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Journal of Polymer & Composites Original Research Special issue

Experimental Assessment and Statistical Argument of Al-Si/CSA/MoS2 Hybrid Composites for Mechanical and Tribological Characteristics

  1. Sivasankara Raju Rallabandi Department of Mechanical Engineering, Aditya Institute of Technology and Management, Tekkali, Srikakulum
  2. Srinivasa Rao Gunji Department of Mechanical Engineering, RVR&JC Engineering College, Guntur
  3. Lakshmi Srinivas Chennupati Department of Mechanical Engineering, Bapatla Engineering College, Bapatla
  4. Suresh Gamini Department of Mechanical Engineering, Vignan's Foundation for Science Technology and Research, Guntur
  5. Mukthikanta Panigrahi Department of Materials Science, Maharaja Sriram Chandra Bhanja Deo University
  6. Ashok Darsigunta Department of Mechanical Engineering, Rise Krishna Sai Prakasam Group of Institutions ONGOLE

Abstract

To augment the mechanical and tribological properties of Al-Si matrix composites complement with molybdenum disulphide (MoS₂) and coconut shell ash (CSA), a mixed experimental and Face-Centered Composite (FCC)strategy was employed. A liquid metallurgical method called stir casting was used to create hybrid composites with 5–15 wt.% CSA and 1–3 wt.% MoS₂. A FCC experimental design with thirty runs was used to thoroughly evaluate the materials. This design allowed for the systematic study of wear rate (WR) and coefficient of friction (COF) as functions of reinforcement (CSA and MoS₂), applied load (15–45 N), and sliding velocity (1–3 m/s). There was a vivid increase in imperative performance indicators due to the synergy fashioned by combining CSA, a hard ceramic phase, with MoS2, a solid lubricant. When compared to the unreinforced base alloy, the optimized Al-Si/10 wt.% CSA/3 wt.% MoS₂ hybrid composite showed an improvement of 31.9% rise in hardness, a 25.9% achieve in tensile strength, a notable 32.5% diminution in density, a 42.2% decline in wear rate, and a 23.3% plunge in COF. The robust contest (R² > 0.94) for together WR and COF retort was formed by arithmetic regression replica erect on the FCC design. This validates the robustness of the tentative approach and persuade of the variables. Feature consequence analysis acknowledged sliding velocity and load as the majority vital factors persuade tribological behavior. The creation of lubricating MoS2 tribofilms and the homogenous scattering of CSA particles were inveterate by microstructural investigations using SEM and EDX, lend credibility to the pragmatic perfection in properties. In order to create multifunctional lightweight composites with improved wear resistance and reduced friction, the study emphasizes the efficacy of mixing CSA produced from agro-waste with MoS₂ reinforcement. The results show that the Al-Si/10 wt.% CSA/3 wt.% combination Cylinder liners and brake rotors are two examples of the kinds of high-stress automotive and maritime components that could benefit greatly from MoS₂ composites due to their exceptional mechanical strength-to-weight ratio and their ability to optimize tribological properties. A potent approach for expedited material development in modern engineering applications is the combination of experimental optimization with machine learning prediction.

Keywords

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