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<p>The tribological and corrosion properties of Al-Si alloy reinforced with coconut shell ash (CSA) and molybdenum disulfide (MoS<sub>2</sub>) are examined in this work. With different amounts of CSA (5, 10, and 15 wt %) and MoS<sub>2</sub> (1, 2, and 3 wt%), hybrid aluminum matrix composites (AMCs) were created through stir casting. The tribological performance was evaluated by means of the face-centered composite design (FCC) by evaluating the wear rate and coefficient of friction based on varied loads (15, 30, and 45 N) and sliding velocity (1, 2, and 3&#xa0;m/s). In comparison with the base alloy, the hybrid composite with 10% CSA and 3% MoS₂ produced a 26.5% hardness increase and a 21.4% improvement in tensile strength. Load directly affects wear performance, since wear rate increased with load. The wear tests showed a 34.3% drop in coefficient of friction and a 54.8% drop in wear rate, caused by the combined effects of the hard ceramic and lubricating phases. Under low loads, SEM analysis showed a shift to adhesive wear, which became dominant under high loads. In order to study the corrosion behavior of composites, potentiodynamic polarization tests were conducted in a 3.5% NaCl solution. Higher concentrations of CSA, as a result of microstructural alterations and galvanic effects, make materials more susceptible to corrosion, as shown by corrosion potential (E<sub>corr</sub>) and current density (I<sub>corr</sub>). A decrease of 47.3% in corrosion current density (<i>I</i><sub>corr</sub>) and a change toward a more noble corrosion potential (<i>E</i><sub>corr</sub>) were confirmed by potentiodynamic polarization findings, indicating an improvement in corrosion resistance. Microstructural research revealed a homogeneous particle distribution and decreased crack propagation in the improved hybrid composite. The results identify the Al-Si/10% CSA/3% MoS₂ composite as a viable option for lightweight, high-performance parts in automotive and marine sectors.</p>

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Development and Optimization of Al-Si/CSA/MoS2 Composites for Superior Tribo-Corrosion Resistance Using FCC Approach

  • 期刊论文

  • 发表日期：

    2025年7月19日

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  • Sivasankara Raju Rallabandi,
  • Srinivasa Rao Gunji,
  • M. Girish Prasad,
  • Ramakrishna Bondala,
  • D. Kondala Rao,
  • Apparao Damarasingu,
  • Azad Duppala

摘要

The tribological and corrosion properties of Al-Si alloy reinforced with coconut shell ash (CSA) and molybdenum disulfide (MoS2) are examined in this work. With different amounts of CSA (5, 10, and 15 wt %) and MoS2 (1, 2, and 3 wt%), hybrid aluminum matrix composites (AMCs) were created through stir casting. The tribological performance was evaluated by means of the face-centered composite design (FCC) by evaluating the wear rate and coefficient of friction based on varied loads (15, 30, and 45 N) and sliding velocity (1, 2, and 3 m/s). In comparison with the base alloy, the hybrid composite with 10% CSA and 3% MoS₂ produced a 26.5% hardness increase and a 21.4% improvement in tensile strength. Load directly affects wear performance, since wear rate increased with load. The wear tests showed a 34.3% drop in coefficient of friction and a 54.8% drop in wear rate, caused by the combined effects of the hard ceramic and lubricating phases. Under low loads, SEM analysis showed a shift to adhesive wear, which became dominant under high loads. In order to study the corrosion behavior of composites, potentiodynamic polarization tests were conducted in a 3.5% NaCl solution. Higher concentrations of CSA, as a result of microstructural alterations and galvanic effects, make materials more susceptible to corrosion, as shown by corrosion potential (Ecorr) and current density (Icorr). A decrease of 47.3% in corrosion current density (Icorr) and a change toward a more noble corrosion potential (Ecorr) were confirmed by potentiodynamic polarization findings, indicating an improvement in corrosion resistance. Microstructural research revealed a homogeneous particle distribution and decreased crack propagation in the improved hybrid composite. The results identify the Al-Si/10% CSA/3% MoS₂ composite as a viable option for lightweight, high-performance parts in automotive and marine sectors.