Exploring the synergistic effects of titanium dioxide reinforcements on microstructural and tribological behaviour of hybrid Al6061/5ZrO2 composite

The present study investigates the influence of n-TiO2 reinforcement on the microstructural and tribological performance of Al-6061 composites fabricated through stir casting with varying TiO2 content (0–12 wt%). Dry sliding wear tests were conducted using a pin-on-disc tribometer to evaluate the effect of normal load, sliding speed, and sliding distance on specific wear rate and coefficient of friction. An L16 Taguchi design and ANOVA were employed to analyze the significance of process parameters. The results reveal that TiO2 addition significantly enhances hardness and wear resistance, with hardness increasing from 74 HV to 94 HV as TiO2 content increased. The improvement in wear resistance is attributed to particle strengthening and the formation of a protective tribolayer during sliding. FESEM analysis of worn surfaces indicates a transition in wear mechanisms from adhesive wear to micro-cutting and surface fatigue, while EDAX confirms the retention of ceramic particles within the wear track. Taguchi analysis identifies TiO2 content as the most influential parameter governing wear behavior. The developed TiO2-reinforced Al-6061/5wt.% ZrO2 hybrid composites demonstrate improved mechanical and tribological performance, indicating strong potential for friction-intensive automotive and engineering applications.