Investigating the Effects of Fly Ash on the Microstructure and Properties of Aluminium Composites using Taguchi Method

Abstract This study aims to investigate the effect of fly ash addition on the mechanical and tribological properties of Al 1100 alloy. Fly ash, a waste by-product from automobile rubbers, was added to Al 1100 at different weight percentages. This study investigates the effect of fly ash content and sintering temperature on the mechanical properties and wear behavior of Al 1100-fly ash composites using the Taguchi method. The composites were fabricated through powder metallurgy, with fly ash content ranging from 0–15% and sintering temperature varied between 500°C and 700°C. Tensile and hardness tests were carried out, and the wear behavior was evaluated using the pin-on-disk method. The results showed that the addition of fly ash significantly improved the hardness of the composites. The highest hardness was observed at 9–10% fly ash content and sintering temperature of 600°C. The tensile strength of the composites was also enhanced with the addition of fly ash. The highest tensile strength was observed at 9% fly ash content and a sintering temperature of 650°C. The wear behavior of the composites was evaluated using the Taguchi method, and the results showed that fly ash content had the most significant effect on the wear resistance of the composites. The wear resistance improved with increasing fly ash content, with the highest wear resistance observed at 9% fly ash content and a sintering temperature of 700°C. The Taguchi method identified the optimal process parameters to obtain the best combination of mechanical and tribological properties. The present study demonstrates the potential of fly ash as a low-cost and sustainable reinforcement material for Al 1100 alloy. In conclusion, the Taguchi method was an effective tool for optimizing the mechanical properties and wear behavior of Al 1100-fly ash composites. The results suggest that fly ash can be used as a reinforcement in Al 1100 to enhance its mechanical properties and wear resistance, making it a promising material for various industrial application.