Microstructural Study and Wear Optimization of Squeeze Stir Casted Al6061/FA/CSA/Graphite Composite Material

Composite materials play a crucial role in the modern manufacturing sector due to their superior mechanical properties. The quality of the final cast structure largely depends on the precise selection of processing parameters. To achieve defect-free castings, these parameters must be meticulously controlled. Various processing factors significantly influence the final properties of the product. Therefore, optimizing squeeze casting parameters is essential to producing high-performance metal matrix composites with enhanced characteristics. This study focuses on the structural morphology of the reinforced Al-6061 metal matrix composites manufactured using the squeeze stir method for casting. The reinforcement materials combined with the metal matrix composite are graphite, coconut shell ash, and fly ash. A dry sliding wear test was conducted for the reinforced Al-6061 composite samples, and the results were optimized using response surface methodology (RSM) Box–Behnken design (BBD). The ANOVA results stated that all the considered parameters are significant for the wear rate analysis. The responses of sample 2, containing 2% coconut shell ash, 2% fly ash, and 2% graphite, exerted better wear resistance. The optimum wear results obtained for sample 2 are at 10.69 N load, 500.01 m sliding distance, and 0.50 m/s sliding velocity, which provided lower volume loss as 0.005 mm³, wear rate as 0.002 mm³/m and 0.33 as a coefficient of friction.