STM Journals Peer-reviewed research from Consortium e-Learning Network

Journal of Polymer & Composites Original Research Special issue

Red Mud Particles' Impact on the Mechanical Properties and Microstructure of AA6005 Composites for Brake Rotor Applications

  1. Kotthapalli Karthik Department of Mechanical Engineering, Koneru Lakshmaiah Education Foundation, Vaddeswaram
  2. Priyaranjan Samal Department of Mechanical Engineering, Koneru Lakshmaiah Education Foundation, Vaddeswaram
  3. Ramatenki Chinna Department of Mechanical Engineering, Koneru Lakshmaiah Education Foundation, Vaddeswaram

Abstract

There is increasing focus on utilizing industrial waste as reinforcement in metal matrix composites, driven by the demand for eco-friendly and cost-effective materials in automotive applications. With an emphasis on their possible use in braking rotors, this study examines how red mud particles affect the microstructure and mechanical characteristics of AA6005 aluminum alloy composites. Red mud, a byproduct of the Bayer process, is a good low-cost ceramic reinforcement because it is high in silica, alumina, and iron oxides. The stir casting method was used to create the composites, which contained different weight percentages of red mud particles (2%, 4%, 6%, and 8%). A consistent distribution of red mud particles and notable grain refinement were found by microstructural analysis, which enhanced the material's hardness and resistance to wear. Although there was a slight decrease in ductility at higher reinforcement levels, mechanical tests showed that the hardness and tensile strength increased as the red mud content increased. Significant improvement was seen in the tribological performance under dry sliding circumstances, indicating improved compatibility for high-friction applications like brake rotors. The study's overall findings highlight the potential of red mud-reinforced AA6005 composites as an effective and environmentally friendly substitute material for vehicle braking systems.

Keywords

References (19)

  1. Saini DK, Jha PK. Fabrication of aluminum metal matrix composite through continuous casting route: A review and future directions. Journal of Manufacturing Processes. 2023;96:138-160. doi:10.1016/j.jmapro.2023.04.041
  2. Chawla KK. Composite Materials. 2012. doi:10.1007/978-0-387-74365-3
  3. PARAMGURU RK, RATH PC, MISRA VN. TRENDS IN RED MUD UTILIZATION – A REVIEW. Mineral Processing and Extractive Metallurgy Review. 2004;26(1):1-29. doi:10.1080/08827500490477603
  4. Hind AR, Bhargava SK, Grocott SC. The surface chemistry of Bayer process solids: a review. Colloids and Surfaces A: Physicochemical and Engineering Aspects. 1999;146(1-3):359-374. doi:10.1016/s0927-7757(98)00798-5
  5. Swain, A. Akcil, and J. Lee, “Red mud valorization an industrial waste circular economy challenge; review over processes and their chemistry,” Critical Reviews in Environmental Science and Technology, vol. 52(4), pp. 520–570, 2022, doi:10.1080/10643389.2020.
  6. Wang S, Jin H, Deng Y, Xiao Y. Comprehensive utilization status of red mud in China: A critical review. Journal of Cleaner Production. 2021;289:125136. doi:10.1016/j.jclepro.2020.125136
  7. Wu X, Zhang W. A review on aluminum matrix composites' characteristics and applications for automotive sector. Heliyon. 2024;10(20):e38576. doi:10.1016/j.heliyon.2024.e38576
  8. Dinesh Kumar PK, Darius Gnanaraj S. Aluminium-Silicon based Metal Matrix Composites for brake rotor applications: a review. Engineering Research Express. 2023;5(2):022002. doi:10.1088/2631-8695/accdb6
  9. Samal P, Mandava RK, Vundavilli PR. Dry sliding wear behavior of Al 6082 metal matrix composites reinforced with red mud particles. SN Applied Sciences. 2020;2(2). doi:10.1007/s42452-020-2136-2
  10. Sharma A, Belokar RM, Kumar S. Dry sliding wear characterization of red mud reinforced aluminium composite. Journal of the Brazilian Society of Mechanical Sciences and Engineering. 2018;40(6). doi:10.1007/s40430-018-1223-4
  11. Huang Z, Li A, Zhou W, Li J, Zhang J. Effects of Red Mud on Microstructures and Heat Resistance of ZL109 Aluminum Alloy. Materials. 2025;18(3):664. doi:10.3390/ma18030664
  12. Kar C, Surekha B. Characterisation of aluminium metal matrix composites reinforced with titanium carbide and red mud. Materials Research Innovations. 2020;25(2):67-75. doi:10.1080/14328917.2020.1735683
  13. Shanmugavel R, Sundaresan TK, Marimuthu U, Manickaraj P. Process Optimization and Wear Behavior of Red Mud Reinforced Aluminum Composites. Advances in Tribology. 2016;2016:1-7. doi:10.1155/2016/9082593
  14. M. Quader, B. S. Murthy, and P. Ravinder Reddy, “Processing and Mechanical Properties of Al2O3 and Red Mud Particle Reinforced AA6061 Hybrid Composites,” Journal of Minerals and Materials Characterization and Engineering, vol. 04, no. 2, pp. 135–142, Mar. 2016, doi:10.4236/JMMCE.2016.42013.
  15. Samal, R. Raj, R. K. Mandava, and P. R. Vundavilli, “Effect of Red Mud on Mechanical and Microstructural Characteristics of Aluminum Matrix Composites,” Lecture Notes in Mechanical Engineering, pp. 75–82, Jan. 2020, doi:10.1007/978-981-15-1307-78.
  16. M GP, S VK, L A. “Evaluation of microstructure and mechanical properties of Al6005 MMCs reinforced with B 4 C via stir casting route and optimisation through ANOVA DOE technique”. Advances in Materials and Processing Technologies. 2024;11(1):175-195. doi:10.1080/2374068x.2024.2306036
  17. Hashim J, Looney L, Hashmi MSJ. Metal matrix composites: production by the stir casting method. Journal of Materials Processing Technology. 1999;92-93:1-7. doi:10.1016/s0924-0136(99)00118-1
  18. Siva Karuna G, Swamy SVG, Naidu GS. Effect of Blast Furnace Slag and Red Mud Reinforcements on the Mechanical Properties of AA2024 Hybrid Composites. Advanced Materials Research. 2018;1148:29-36. doi:10.4028/www.scientific.net/amr.1148.29" rel="nofollow">doi:10.4028/www.scientific.net/amr.1148.29
  19. Kumar S, Bera S, Mandal D, Chakraborty AK. Transforming waste red mud and fly ash to wealth by designing a hybrid Al alloy composite with improved mechanical and tribological properties. Materialwissenschaft und Werkstofftechnik. 2025;56(1):122-131. doi:10.1002/mawe.202300378
Support