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Aluminium alloy (Al/3.25Cu/8.5Si) composites reinforced with fly ash particles of three different size ranges (53-75 mm, 75-103 mm and 103-125 mm) in 3, 6 and 9 wt-% were fabricated using liquid metallurgy technique. Pin on disc abrasive wear tests were carried against the disc surface fixed with SiC emery paper (120 grades). A mathematical model was developed to predict the abrasive wear and coefficient of friction of the composites. Analysis of variance technique was used to check the validity of the developed model. Composites reinforced with coarse fly ash particles exhibited better abrasive wear resistance than those reinforced with fine fly ash particles. Abrasive wear in composites with fine fly ash particles is a combination of adhesive wear and abrasive wear. Larger fly ash particles present in composites gets fractured into fine particles and entrapped between the composite pin and the disc, thereby decreasing the wear rate. Worn surfaces of the pins were then analysed using scanning electron microscopy to study the wear mechanisms of the composites. The abrasive wear was optimised using desirability based multiobjective optimisation technique.

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