Analysis of Output Performance Measures for Stir-Cast Aluminium 6061-Fly Ash Composites by Non-dominated Sorting using Pareto Front

Metal matrix composites (MMCs) are gaining prominence over conventional metals due to their superior strength-to-weight ratio, low density, minimal thermal expansion, and high-temperature resistance. This study investigates the enhancement of MMC properties by reinforcing Al-6061 alloy with fly ash particles. The composites were fabricated using the stir casting method, varying fly ash grain sizes (0–75[Formula: see text][Formula: see text]m, 75–90[Formula: see text][Formula: see text]m, and 90–150[Formula: see text][Formula: see text]m), weight percentages (10%, 20%, and 30%), and melting temperatures (800 ∘ C, 850 ∘ C, and 900 ∘ C). A novel multi-objective optimization technique based on non-dominated sorting with Pareto fronts identified the optimal parameters as 30% fly ash weight, 0–75[Formula: see text][Formula: see text]m grain size, and 850 ∘ C melting temperature. Microstructural analysis confirmed the uniform distribution of fly ash in the matrix, and hardness testing revealed significant improvement with smaller grain sizes and higher fly ash content. This study highlights the potential of fly ash-reinforced MMCs for applications demanding superior mechanical properties.