Development of cow horn-eggshell reinforced AA 6063 aluminum metal matrix composite

In this study, powdered cow horn and eggshell were used as reinforcement materials for Aluminum Alloy (AA6063) composite. The cow horn and eggshell reinforced AA6063 metal matrix composite specimens were casted in a mold with dimensions of 120 mm X 20 mm X 5 mm. The specimens were produced in the following percentages (AA6063: Eggshell: cow horn) which were derived using extreme vertices design: 64.5:11.5:24:0, 57.0:19.0:24.0, 64.0:18.0:18.0, 77.0:11.5:11.5, 65.0:30.0:5.0, 57.0:24.0:19.0, 64.5:24.0:11.5, 50.0:20.0:30.0, 65.0:5.0:30.0, 50.0:30.0:20.0, 90.0:5.0:5.0 and 100.0:0.0:0.0 respectively. Flexural strength, tensile strength and impact strength tests were conducted on the developed AA6063 composites. The results of the tests showed that the 100% aluminum sample gave the highest flexural strength value of 328.035 N/mm 2 , followed by the sample with 11.5% eggshell and 11.5% cow horn which gave a flexural strength value of 320.874 N/mm 2 . Also, the 100% aluminum sample gave the highest tensile strength of value of 252.908 N/mm 2 , followed by the 5% eggshell and 5% cow horn sample with tensile strength value of 232.908 N/mm 2 . Finally, the 30% eggshell and 20% cow horn sample had the highest impact strength value of 18.645 J, while the 5% eggshell and 5% cow horn sample had the lowest impact strength of 14.967 J. XRD, FTIR, SEM and XRF analysis results showed that changes in the composite contents have little effect on the matrix’s basic crystalline structure. XRD reveals slight detectable change in the Al matrix crystal structure showing that the reinforcement participated in metallurgical bonding . The results suggest that the developed aluminum composites may be suitable for non-structural , high-impact applications such as interior automotive trim, protective packaging, or proof-of-concept demonstration of agro-waste valorization, subject to further validation of fatigue and corrosion performance.