Integrated manufacturing of REciclable multi-material COmposites for the TRANSport sector

Hybrid LM26 aluminum alloy composites reinforced with aluminum nitride and coconut shell ash powder are fabricated via powder metallurgy. The developed composites demonstrate enhanced microstructural uniformity, hardness, and wear resistance. The study demonstrates the potential of combining synthetic ceramics and agricultural by?products to develop cost?effective and sustainable solution for automotive applications.In this study, LM26 Al?alloy reinforced with 5?wt% aluminum nitride powder (AlNP) and varying coconut shell ash powder (CSAP) content (0.0, 1.5, 3.0, 4.5, and 6.0?wt%) is synthesized using powder metallurgy (P/M). The influence of these reinforcements on the physical properties, microstructure, mechanical behavior, and tribological performance of the composites is systematically investigated. Phase identification and elemental composition are assessed using X?ray diffraction and energy?dispersive spectroscopy, whereas field emission scanning electron microscopy is used to examine the powder morphology and microstructure of composites. The results indicate that increasing the CSAP content led to a decrease in both green and sintered density, reaching values of 2.36 and 2.42?g?cm?3, respectively. The composite containing 5?wt% AlN and 4.5?wt% CSAP exhibits the highest microhardness (54.15?HV) and compressive strength (406.03?MPa), showing improvements of 26.23% and 119.80%, respectively. Fretting wear tests demonstrated that wear loss and the coefficient of friction (COF) decrease up to 4.5?wt% CSAP, followed by an increase beyond this concentration. Furthermore, higher normal loads intensify both wear rate and COF. Worn surface analysis indicates that delamination and abrasion wear are the dominant mechanisms.

» Author: Puneet Kumar Sonker, Thingujam Jackson Singh, Ashish Srivastava, Binayak Nahak, Sandeep Kumar Singh

» Publication Date: 09/09/2025

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