Processing Optimization of Sustainable AA6061-Fly Ash Composites by Compocasting.

Obinna Onyebuchi Barah, Ige Bori, Abdulrazak Jinadu Otaru, Zaid Abdulhamid Alhulaybi Albin Zaid

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Article in ACS omega, 2026. The graph could read no effect estimate from its abstract, so it casts no vote on the map. Not yet cited in PubMed.

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4 · The record

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5 · Who and what money

Authors and funding

4 authors.

Obinna Onyebuchi BarahDepartment of Mechanical Engineering, School of Engineering and Applied Sciences, Kampala International University, P.O. Box 20,000, Kampala 25601, Uganda.ORCID https://orcid.org/0000-0002-5131-3045

Ige BoriDepartment of Mechanical Engineering, Kabale University, Plot 364, Kabale Municipality, Kampala 25601, Uganda.

Abdulrazak Jinadu OtaruChemical Engineering Department, College of Engineering, King Faisal University, P.O. Box 380, Al Ahsa 31982, Saudi Arabia.ORCID https://orcid.org/0000-0002-3057-4991

Zaid Abdulhamid Alhulaybi Albin ZaidChemical Engineering Department, College of Engineering, King Faisal University, P.O. Box 380, Al Ahsa 31982, Saudi Arabia.

Funding

No grant is acknowledged in the PubMed record.

6 · The paper itself

Abstract

Fly ash is an abundant industrial byproduct with potential as a particulate reinforcement in aluminum matrices, yet conventional stir casting often yields poor dispersion and weak interfaces. AA6061/fly ash composites containing 4-12 wt.% reinforcement were fabricated by compocasting (semisolid) and followed by material characterizations: XRD, SEM, fractography, hardness testing, and tensile testing. Reproducibility was assessed by analysis of variance (ANOVA), and performance was benchmarked against stir-cast counterparts. XRD detected no interfacial reaction products. SEM revealed a uniform dispersion of 20-50 μm particles, pore-free interfaces, and grain refinement, attributed to Zener pinning and heterogeneous nucleation. The microhardness doubled from 55 HV (unreinforced AA6061) to 110 HV (fly ash 12 wt.%), while the ultimate tensile strength increased from 140 to 249 MPa (+78%). Ductility decreased from 14% to 5%, consistent with the trade-offs associated with ceramic-particle toughening. Fractography revealed mixed-mode fracture surfaces with both intact and fractured particles, indicating robust interfacial bonding. ANOVA supported measurement reproducibility (

Identifiers

PMID41658175

DOI10.1021/acsomega.5c11742

PMCPMC12878745

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LicenceCC BY-NC-ND

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