Response Surface Methodology Analysis of Wear Behavior in Aluminium Matrix Composites Reinforced with Rice Husk Ash–Derived Silica

Abstract

The sustainable AA6061 aluminium matrix composites reinforced with rice husk ash (RHA) derived silica (RHA-Si) were developed and optimized using Response Surface Methodology (RSM) which was designed using Box–Behnken (B–B) experimental design. The influencing effect of silica reinforcement (2–6 wt.%), applied load (10–30 N) and sliding speed (1–3 m s^-1) on wear rate, coefficient of friction and surface roughness were systematically scrutinized. The coefficient of regression of developed quadratic and two-factor interaction regression model had high values of R² for wear rate (0.9948), coefficient of friction (0.9668), and surface roughness (0.9672), respectively, having excellent predictive capability. The optimum condition was determined to be silica content of 6 wt.%, applied load of 10 N, sliding speed of 1.513 m s^-1, with a wear rate of 1.725 × 10^-3 mm³/N·m, coefficient of friction of 0.339, surface roughness of 0.663 μm, and overall desirability of 0.981. The confirmation experiments were consistent with the expected results, confirming the validity of the statistical models developed for the purpose of optimizing the tribological behavior of the system in a sustainable way.