Tribological and corrosion characteristics of tetra hybrid particulate-reinforced aluminum composites for aerospace and automotive applications

Abstract

This study investigates Hybrid Particulate-Reinforced Aluminum Matrix Composites (HPRAMCs), a material class known for exceptional physico-mechanical, tribological, and corrosion resistant properties. The research synthesizes HPRAMCs using SiC, Al2O3, graphite (Gr), and sugar cane bagasse ash (SCBA) reinforcements through a powder metallurgy process, followed by sintering at 550°C for 3 h. Comprehensive tests include X-ray diffraction (XRD) for phase analysis, physico-mechanical assessments, tribological evaluations, and corrosion resistance analyses. Notably, secondary reinforcements significantly reduce porosity, with AS4 HPRAMC exhibiting a 0.53% porosity, while AS1 HPRAMC has 1.446%. AS4 HPRAMC displays a remarkable 209.76% increase in compressive strength and a 446.40% boost in material hardness compared to pure aluminum. Secondary reinforcements also improve tribological performance, reducing wear loss by 60.27% and the coefficient of friction by 89.89%. Exceptional corrosion resistance, with an inhibition efficiency of 99.691%, is observed in the AS4 HPRAMC sample, confirmed by scanning electron microscopy (SEM). These findings underline the substantial potential of HPRAMC materials, positioning them as promising candidates for aerostructural components, aircraft systems, automobiles, spacecraft, and high-performance engineering applications.