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<p>This study presents the design, fabrication, and performance evaluation of novel AA7075-based hybrid metal matrix composites (HMMCs) reinforced with fly ash (FA) and boron carbide (B<sub>4</sub>C), developed via an ultrasonic-assisted stir casting route. The dual-reinforcement strategy leverages the low density and thermal insulating nature of FA, alongside the exceptional hardness of B4C, to achieve superior mechanical and tribological properties while promoting sustainability through the utilization of industrial waste. Comprehensive characterization—including optical, SEM, EDS, and XRD—revealed uniform reinforcement dispersion, strong interfacial bonding, and the formation of strengthening phases such as Al<sub>2</sub>O<sub>3</sub>, Al<sub>2</sub>CuMg, B<sub>4</sub>C, and MgZn<sub>2</sub> within the Al matrix. The incorporation of reinforcements led to a progressive reduction in density, accompanied by an increase in porosity at higher loadings, due to clustering and reduced wettability. Notably, the composite with 2 wt.% FA and 6 wt.% B<sub>4</sub>C demonstrated the highest hardness and wear resistance, with significant improvements over monolithic AA7075. Wear behavior was systematically studied under varying sliding distances (up to 5000 m) and applied pressures (0.25–1.00 MPa). The wear rate decreased with distance due to the formation of a stable, mechanically mixed layer, while hybrid composites exhibited a delayed transition to severe wear, higher seizure resistance, and reduced thermal softening effects.</p>

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Ultrasonic-assisted stir casting of AA7075 hybrid composites reinforced with B4C and Fly Ash: enhanced mechanical and tribological performance

  • 期刊论文

  • 发表日期：

    2026年1月28日

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  • Pradyumna Vishwakarma,
  • Ashutosh Singh Raghubanshi,
  • Anchit Modi,
  • Virendra Pratap Singh,
  • Dineshkumar Harursampath,
  • Deepak Kumar

摘要

This study presents the design, fabrication, and performance evaluation of novel AA7075-based hybrid metal matrix composites (HMMCs) reinforced with fly ash (FA) and boron carbide (B4C), developed via an ultrasonic-assisted stir casting route. The dual-reinforcement strategy leverages the low density and thermal insulating nature of FA, alongside the exceptional hardness of B4C, to achieve superior mechanical and tribological properties while promoting sustainability through the utilization of industrial waste. Comprehensive characterization—including optical, SEM, EDS, and XRD—revealed uniform reinforcement dispersion, strong interfacial bonding, and the formation of strengthening phases such as Al2O3, Al2CuMg, B4C, and MgZn2 within the Al matrix. The incorporation of reinforcements led to a progressive reduction in density, accompanied by an increase in porosity at higher loadings, due to clustering and reduced wettability. Notably, the composite with 2 wt.% FA and 6 wt.% B4C demonstrated the highest hardness and wear resistance, with significant improvements over monolithic AA7075. Wear behavior was systematically studied under varying sliding distances (up to 5000 m) and applied pressures (0.25–1.00 MPa). The wear rate decreased with distance due to the formation of a stable, mechanically mixed layer, while hybrid composites exhibited a delayed transition to severe wear, higher seizure resistance, and reduced thermal softening effects.