Red Mud Particles’ Impact on the Mechanical Properties and Microstructure of AA6005 Composites for Brake Rotor Applications

Year : 2025 | Volume : 13 | Special Issue 06 | Page : 573 581
    By

    Kotthapalli Karthik,

  • Priyaranjan Samal,

  • Ramatenki Chinna,

  1. Research Scholar, Department of Mechanical Engineering, Koneru Lakshmaiah Education Foundation, Vaddeswaram, Andhra Pradesh, India
  2. Assistant Professor, Department of Mechanical Engineering, Koneru Lakshmaiah Education Foundation, Vaddeswaram, Andhra Pradesh, India
  3. Research Scholar, Department of Mechanical Engineering, Koneru Lakshmaiah Education Foundation, Vaddeswaram, Andhra Pradesh, India

Abstract

There is increasing focus on utilizing industrial waste as reinforcement in metal matrix composites, driven by the demand for eco-friendly and cost-effective materials in automotive applications. With an emphasis on their possible use in braking rotors, this study examines how red mud particles affect the microstructure and mechanical characteristics of AA6005 aluminum alloy composites. Red mud, a byproduct of the Bayer process, is a good low-cost ceramic reinforcement because it is high in silica, alumina, and iron oxides. The stir casting method was used to create the composites, which contained different weight percentages of red mud particles (2%, 4%, 6%, and 8%). A consistent distribution of red mud particles and notable grain refinement were found by microstructural analysis, which enhanced the material’s hardness and resistance to wear. Although there was a slight decrease in ductility at higher reinforcement levels, mechanical tests showed that the hardness and tensile strength increased as the red mud content increased. Significant improvement was seen in the tribological performance under dry sliding circumstances, indicating improved compatibility for high-friction applications like brake rotors. The study’s overall findings highlight the potential of red mud-reinforced AA6005 composites as an effective and environmentally friendly substitute material for vehicle braking systems.

Keywords: Aluminum, Red mud, Brake Rotor, Composites, Mechanical.

[This article belongs to Special Issue under section in Journal of Polymer & Composites (jopc)]

How to cite this article:
Kotthapalli Karthik, Priyaranjan Samal, Ramatenki Chinna. Red Mud Particles’ Impact on the Mechanical Properties and Microstructure of AA6005 Composites for Brake Rotor Applications. Journal of Polymer & Composites. 2025; 13(06):573-581.
How to cite this URL:
Kotthapalli Karthik, Priyaranjan Samal, Ramatenki Chinna. Red Mud Particles’ Impact on the Mechanical Properties and Microstructure of AA6005 Composites for Brake Rotor Applications. Journal of Polymer & Composites. 2025; 13(06):573-581. Available from: https://journals.stmjournals.com/jopc/article=2025/view=234343


References

  1. K. Saini, P.K. Jha, “Fabrication of aluminum metal matrix composite through continuous casting route: A review and future directions,” Journal of Manufacturing Process, vol. 96, pp. 138–160, 2023, doi.org/10.1016/j.jmapro.2023.04.041.
  2. K. Chawla, “Composite materials: Science and engineering, third edition,” Composite Materials: Science and Engineering, Third Edition, pp. 1–542, Jan. 2012, doi: 10.1007/978-0-387-74365-3.
  3. K. Paramguru, P. C. Rath, and V. N. Misra, “Trends in red mud utilization – A review,” Mineral Processing and Extractive Metallurgy Review, vol. 26, no. 1, pp. 1–29, 2005, doi: 10.1080/08827500490477603.
  4. Hind, S. Bhargava, S. G.-C. and surfaces A, “The surface chemistry of Bayer process solids: a review,” Colloids and surfaces A: Physicochemical and engineering aspects, vol. 146, pp. 359–374, 1999, doi.org/10.1016/S0927-7757(98)00798-5.
  5. Swain, A. Akcil, and J. Lee, “Red mud valorization an industrial waste circular economy challenge; review over processes and their chemistry,” Critical Reviews in Environmental Science and Technology, vol. 52(4), pp. 520–570, 2022, doi:10.1080/10643389.2020.
  6. Wang, H. Jin, Y. Deng, and Y. Xiao, “Comprehensive utilization status of red mud in China: A critical review,” J Clean Prod, vol. 289, p. 125136, Mar. 2021, doi: 10.1016/J.JCLEPRO.2020.125136.
  7. Wu, W. Zhang, “A review on aluminum matrix composites’ characteristics and applications for automotive sector,” Heliyon, vol. 10, pp. e38576, 2024, doi: 10.1016/j.heliyon.2024.e38576.
  8. Kumar, S. Gnanaraj, “Aluminium-silicon based metal matrix composites for brake rotor applications: a review,” Engineering Research Express, vol. 5, pp. 022002, 2023. doi:10.1088/2631-8695/accdb6.
  9. Samal, R.K. Mandava, P.R. Vundavilli, “Dry sliding wear behavior of Al 6082 metal matrix composites reinforced with red mud particles”, SN Applied Sciences, vol. 2(2), pp. 313, 2020. doi.org/10.1007/s42452-020-2136-2
  10. Sharma, R.M. Belokar, S. Kumar, Dry sliding wear characterization of red mud reinforced aluminium composite, Journal of the Brazilian Society of Mechanical Sciences and Engineering, vol. 40, pp. 194, 2018, doi.org/10.1007/s40430-018-1223-4.
  11. Huang, A. Li, W. Zhou, J. Li, J. Zhang, Effects of Red Mud on Microstructures and Heat Resistance of ZL109 Aluminum Alloy, Materials, vol. 18(3) pp. 664, 2025. doi.org/10.3390/ma18030664.
  12. Kar and B. Surekha, “Characterization of aluminium metal matrix composites reinforced with titanium carbide and red mud,” Materials Research Innovations, vol. 25, no. 2, pp. 67–75, Feb. 2021, doi: 10.1080/14328917.2020.1735683.
  13. Shanmugavel, T. K. Sundaresan, U. Marimuthu, and P. Manickaraj, “Process optimization and wear behavior of red mud reinforced aluminum composites,” Advances in Tribology, 2016. doi: 10.1155/2016/9082593.
  14. M. Quader, B. S. Murthy, and P. Ravinder Reddy, “Processing and Mechanical Properties of Al2O3 and Red Mud Particle Reinforced AA6061 Hybrid Composites,” Journal of Minerals and Materials Characterization and Engineering, vol. 04, no. 2, pp. 135–142, Mar. 2016, doi: 10.4236/JMMCE.2016.42013.
  15. Samal, R. Raj, R. K. Mandava, and P. R. Vundavilli, “Effect of Red Mud on Mechanical and Microstructural Characteristics of Aluminum Matrix Composites,” Lecture Notes in Mechanical Engineering, pp. 75–82, Jan. 2020, doi: 10.1007/978-981-15-1307-78.
  16. G. Prasad, S. Vijay Kumar and L. Avinash, “Evaluation of microstructure and mechanical properties of Al6005 MMCs reinforced with B4C via stir casting route and optimisation through ANOVA DOE technique” Advances in Materials and Processing Technologies, vol. 11(1). pp. 175-195, 2025, doi: 10.1080/2374068X.2024.2306036.
  17. Hashim, L. Looney, M. Hashmi. “Metal matrix composites: production by the stir casting method,” Journal of materials processing technology, vol. 92-93, pp. 1–7. 1999. doi.org/10.1016/S0924-0136(99)00118-1
  18. Siva Karuna, S. Swamy, G.S. Naidu, “Effect of blast furnace slag and red mud reinforcements on the mechanical properties of AA2024 hybrid composites”, Advanced Materials Research, Volume 1148, pp. 29–36, 2018, doi.org/10.4028/www.scientific.net/AMR.1148.29.
  19. Kumar, S. Bera, D. Mandal, A. K. Chakraborty, “Transforming waste red mud and fly ash to wealth by designing a hybrid Al alloy composite with improved mechanical and tribological properties”, Materials Science and Engineering Technology, 2025 (In Press) doi.org/10.1002/mawe.202300378.
Special Issue Subscription Original Research
Volume 13
Special Issue 06
Received 30/05/2025
Accepted 08/07/2025
Published 16/09/2025
Publication Time 109 Days
114

Login


My IP

PlumX Metrics