Microstructural and Tribological Behaviour of Ceramics Particles Reinforced Al-Matrix Composites: A Review

Abstract

Natural minerals like sillimanite, zircon, rutile, ilmenite, and garnet have been found to be successful reinforcement materials for aluminium matrix composites (AMCs), providing a low-cost, thermally stable, and wear-resistant material alternative to fully synthetic ceramics like SiC, B4C, and Al2O3. This paper critically examines the application of natural minerals and hybrid mineral-ceramic materials in cast Al-Si matrix AMCs (specifically LM13, LM27, LM30, A356, and A390 alloys), with a focus on microstructural development, mechanical, and thermal properties, as well as tribological performance in dry sliding and brake simulated conditions. It is evident from the literature that mineral particles serve as nucleation sites, refine α-Al and silicon morphology, and influence interfacial reactions to form beneficial oxide and intermetallic compounds, thus improving hardness, dimensional stability, and high-temperature wear resistance. Quantitative results from LM13-B₄C-ilmenite, LM30-ilmenite-Sn/Gr, and zircon and sillimanite-reinforced composites reveal ~30-35% hardness enhancement, 50-70% wear resistance reduction, and marked friction coefficient stabilization compared to their respective base alloys, in some instances approaching or even surpassing grey cast iron brake materials at significantly lower densities. The importance of reinforcement architecture (fine versus coarse, two-range particles), hybridization with solid lubricants, and T4/T6 heat treatment in managing particle distribution, dislocation density, tribolayer development, and stability is emphasized. Finally, the techno-economic and sustainability implications of the substitution of synthetic ceramics and ferrous materials by mineral-based AMCs are discussed, and the research gaps in high-temperature fatigue, tribolayer modeling, and life cycle assessment that need to be addressed for the successful implementation of the technology are identified.