AL6061/Al2O3-Ash Reinforced Composites: An Experimental and Statistical Study Using Ultrasonic Stir Casting

Year : 2025 | Volume : 13 | Special Issue 06 | Page : 1123 1133
    By

    M Naga Phani Sastry,

  • K. Devaki Devi,

  • Borigorla Venu,

  • PVR Girish Kumar,

  1. Associate Professor, Department of Mechanical Engineering, G. Pulla Reddy Engineering College (Autonomous), Kurnool, Andhra Pradesh, India
  2. Associate Professor, Department of Mechanical Engineering, G. Pulla Reddy Engineering College (Autonomous), Kurnool, Andhra Pradesh, India
  3. Assistant Professor, Department of Mechanical Engineering, Vignan’s Foundation for Science, Technology and Research (Deemed to be University), Campus Hyderabad, Telangana, India
  4. Senior Assistant Professor, Department of Mechanical Engineering, Geethanjali College of Engineering and Technology (Autonomous), Hyderabad, Telangana, India

Abstract

This study presents an experimental investigation on the influence of fly ash particle size on the mechanical properties of aluminum alloy (Al6061) composites fabricated through Ultrasonic Assisted Stir Casting. Fly ash, a low-cost and low-density by-product of thermal power plants, has emerged as an effective reinforcement material due to its excellent fluidity, high filling capability, and ease of processing. It has been increasingly utilized in metal, polymer, and rubber composites to enhance mechanical and thermal performance. In this research, Al6061-based composites were developed with fly ash contents of 5%, 10%, and 15% by weight, incorporating particle sizes ranging from 5–20 µm, 25–30 µm, and 50–60 µm. The mechanical behavior of the composites was evaluated in terms of ultimate tensile strength (UTS), ultimate compressive strength (UCS), and hardness. The results revealed that the mechanical properties improved with an increase in fly ash content, owing to enhanced interfacial bonding and particle dispersion within the matrix. However, as the particle size increased, a decline in mechanical performance was observed due to reduced surface area and weaker bonding with the matrix. An optimal fly ash content of around 10% was found to provide the best balance between strength and ductility, whereas a slight reduction in UTS occurred at 15% reinforcement, indicating a saturation threshold for effective load transfer.

Keywords: Ultrasonic-assisted stir casting, Al6061, metal matrix composites, fly ash powder, Al2O3, mechanical properties

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

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How to cite this article:
M Naga Phani Sastry, K. Devaki Devi, Borigorla Venu, PVR Girish Kumar. AL6061/Al2O3-Ash Reinforced Composites: An Experimental and Statistical Study Using Ultrasonic Stir Casting. Journal of Polymer & Composites. 2025; 13(06):1123-1133.
How to cite this URL:
M Naga Phani Sastry, K. Devaki Devi, Borigorla Venu, PVR Girish Kumar. AL6061/Al2O3-Ash Reinforced Composites: An Experimental and Statistical Study Using Ultrasonic Stir Casting. Journal of Polymer & Composites. 2025; 13(06):1123-1133. Available from: https://journals.stmjournals.com/jopc/article=2025/view=235316


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Special Issue Subscription Original Research
Volume 13
Special Issue 06
Received 27/08/2025
Accepted 26/09/2025
Published 21/11/2025
Publication Time 86 Days
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