Development and characterization of grinding sludge-reinforced aluminum-based composite by friction stir process technique

Purpose The quantum of metal particle waste generation in manufacturing industries is posing a great concern for the environment. The iron forging industries generate a huge amount of grinding sludge (GS) waste, which is disposed into the earth. The accumulation of this waste in dump yards causes an increase in soil and air pollution levels. Design/methodology/approach In the current investigation, an effort was made to use this waste GS for the progress of aluminum-based composite. To maintain uniform distribution of reinforcing material, the friction stir processing technique was used. Findings The characterization based on the SEM image of the Al/GS composite revealed that uniform dispersal of reinforcement content can be attained in a single tool pass. Number of grains/inch was approximately 2,402. XRD of GS powder confirmed the presence of SiO2, Fe2O3, Al2O3 and CaO phases. These phases proved GS to be a better reinforcement with aluminum alloy. Tensile strength and hardness were significantly improved in comparison to the aluminum alloy. Thermal expansion and corrosion weight loss were evaluated to observe the influence of GS addition. Originality/value The studies proved that the use of GS as reinforcement material can help in curbing the menace of soil pollution to a large extent.