Abstract
Fly ash (FA) is a waste product of coal combustion in thermal power plants which is
available in massive quantities all over the world causing land pollution. This paper reports
the characterization of AA6061 aluminum matrix composites (AMCs) reinforced with FA
particles synthesized using friction stir processing (FSP). The volume fraction of FA particles
was varied from 0 to 18 in steps of 6. The prepared AMCs were characterized using optical
microscopy (OM), scanning electron microscopy (SEM) and electron backscattered diagram
(EBSD). The wear rate was estimated using a pin-on-disc wear apparatus. FA particles were
observed to be distributed homogeneously in the AMC irrespective of the location within the
stir zone. The EBSD micrographs revealed remarkable grain refinement in the AMC. The
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incorporation of FA particles enhanced the microhardness and wear resistance of the AMC.
The strengthening mechanisms of the AMC were discussed and correlated to the observed
microstructures. The wear mechanisms were identified by characterizing the wear debris and
worn surfaces.