On the multi-parametric optimization of quality characteristics of the hybrid Al-6061 composites fabricated through powder metallurgy

Aluminium matrix composites (AMCs) have gained enormous attention of almost all types of manufacturing sectors owing to their excellent strength to weight ratio, ease of processing, good thermal conductivity, corrosion resistance, and desirable mechanical properties. Amongst the various processing routes available for AMCs, mechanical alloying assisted powder metallurgy (MA2PM) is particularly efficient in achieving the required physical, mechanical, and metallurgical characteristics. Therefore, in this present work, an effort has been made to develop the hybrid Al-6061 composites via MA2PM route under the influence of controllable and significant process variables. A specified proportion of graphite, silicon carbide (SiC), magnesium (Mg), zinc (Zn), and fly ash were selected and the process parameters (such as compaction pressure, sintering temperature, and sintering time) were varied as per Taguchi L9 orthogonal array. It has been found that the hardness and wear responses of the developed samples were significantly influenced by the processing parameters at 95% confidence level. Overall, the study conducted indicated that for hardness and wear rate only the compaction pressure found as significant parameter with 89.40 and 72.52% contribution.