Experimental investigation in enhancing the mechanical, wear and corrosion resistance properties of Al6061-SiC-NSA composites fabricated using stir casting process

The study investigates the mechanical, and tribological properties of Al6061-SiC-NSA hybrid composites. The characterization via FE-SEM reveals NSA particle's crystal structure and agglomeration, with an average particle size of approximately 400 nm. The EDS analysis confirms the presence of oxides (TiO2, SiO2, Fe2O3, Al2O3) along with calcium and potassium. The XRD spectra corroborate these findings, additionally identifying Calcite and intermetallic compounds. The Al6061-5SiC-10NSA composites has improved compressive strength of 254 MPa compared to 220 MPa for base Al6061 alloy. The tensile strength of base Al6061 (100 MPa) decreased to 70 MPa for Al6061-5SiC-20NSA composites. The tensile strength decreases with increasing NSA content. Fracture analysis indicates ductile fracture mechanisms, supported by FE-SEM images displaying honeycomb-like structures and dimples. Impact testing reveals reduced impact strength in composites compared to Al6061 (26J3), with Al6061-10SiC-5NSA exhibiting the best toughness of 22.5 J3. Density decreases in composites, with density of Al6061-5SiC-20NSA composites has reduced to 2.40 g cm-3. The microhardness of Al6061-10SiC-5NSA has better value of 109 HV, whereas further addition of NSA has resulted in decrease in microhardness of composites. Pin-on-disc wear tests demonstrate improved wear resistance with increased NSA content, with Al6061-5SiC-20NSA outperforming other compositions. COF decreases with increased NSA content and sliding speed. FE-SEM analysis of worn surfaces reveals that the major wear mechanism is adhesive wear followed by delamination, further the oxide formation along the surface aiding wear resistance of the composites. Tafel testing indicates decreased corrosion potential with increased NSA content, with Al6061-5SiC-20NSA exhibiting improved corrosion resistance.