Development of Sustainable Aluminum-Based Composite Material Using Waste Eggshell, Iron Slag, and Nano-MgSO4

Abstract

This study delineates the development and thorough evaluation of AA3105 aluminum alloy composites fortified with carbonized eggshell powder, iron slag, and Nano-MgSO₄. To get even distribution, the reinforcement particles were ball-milled and then turned into a single entity before being added to the aluminum matrix using stir casting. To make the composites even better, precipitation hardening was used to improve their mechanical and functional qualities. Microstructural examination showed that the particle distribution was more uniform and refined, and that the particle-matrix interfacial bonding was strong. This made the load transfer better and the overall structural integrity better. Mechanical tests showed a big improvement in tensile strength and hardness. After heat treatment, the AA3105/7.5% CESA/7.5% Iron Slag/1.5% MgSO₄ composite’s tensile strength and hardness went up by about 36 and 65%, respectively. The presence of strong reinforcing phases made ductility and impact toughness go down a little bit, but heat treatment brought them back up by refining the grains and relieving stress. Corrosion testing in 3.5 wt % NaCl showed very little weight loss (around 0.009–0.010 g), and thermal expansion tests showed that the material was very stable in size (4.0–4.1 mm³), which shows that it is quite resistant to chemicals and heat. The findings underscore the synergistic effect of eggshell, iron slag, and Nano-MgSO₄, demonstrating that industrial and agricultural waste can be efficiently employed to create sustainable, high-performance aluminum matrix composites. The research confirms that these hybrid composites have superior mechanical, thermal, and corrosion characteristics, rendering them appropriate for structural and high-temperature engineering applications.