Fabrication and wear analysis of AA2024 aluminum hybrid composites reinforced with waste stainless steel and eggshell particles by hot pressing

Purpose This study aims to develop and assess the tribological performance of AA2024-based hybrid composites reinforced with waste industrial stainless steel (SS) grinding particles and eggshell (ES) particles. By using waste materials, the research promotes a circular economy approach for sustainable and lightweight structural applications. Design/methodology/approach Hybrid composites were fabricated using the hot press sintering method. Microstructural analysis was conducted to examine reinforcement distribution and porosity. The relative density was measured to assess densification. Microhardness tests were performed to evaluate strengthening mechanisms, while wear analysis was carried out to determine wear rate and the coefficient of friction (COF). Findings Microstructural analysis confirmed a homogeneous distribution of reinforcements with minimal porosity (approximately 5.12% in AA2024 + 3ES + 4SS). The composites exhibited relative densities between 92% and 94.5%, demonstrating effective densification. Microhardness increased from 92.4 ± 3.1 HV (AA2024) to 128.6 ± 4.2 HV (AA2024 + 3ES + 4SS), attributed to grain refinement and reinforcement hardening effects. The lowest wear volume loss (3.293 mm3) and the COF (0.38) in AA2024 + 3ES + 4SS, indicating enhanced tribological performance. Originality/value This study introduces a novel approach to developing hybrid aluminum composites using industrial and biowaste reinforcements, offering a sustainable and cost-effective alternative for aerospace and automotive applications.