Experimental Studies on Microstructural, Physical, and Mechanical Characterizations of Hybrid Aluminium Metal Matrix Composites Incorporated with Cenosphere and Molybdenum Disulphide

This study addresses a research gap in composite material development by exploring the potential of innovative waste materials to enhance performance. An innovative and cost‐effective waste material serves as a reinforcing agent, with cenosphere and molybdenum disulphide used in proportions ranging from 0% to 4%. Employing a cost‐effective stirring cast technique, composites are fabricated, combining AA7075 alloy with cenosphere particles (AA7075/cenosphere) and molybdenum disulphide particles (AA7075/MoS2). The experimental design, utilizing a central composite design within the response surface methodology framework, examines the weight percentages of cenosphere and MoS2. Scanning electron microscopy reveals strengthening chemicals within the matrix, confirmed by electronic dispersive X‐ray spectroscopy for individual reinforcements in the aluminium alloy matrix. Density determination follows Archimedes’ principle and the OIML G14 standard, while mechanical properties (hardness and ultimate tensile strength) are assessed per ASTM standards. Results demonstrate a significant reduction in composite density with cenosphere reinforcement, while molybdenum disulphide marginally affects density. The incorporation of reinforcements notably enhances both hardness and ultimate tensile strength. In conclusion, this research bridges a composite material development gap, presenting a novel and sustainable approach. By showcasing the potential of unconventional waste materials, the study contributes valuable insights to material science and engineering, opening new avenues for future research.