Evaluating the Impact of Fly Ash Content on the Dry Sliding Wear Behaviour of Al–Si–Mg–Cu Metal Matrix Composite for Lightweight Application

In this work, the A354 alloy is reinforced with fly ash ceramic particles to study the dry sliding wear features of the developed aluminium metal matrix composite (AMMC). The metal matrix composite (MMC) of varying wt.% (5, 10, and 15) of fly ash was synthesized through a liquid metallurgy route. The developed AMMC was characterized by microstructure, hardness, density, wear rate, and coefficient of friction. Observations indicate that reinforcing 5 weight % of fly ash particles enhances the developed MMC's hardness, wear resistance, and density. Specifically, samples with 5 wt.% of fly ash have shown the highest microhardness values. The dry sliding wear analysis was performed at room temperature using a tribometer per ASTM G99 standard. Results show that the specimen reinforced with 5 wt.% of fly ash has the least specific wear rate compared to all other specimens. The least wear rate obtained is at a normal load of 15N and a sliding velocity of 3 m/s. The wear test also divulges that the coefficient of friction was highest in samples tested at a sliding velocity of 3 m/s and 15 N load. Further, the wear properties of the specimens were characterized using SEM and EDS analyses. Hence, the investigation proved that adding fly ash in a minimal weight percentage (5 wt.%) enhances the potential of A354 MMC to be used in developing cylinder heads and other such drive train components. © 2023, The Author(s), under exclusive licence to Springer Nature Switzerland AG.