium matrix composites. International Materials Reviews. 1994; 39(1):1-23.

[6] Chauhan A, Kumar M, Kumar S. Fabrication of polymer hybrid composites for automobile leaf spring application. Materials Today: Proceedings. 2022; 48:1371-7.

[7] Rao CP, Bhagyashekar MS, Viswanath N. Machining behavior of Al6061-fly ash composites. Procedia Materials Science. 2014; 5:1593-602.

[8] Kulkarni SG, Meghnani JV, Lal A. Effect of fly ash hybrid reinforcement on mechanical property and density of aluminium 356 alloy. Procedia Materials Science. 2014; 5:746-54.

[9] Dinaharan I, Akinlabi ET. Low cost metal matrix composites based on aluminum, magnesium and copper reinforced with fly ash prepared using friction stir processing. Composites Communications. 2018; 9:22-6.

[10] Surappa MK. Synthesis of fly ash particle reinforced A356 Al composites and their characterization. Materials Science and Engineering: A. 2008; 480(1-2):117-24.

[11] Matsunaga T, Kim JK, Hardcastle S, Rohatgi PK. Crystallinity and selected properties of fly ash particles. Materials Science and Engineering: A. 2002; 325(1-2):333-43.

[12] Surappa MK. Dry sliding wear of fly ash particle reinforced A356 Al composites. Wear. 2008; 265(3-4):349-60.

[13] Dinaharan I, David RSJ, Jose J, Palanivel R. Influence of fly ash particles on machining characteristics of AA6061 aluminum matrix composites produced using semisolid slurry casting. Transactions of the Indian Institute of Metals. 2023; 76(6):1447-52.

[14] Manimaran R, Jayakumar I, Mohammad GR, Narayanan L. Mechanical properties of fly ash composites-a review. Energy Sources, Part A: Recovery, Utilization, and Environmental Effects. 2018; 40(8):887-93.

[15] Badoniya P, Srivastava M, Jain PK, Rathee S. A state-of-the-art review on metal additive manufacturing: milestones, trends, challenges and perspectives. Journal of the Brazilian Society of Mechanical Sciences and Engineering. 2024; 46(6):339.

[16] Razzaq AM, Majid DL, Basheer UM, Aljibori HS. Research summary on the processing, mechanical and tribological properties of aluminium matrix composites as effected by fly ash reinforcement. Crystals. 2021; 11(10):1-20.

[17] Vinothkumar S, Karunakaran S, Jayanthi N, Bodkhe MG, Sadasivuni H, Hasane SA. Experimental investigation on the impact of mechanical properties of SiC, Al2O3 and ZrSiO4 particles on AA6063 composites. Materials Today: Proceedings. 2023.

[18] Kumar A, Lal S, Kumar S. Fabrication and characterization of A359/Al2O3 metal matrix composite using electromagnetic stir casting method. Journal of Materials Research and Technology. 2013; 2(3):250-4.

[19] Ravindran S, Mani N, Balaji S, Abhijith M, Surendaran K. Mechanical behaviour of aluminium hybrid metal matrix composites–a review. Materials Today: Proceedings. 2019; 16:1020-33.

[20] Kök M, Özdin K. Wear resistance of aluminium alloy and its composites reinforced by Al2O3 particles. Journal of Materials Processing Technology. 2007; 183(2-3):301-9.

[21] Molina JM, Rhême M, Carron J, Weber L. Thermal conductivity of aluminum matrix composites reinforced with mixtures of diamond and SiC particles. Scripta Materialia. 2008; 58(5):393-6.

[22] Ji X, Li S, Liu H, Li X, Zhang X, Liu L, et al. Process optimization of SiC-reinforced aluminum matrix composites prepared using laser powder bed fusion and the effect of particle morphology on performance. Materials. 2024; 17(5):1-17.

[23] Hu CQ, Du HL. Fretting fatigue behaviours of SiC reinforced aluminium alloy matrix composite and its monolithic alloy. Materials Science and Engineering: A. 2022; 847:143347.

[24] Karthikraja M, Ramanathan K, Loganathan KT, Selvaraj S. Corrosion behaviour of SiC and Al2O3 reinforced Al 7075 hybrid aluminium matrix composites by weight loss and electrochemical methods. Journal of the Indian Chemical Society. 2023; 100(5):101002.

[25] Reddy SP, Chandrasekhara RPV, Kolli M. Effect of reinforcement on compacting characteristics of aluminum/10-Al2O3/fly ash metal matrix composite. Journal of Testing and Evaluation. 2020; 48(2):955-69.

[26] Mohanty S, Singh SS, Routara BC, Nanda BK, Nayak RK. A comparative study on machining of AlSiCp metal matrix composite using electrical discharge machine with and without nano powder suspension in dielectric. Materials Today: Proceedings. 2019; 18:4281-9.

[27] Valizade N, Farhat Z. A review on abrasive wear of aluminum composites: mechanisms and influencing factors. Journal of Composites Science. 2024; 8(4):1-27.

[28] Chak V, Chattopadhyay H, Dora TL. A review on fabrication methods, reinforcements and mechanical properties of aluminum matrix composites. Journal of Manufacturing Processes. 2020; 56:1059-74.

[29] Zoeram AS, Anijdan SM, Jafarian HR, Bhattacharjee T. Welding parameters analysis and microstructural evolution of dissimilar joints in Al/Bronze processed by friction stir welding and their effect on engineering tensile behavior. Materials Science and Engineering: A. 2017; 687:288-97.

[30] Sahin Y. Wear behaviour of aluminium alloy and its composites reinforced by SiC particles using statistical analysis. Materials & Design. 2003; 24(2):95-103.

[31] Xiao GB, To S, Jelenković EV. Effects of non-amorphizing hydrogen ion implantation on anisotropy in micro cutting of silicon. Journal of Materials Processing Technology. 2015; 225:439-50.

[32] Prabu SB, Karunamoorthy L, Kathiresan S, Mohan B. Influence of stirring speed and stirring time on distribution of particles in cast metal matrix composite. Journal of Materials Processing Technology. 2006; 171(2):268-73.

[33] Mondal DP, Das S, Ramakrishnan N, Bhasker KU. Cenosphere filled aluminum syntactic foam made through stir-casting technique. Composites Part A: Applied Science and Manufacturing. 2009; 40(3):279-88.

[34] Hrairi M, Ahmed M, Nimir Y. Compaction of fly ash–aluminum alloy composites and evaluation of their mechanical and acoustic properties. Advanced Powder Technology. 2009; 20(6):548-53.

[35] Sharma VK, Singh RC, Chaudhary R. Effect of flyash particles with aluminium melt on the wear of aluminium metal matrix composites. Engineering Science and Technology, an International Journal. 2017; 20(4):1318-23.

[36] Khalid MY, Umer R, Khan KA. Review of recent trends and developments in aluminium 7075 alloy and its metal matrix composites (MMCs) for aircraft applications. Results in Engineering. 2023; 20:101372.

[37] Sadeghi B, Cavaliere P, Pruncu CI, Balog M, Marques DCM, Chahal R. Architectural design of advanced aluminum matrix composites: a review of recent developments. Critical Reviews in Solid State and Materials Sciences. 2024; 49(1):1-71.

[38] Kumar A, Singh VP, Singh RC, Chaudhary R, Kumar D, Mourad AH. A review of aluminum metal matrix composites: fabrication route, reinforcements, microstructural, mechanical, and corrosion properties. Journal of Materials Science. 2024; 59(7):2644-711.

[39] Zhang J, Zhang X, Qian M, Jia Z, Imran M, Geng L. Recent progress in particulate reinforced aluminum composites fabricated via spark plasma sintering: microstructure and properties. Critical Reviews in Solid State and Materials Sciences. 2024; 49(3):408-63.

[40] Kumar J, Singh D, Kalsi NS, Kumar S. Characterization of aluminium metal matrix composites reinforced with silicon carbide and nickel particulates. Journal of Management and Engineering Sciences. 2024; 1(4):132-42.

[41] Kumar J, Singh D, Kalsi NS, Kumar S. Role of alloying elements as reinforcements during fabrication of aluminium metal matrix composites. Journal of Management and Engineering Sciences. 2025; 2(1):1-21.

[42] Juang SH, Li CF. Influence of different addition ratios of fly ash on mechanical properties of ADC10 aluminium matrix composites. Metals. 2022; 12(40):1-13.

[43] Biswas P, Nayak J, Kundu A, Patel D, Mallik A, Das S. A review on the development of processing techniques for the production and casting of Al-alloy and metal matrix composite material. Iranian Journal of Science and Technology, Transactions of Mechanical Engineering. 2024; 49:35-66.

[44] Singla M, Dwivedi DD, Singh L, Chawla V. Development of aluminium based silicon carbide particulate metal matrix composite. Journal of Minerals and Materials Characterization and Engineering. 2009; 8(6):455-67.

[45] Singh B, Kumar I, Saxena KK, Mohammed KA, Khan MI, Moussa SB, et al. A future prospects and current scenario of aluminium metal matrix composites characteristics. Alexandria Engineering Journal. 2023; 76:1-7.

[46] Bieliatynskyi A, Yang S, Pershakov V, Shao M, Ta M. Exploring the use of modern fly ash materials from chinese power plants in road and airfield infrastructure. Environmental Engineering & Management Journal. 2023; 22(3):527-37.

[47] Kanta DD, Chandra MP, Singh S, Kumar TR. Properties of ceramic-reinforced aluminium matrix composites-a review. International Journal of Mechanical and Materials Engineering. 2014; 9(12):1-6.

[48] Alam MA, Ya HB, Azeem M, Mustapha M, Yusuf M, Masood F, et al. Advancements in aluminum matrix composites reinforced with carbides and graphene: a comprehensive review. Nanotechnology Reviews. 2023; 12(1):1-46.

[49] Sahu MK, Sahu RK. Optimization of stirring parameters using CFD simulations for HAMCs synthesis by stir casting process. Transactions of the Indian Institute of Metals. 2017; 70:2563-70.

[50] Fan R, Wang L, Zhao S, Wang L, Guo E. Strengthening of Mg alloy with multiple RE elements with Ag and Zn doping via heat treatment. Materials. 2023; 16(11):1-11.

[51] Wang Y, Konovalov S, Chen X, Ramachandra AS, Subramanian J. Influence of silicon and magnesium on the mechanical properties of additive manufactured Cu-Al alloy. 3D Printing and Additive Manufacturing. 2021; 8(5):331-9.

[52] Chen X, Yin J, Huang L, Lee SH, Liu X, Huang Z. Microstructural tailoring, mechanical and thermal properties of SiC composites fabricated by selective laser sintering and reactive melt infiltration. Journal of Advanced Ceramics. 2023; 12(4):830-47.

[53] Chavana N, Jambagi SC. An effective utilization of raw fly ash obtained from thermal power plants using thermal spray technique to improve corrosion resistance for marine applications. Materials Chemistry and Physics. 2024; 324:129688.

[54] Cosnita M, Balas M, Cazan C. The influence of fly ash on the mechanical properties of water immersed all waste composites. Polymers. 2022; 14(10):1-16.

[55] Matvienko O, Daneyko O, Kovalevskaya T, Khrustalyov A, Zhukov I, Vorozhtsov A. Investigation of stresses induced due to the mismatch of the coefficients of thermal expansion of the matrix and the strengthening particle in aluminum-based composites. Metals. 2021; 11(2):1-20.

[56] Kumar R, Kumar H, Kumar S, Kumar M, Luthra G. Corrosion and wear behaviour of metal matrix composites. In metal matrix composites: a modern approach to manufacturing 2024 (pp. 224-48). Bentham Science Publishers.

[57] Nasir NH, Usman F, Woen EL, Ansari MN, Sofyan M. Effect of fly ash on mechanical properties and microstructural behaviour of injected moulded recycled polypropylene composites. Construction and Building Materials. 2024; 447:138130.

[58] Meng T, Dai D, Yang X, Yu H. Effect of fly ash on the mechanical properties and microstructure of cement-stabilized materials with 100% recycled mixed aggregates. Minerals. 2021; 11(9):1-15.

[59] Islam MN, Noaman MA, Islam KS, Hanif MA. Mechanical properties and microstructure of brick aggregate concrete with raw fly ash as a partial replacement of cement. Heliyon. 2024; 10(7):1-13.

Cite this article