Corrosion Behaviour, Wear Performance, and Mechanical Properties of Al5052 Hybrid Nanocomposites for Marine and Automotive Applications

Aluminium alloys are widely used in transportation and structural applications because of their low density and good castability, but their performance in aggressive environments requires enhanced corrosion resistance and wear reliability along with adequate mechanical strength. In this study, Al5052-based nanocomposites reinforced with TiB 2 and ZrO 2 were developed using stir-casting with primary emphasis on corrosion behaviour and statistically validated wear performance. Corrosion resistance was evaluated in a 3.5 wt% NaCl solution using a mass-loss method, simulating marine conditions, while dry sliding wear behaviour was systematically analyzed using a Taguchi L27 design and ANOVA to determine the influence and significance of load, sliding speed, and reinforcement composition on wear rate. Microstructural examination revealed fairly uniform dispersion of TiB 2 and ZrO 2 particles within the Al5052 matrix, with minor agglomeration and porosity at higher reinforcement levels. Grain size analysis indicated refinement due to the presence of ceramic reinforcements, contributing to improved overall performance. Corrosion results demonstrated enhanced resistance of hybrid composites compared to the base alloy, attributed to the combined effect of grain refinement and the barrier action of reinforcements. Taguchi-ANOVA results identified load as the most significant parameter affecting wear behaviour, followed by sliding speed and composition, confirming the effectiveness of statistical optimization in evaluating wear mechanisms. Mechanical characterization showed consistent improvement in tensile strength and hardness with reinforcement addition. These results indicate that the developed nanocomposites are promising for lightweight structural components such as piston rings, cylinder liners, drive shafts and brake parts in aerospace, automotive and marine applications.