Hybrid Waste SAC-DPF Ash Reinforced Aluminium Composites: Linking Processing, Structure and Performance

Shailendra Kumar Verma; Pankaj Kumar Chauhan; Jayant Raj; Rashmi Mishra; Bharat Singh Yadav; Kishan Pal Singh

doi:10.5750/ijme.v168iA5(S).2001

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Published: Oct 21, 2026

DOI: https://doi.org/10.5750/ijme.v168iA5(S).2001

Keywords:

Date palm fiber Ash Spent alumina catalyst Metal matrix green composite Mechanical properties Wear test

Shailendra Kumar Verma

Noida Institute of Engineering and Technology, Greater Noida, Uttar Pradesh, India

Pankaj Kumar Chauhan

Galgotias University, Greater Noida, U.P., India

Jayant Raj

Government Polytechnic Motahari, Bihar, India

Rashmi Mishra

G L Bajaj Institute of Technology & Management Greater Noida, U.P., India

Bharat Singh Yadav

Delhi Skill and Entrepreneurship University, Pusa-1 Campus, (Formerly Pusa Institute of Technology) New Delhi, 110012, India

Kishan Pal Singh

Mangalayatan University, Aligarh, U.P., India

Abstract

The development of sustainable aluminium matrix composites using waste-derived reinforcements requires careful
control of manufacturing processes to achieve reliable performance. In this work, high-strength green aluminium matrix composites reinforced with waste SAC-DPF ash were fabricated via a controlled stir casting route, and the resulting process-property correlations were systematically examined. The influence of processing parameters on reinforcement distribution, densification, and interfacial integrity was evaluated through microstructural characterization. Improved dispersion of ash particles and reduced casting-related defects were observed under optimized processing conditions, which directly influenced the mechanical response of the composites. Enhanced hardness and tensile strength were primarily attributed to improved particle–matrix interaction and reduced porosity arising from effective process control. Tribological investigations revealed improved wear resistance and modified frictional behavior, associated with the presence of hard ash particles and the formation of a stable load-bearing surface during sliding. The results demonstrate that appropriate manufacturing control plays a decisive role in governing the properties of waste-reinforced aluminium composites. This study establishes a clear process–property correlation, confirming the feasibility of utilizing waste SAC-DPF ash as an effective reinforcement for producing sustainable aluminium matrix composites suitable for engineering applications.

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Vol. 168 No. A5(S) (2026): Integrating Innovation Across Disciplines New Paradigms in Multidisciplinary Research

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