Volume 48, No 1, 2026, Pages 117-130
Download full text in PDFDevelopment and Characterization of Al6061-Rice Husk Ash and Al6061-Fly Ash Composites for Tribological Brake Disc Applications
Authors:
S. Suresh Kumar 
,
A.S. Bindhu ,
V.S. Niranjan Kumar ,
H.S. Manjunatha ,
K. Praveen Kumar ,
Pavankumar Ravikumar
DOI: 10.24874/ti.2019.09.25.12
Received: 9 September 2025
Revised: 11 October 2025
Accepted: 15 December 2025
Published: 15 March 2026
Abstract:
The increasing demand for lightweight and sustainable automotive components has driven significant research into alternative materials for brake disc systems, as conventional cast iron discs contribute to excessive vehicle weight, reduced fuel efficiency, and higher emissions. This study develops and evaluates aluminum matrix composites (AMCs) based on Al6061 reinforced with rice husk ash (RHA) and fly ash (FA) to assess their mechanical and tribological performance for brake disc applications. Six composite samples containing 2, 4, and 6 wt% of RHA and FA reinforcements were fabricated using vortex-assisted stir casting, and their properties were characterized following ASTM standards (tensile: E8M-13a, hardness: E384, wear: G99-95). Wear optimization and statistical analysis were performed using Taguchi L9 orthogonal design, ANOVA, and regression modeling, with low R˛ values (18.95% for FA, 20.24% for RHA) supporting the Taguchi approach that emphasizes parameter ranking. The composite containing 6 wt% hybrid (RHA+FA) reinforcement exhibited optimal performance, showing a 10–15% improvement in hardness, approximately 20% reduction in wear rate, and a stable coefficient of friction between 0.35 and 0.40—values comparable to those of cast iron. Overall, the developed Al6061–RHA–FA composite offers a 40–60% reduction in weight compared to traditional brake discs while maintaining excellent thermal stability and wear resistance, presenting a sustainable, high-performance alternative that utilizes agro-industrial waste for automotive applications.
Keywords:
Al6061, Brake disc, Fly ash, Rice husk ash, Tribology, XRD
