Sustainable development of AA6063 hybrid composites using agro-Waste and industrial waste reinforcements for enhanced wear resistance

Wear limits the service life of engineering components by causing material degradation and frequent replacement. Although aluminum 6063 offers low density and good corrosion resistance, its poor wear resistance restricts its wider use. In this study, AA6063-based hybrid metal matrix composites (C1–C4) were fabricated using the stir casting method by incorporating 5 wt% SiC, 5 wt% graphite, 1 wt% marble dust, and varying rice husk ash (RHA) content (1–2.5 wt%). Mechanical properties, including tensile strength and microhardness, were evaluated for both the base alloy and composites. Dry sliding wear behaviour was analysed using a ball-on-flat reciprocating tribometer based on a Taguchi L16 design, with RHA wt.%, load, and sliding frequency as input parameters, and specific wear rate and coefficient of friction (COF) as responses. Grey Relational Analysis (GRA) and ANOVA identified optimal parameters and the percentage contributions of factors to the responses. Confirmation tests showed improved wear resistance, reduced COF, and increased GRG value. Microstructural analysis confirmed uniform reinforcement distribution, demonstrating a cost-effective and sustainable enhancement in wear performance.