Investigation of the mechanical, tribological, and corrosion behaviour of ZrO ₂ -reinforced aluminium-based alloy composites

Aluminium-based composites are quite interesting materials for automobile components design due to their promising characteristics, including strength-to-weight ratio, ease of fabrication and machinability, and cost effectiveness. In this present study, aluminium-based alloy composites filled with 0, 5, and 15 wt% ZrO 2 particles were produced by a two-stage stir casting process. Microstructure, mechanical, tribological, and corrosion behaviour of the composites were evaluated using SEM, nanoindentation tests, wear tests, and Tafel polarization tests. Microstructural examination showed uniform distribution of ZrO 2 particles into the alloy matrix. Based on the load against penetration depth curve, which was obtained from the nanoindentation test, reduction in depth of about 33% and 13% was noticed in 5 wt% and 15 wt% reinforced composites, respectively compared to unreinforced alloy (0 wt%). Utilization of ZrO 2 as filler material was observed to be favourable for enhancement of hardness and elastic modulus compared with pure alloy. Incorporation of the ZrO 2 particles in the alloy matrix, remarkably improved its wear resistance. Composite with 5 wt% depicted the lowest friction coefficient (0.4) and wear rate (2.3 × 10 −3 mm 3 /Nm). Additionally, the corrosion resistance performance of the alloy matrix composites was slightly improved with ZrO 2 particles addition. The findings of the present experimental investigation provide a base in the design and manufacturing of aluminium-based alloy composites with desired mechanical, wear, and corrosion resistance properties for automobile applications.