Mechanical Properties of Al2024/Al₂O₃/MgO/Graphite composites via hydro-thermal hot pressing route

Currently, the research community is focused on hybrid composites with two different reinforcements. However, it's difficult to attain both mechanical strength and wear resistance simultaneously. So, the prime novelty of this research work is to enhance both the mechanical strength and wear performance of the composites by adding three reinforcement particles effectively through the hydro-thermal hot pressing technique. In this research, Al2024 alloy was reinforced with Al₂O₃–MgO-Gr particles in five different reinforcement combinations. With the help of a 3D mixer, the reinforcements were mixed in determined ratios for 30 min. The mixed powders were cold pressed under 50 MPa pressure, and then hot pressed at 550 °C under 200 MPa pressure. The fabricated hybrid composite materials were evaluated for their density and porosity. Further, hardness, transverse rupture strength and wear performance were investigated. The predominant wear mechanism was examined by wear mechanism maps under various sliding and normal conditions. The outcome shows that the inclusion of excess (>3%) nano MgO and (>1.5%) Gr particles decrease the density of the composite materials by forming micropores. The optimum reinforcement combination of 10% Al₂O₃, 3% of MgO and 1.5% of Gr particles shows improved cross-fracture strength of 132.6 MPa, minimum volume loss of 0.55 mm³ and decreased frictional coefficient of 0.18. Further, the smoothness in the worn-out surface SEM images of the composites substantiates the enhanced wear performance.