MECHANICAL, TRIBOLOGICAL AND CORROSION BEHAVIOR OF STIR COMPOCAST Al 6063 COMPOSITES: IMPACT OF CENOSPHERE REINFORCEMENT

This study investigated the impact of cenosphere reinforcement on the mechanical, tribological, and corrosion properties of Al 6063 alloy composites. Using the stir compocasting technique, five samples with varying cenosphere contents (0%, 4%, 8%, 12%, and 16%) were prepared to evaluate the influence of the addition of cenosphere on the tensile strength, hardness, wear rate, friction coefficient, and corrosion resistance. The results demonstrated that the incorporation of cenosphere particles significantly enhanced the performance of the Al 6063 composites. The tensile strength of the composites initially increased, peaking at 8% cenosphere content, followed by a slight decrease at higher concentrations. Hardness improved consistently with increasing cenosphere content, achieving a maximum value of 16%. The specific wear rate decreased notably with the addition of cenosphere, with the lowest wear rate observed at 16% cenosphere. Similarly, the coefficient of friction decreased significantly, particularly in samples with higher cenosphere content. Corrosion resistance was also improved, with optimal protection observed at 12% cenosphere. These findings suggest that cenosphere reinforcement effectively enhances the wear resistance, hardness, and corrosion resistance of Al 6063 composites, making them more suitable for applications where these properties are critical. This study highlights the potential of the cenosphere as a cost-effective reinforcement material for improving the overall performance of aluminum alloys in demanding environments.