Optimization of mechanical, tribological, and machining properties of TiO₂-reinforced AA6013 composites

Abstract

Aluminum-based metal matrix composites (MMCs) have emerged as strong candidates for next-generation automotive and aerospace components due to their high strength-to-weight ratio and improved performance under demanding service conditions. Among these, the incorporation of TiO₂ ceramic particles into AA6013 aluminum alloy provides an opportunity to enhance mechanical properties, wear resistance, and machining behavior in a unified manner. This study investigates AA6013–TiO₂ composites fabricated by stir casting with reinforcement levels of 3%, 6%, and 9% by weight. Mechanical characterization revealed consistent improvements in hardness, tensile strength, and impact resistance with increasing TiO₂ addition, while tribological testing demonstrated significant reductions in wear rate and friction coefficient. Machinability was systematically evaluated and optimized using Taguchi design of experiments, which identified cutting speed, feed rate, and depth of cut as the most influential parameters. Confirmation testing at the optimal conditions yielded superior surface quality and lower thermal stresses. The novelty of this work lies in its integrated assessment of mechanical, tribological, and machining responses of TiO₂-reinforced AA6013 composites, supported by statistical validation and optimization strategies. The findings establish AA6013–TiO₂ composites as promising lightweight materials for high-performance applications in the automotive and aerospace industries.