Revolutionizing Aluminum-Based Composite Manufacturing: Harnessing Fly Ash and Rice Husk Ash Reinforcement through Stir Casting for Sustainability

¹ Hilla University College, Babylon, Iraq
² New Horizon College of Engineering, Bangalore
³ Department of AIMLE, GRIET, Hyderabad, Telangana, India.
⁴ Lovely Professional University, Phagwara
⁵ Lloyd Institute of Management and Technology, Greater Noida, Uttar Pradesh, India -201306
⁶ Lloyd Institute of Engineering & Technology, Greater Noida, Uttar Pradesh 201306

^* Corresponding author: raghad_ah@gmail.com

Abstract

The revolution in aluminum-based composite manufacturing is underway, propelled by the innovative integration of fly ash and rice husk ash (RHA) reinforcement through stir casting, heralding a sustainable approach to materials engineering. At the heart of this transformation lies a meticulous process: aluminum alloy melting at 700°C within a muffle furnace, augmented by the gradual introduction of RHA and fly ash particles into the molten alloy, stirred at 500 rpm for 15 minutes. This rigorous stirring method ensures a uniform dispersion of reinforcement particles, optimizing their distribution throughout the alloy matrix.The resultant composite exhibits remarkable enhancements across key mechanical properties. With the addition of 5% fly ash and 2.5% RHA, a notable 13.44% increase in tensile strength is achieved, accompanied by a remarkable 25.68% improvement in hardness. Furthermore, fatigue strength experiences a substantial boost of 20.12%, while wear resistance demonstrates a notable enhancement of 19.90% compared to the base composite.These findings underscore the efficacy of fly ash and RHA reinforcement in aluminum composites, offering a sustainable pathway towards enhanced material performance and resource efficiency in manufacturing practices. This study represents a paradigm shift towards greener and more resilient composite materials, driving sustainability in the realm of aluminum-based manufacturing.