Fabrication of Al-4.5% Cu alloy with fly ash metal matrix composites and its characterization

Metal matrix composites (MMCs) are engineered materials, formed by the combination of two or more dissimilar materials (at least one of which is a metal) to obtain enhanced properties. In the present investigation, an Al-4.5% Cu alloy was used as the matrix and fly ash as the filler material. The composite was produced using conventional foundry techniques. The fly ash was added in 5%, 10%, and 15 wt. % to the molten metal. The composite was tested for fluidity, hardness, density, mechanical properties, impact strength, dry sliding wear, slurry erosive wear, and corrosion. Microstructure examination was done using a scanning electron microscope to obtain the distribution of fly ash in the aluminium matrix, The results show an increase in hardness, tensile strength, compression strength, and impact strength with increasing the fly ash content. The density decreases with increasing fly ash content. Resistance to dry wear and slurry erosive wear increases with increasing fly ash content. Corrosion increases with increasing fly ash content.