Fly ash as a sustainable reinforcement in composite materials: a comprehensive review on enhancing mechanical properties for eco-friendly engineering

The use of Powder metallurgy is used to strengthen metal matrix composites with fly ash. This study extensively explores the fabrication and characterization of MMCs reinforced with fly ash particles. A range of fabrication techniques are examined, providing insight into possible uses and improvements in MMCs production procedures. MMCs can be made for specific uses by adding particles of fly ash that change their physical and mechanical properties. Microstructural analysis can provide insight into the functioning of a combination by examining the minute structures of materials, such as fly ash particles inside a metal matrix composite. This review consolidates and examines documented data on the density, porosity, and microstructural attributes of fly ash-reinforced aluminum composites to evaluate their material qualities and prospects for further advancement. Wear resistance and hardness are measured mechanically to evaluate composite performance under varied loading conditions. This study objectives to explore the fabrication, characterization, and performance evaluation of cost-effective hybrid metal matrix composites (MMCs) using fly ash (FA) as a reinforcement in MMCs, with an emphasis on employing industrial waste materials to improve sustainability and minimize production costs. Al-7Si-3Cu-0.4Mg alloy-based composites with fly ash up to 10% weight% improve mechanical properties. Particle aggregation lowering ductility and increasing brittleness occurs at concentrations over 10 wt%. Different fly ash percentage affects eutectic Si form and distribution, which balances strength and ductility in automotive components. fly ash additions up to 15% improve micro hardness and tribological performance in Fe–Cu–C composites, especially under abrasive circumstances, as confirmed by SEM and EDS investigations verifying matrix uniformity.