Enhancing Wear Resistance of Al6061 Composites: Insights from Microstructural and Tribological Investigations with ECAP

This work presents a comprehensive investigation into the microstructural and tribological properties of Al6061 alloy composites reinforced with E-glass fibers and soda–lime particulates, both before and after Equal Channel Angular Pressing (ECAP) processing. The study explores the intricate relationships between reinforcement materials and the aluminum matrix, shedding light on their collective impact on material behavior. Elemental composition analysis via Energy Dispersive X-ray (EDX) reveals crucial elements shaping the properties of these composites, highlighting the dominance of aluminum in the matrix and the contributions of silicon, calcium, sodium, and oxygen from the reinforcement materials. Scanning Electron Microscopy (SEM) and Optical Microscopy (OM) demonstrate refined grain structures, improved reinforcement dispersion, and enhanced interfacial bonding post-ECAP, indicating potential for superior mechanical properties. Furthermore, wear test analysis on these composites, encompassing varying reinforcement percentages and load conditions, unveils consistent trends in wear behavior. Higher reinforcement percentages, particularly with E-glass fibers, lead to reduced specific wear rates, showcasing enhanced wear resistance. Post-ECAP results consistently exhibit lower wear rates, highlighting the positive impact of ECAP on wear resistance. Statistical analysis using Taguchi and Analysis of Variance (ANOVA) techniques underscores the critical role of reinforcement percentage in wear characteristics, with optimal configurations identified for both E-glass fiber and soda–lime particulate composites. These findings offer valuable insights for designing and optimizing materials, emphasizing the importance of reinforcement levels, load, and speed in enhancing wear resistance and optimizing material performance for specific applications.