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<p>Aluminum 7075 (Al7075) alloys are widely used in the aerospace and automotive industries but are limited by poor wear resistance and non-uniform reinforcement dispersion. This research proposed a novel multiscale hybrid metal-matrix composite reinforced with 5 wt.% red mud (RM) and 1–3 wt.% nanosilica (NS) using the stir casting method to improve mechanical and tribological properties. The composites are fabricated under controlled processing conditions to ensure uniform particle distribution and enhanced interfacial bonding. The results show significant improvements using the Python tool compared with unreinforced Al7075. The hardness increased from 75 BHN to 102 BHN, while tensile strength improved from 300&#xa0;MPa to 400&#xa0;MPa at 3 wt.% NS. At 1 wt.% NS, maximum flexural strength (290&#xa0;MPa) was observed, beyond which a slight decrease occurred because of nanoparticle agglomeration. The wear rate is significantly reduced (0.19–0.08 mm<sup>3</sup>/Nm), indicating tribological performance. The synergistic hybrid reinforcement mechanism is attributed to observed improvements, in which RM provides load-bearing capability and NS improves interfacial bonding, grain refinement, and microvoid bridging. This micro-nano hybrid system promotes efficient load transfer and crack resistance, demonstrating that RM-NS hybrid reinforcement offers a cost-effective, sustainable, and high-performance solution for advanced engineering applications supporting industrial waste utilization.</p>

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Mechanical and Tribological Enhancement of Al7075 Alloy Using Red Mud and Nanosilica Hybrid Reinforcements via Stir Casting

  • 期刊论文

  • 发表日期：

    2026年5月28日

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  • M. Ramamurthy,
  • A. Maniram Kumar,
  • Sabbah Ataya,
  • K. Antony Alex Raja,
  • M. Pradeep,
  • G. Yuvaraj

摘要

Aluminum 7075 (Al7075) alloys are widely used in the aerospace and automotive industries but are limited by poor wear resistance and non-uniform reinforcement dispersion. This research proposed a novel multiscale hybrid metal-matrix composite reinforced with 5 wt.% red mud (RM) and 1–3 wt.% nanosilica (NS) using the stir casting method to improve mechanical and tribological properties. The composites are fabricated under controlled processing conditions to ensure uniform particle distribution and enhanced interfacial bonding. The results show significant improvements using the Python tool compared with unreinforced Al7075. The hardness increased from 75 BHN to 102 BHN, while tensile strength improved from 300 MPa to 400 MPa at 3 wt.% NS. At 1 wt.% NS, maximum flexural strength (290 MPa) was observed, beyond which a slight decrease occurred because of nanoparticle agglomeration. The wear rate is significantly reduced (0.19–0.08 mm3/Nm), indicating tribological performance. The synergistic hybrid reinforcement mechanism is attributed to observed improvements, in which RM provides load-bearing capability and NS improves interfacial bonding, grain refinement, and microvoid bridging. This micro-nano hybrid system promotes efficient load transfer and crack resistance, demonstrating that RM-NS hybrid reinforcement offers a cost-effective, sustainable, and high-performance solution for advanced engineering applications supporting industrial waste utilization.