Fabrication and mechanical characterization of AlSi10Mg-reinforced hybrid composites using bottom pouring top-loaded stir-casting method

This study explores the fabrication and mechanical characterization of AlSi10Mg (Aluminum Silicon 10 Magnesium) reinforced hybrid composites, aiming to enhance performance in aerospace and automotive applications. Using a systematic Design of Experiments (DoE) approach, the Taguchi method was applied to optimize fabrication parameters for improved properties. AlSi10Mg, known for its lightweight and superior strength, was reinforced with varying weight percentages of aluminum, silicon, and magnesium via stir-casting. The Taguchi L9 orthogonal array identified optimal composition levels and processing conditions. Mechanical testing showed that a composition of 70% Al, 20% Si, and 10% Mg achieved the highest tensile strength (269 MPa) and Brinell hardness (87 HB), while 90% Si with 10% Mg showed the lowest tensile strength (176 MPa). Scanning Electron Microscopy (SEM) analysis revealed that minimizing agglomeration, voids, and micro-cracks significantly improved performance. The findings demonstrate the Taguchi method's effectiveness in optimizing AlSi10Mg composites for high-performance engineering applications.