Microstructural characteristics and tribological behaviour of LM13-based hybrid composites with zirconium carbide and fly ash

• LM13 aluminium alloy was reinforced with 0–9 wt.% zirconium carbide (in 3 wt.% increments) and 3 wt.% fly ash. • Composites were produced using stir casting and subsequently through squeeze casting. • Optical microscopy, FESEM, and EDS demonstrated enhanced agglomeration with elevated filler content. • Statistical research verified that composition greatly affected wear and surface qualities. • Atomic force microscopy revealed less surface roughness with elevated filler content, hence improving overall performance. The increasing interest in metal matrix composites (MMCs) in the last decade is propelled by their extensive applications in the automotive and aerospace sectors. Aluminum-based composites are extensively employed among MMCs. This study examines LM13 aluminium alloy reinforced with zirconium carbide and fly ash, produced via stir casting and subsequently through squeeze casting. The zirconium carbide content ranged from 0 to 9 wt.%, increasing in 3 wt.% increments, whereas the fly ash percentage was maintained at a constant 3 wt.%. The composites were examined for morphology (optical microscopy, scanning electron microscopy (SEM) and energy dispersion spectroscopy (EDS), tribological parameters (weight loss, coefficient of friction, specific wear rate, worn surface morphology), density, porosity, and surface roughness (atomic force microscopy). Tribological assessments were conducted utilising a pin-on-disc apparatus, adhering to the Taguchi experimental design. The addition of filler content is found to affect the density and porosity of the fabricated composites. Nonetheless, wear resistance enhanced with increasing reinforcement concentrations, shown by worn surface analysis. Furthermore, atomic force microscopic studies show less surface roughness with higher filler content, underscoring improved material performance. Thus, when the reinforcement was added at 9 wt.% there is an increase in properties.