Advanced optimization of Al based hybrid matrix composites reinforced with TiC, waste glass and fly ash using statistical modeling for industrial applications

The purpose of this research is to develop and optimize Al 2024/TiC/waste glass powder/fly ash powder hybrid metal matrix composites (HMMCs) through stir casting method. The research examined how reinforcement composition (TWF: TiC+waste glass powder+fly ash powder), melt temperature (MT), stirring speed (SS) and die temperature (DT) affect the mechanical properties of the composites such as UTS and BHN. From Taguchi result, The optimal tensile strength occurred when using TWA1-MT2-SS1-DT1 parameters which correspond to 1.5 wt% reinforcement material and 700°C melting temperature running at 450 rpm with a die temperature of 150°C. From Taguchi-GRA combination, The Grey Relational Grade analysis established TWA3-MT3-SS2-DT1 as the optimal combination that includes 4.5 wt% reinforcement alongside 900°C melting temperature and 550 rpm stirring speed and 150°C die temperature. The optimization strategy based on GRA-Taguchi analysis led to major enhancements in materials properties with final results reaching 351.2 MPa tensile strength combined with 92.6 Hv hardness. The research identifies statistical optimization as a successful method to improve the mechanical output of Al 2024-based hybrid composites for their use in structure and industrial applications.