Structural and morphological behavior of Al-based hybrid composites reinforced by SiC and WS₂ inorganic material

Abstract

Aluminum-based composites exhibit significant potential in automotive engineering, especially in engine components, with potential to improve efficiency and lifespan. The potential and usability of developing high-performance aluminum-based hybrid composites with silicon carbide and tungsten disulfide for automotive applications were investigated in the present study. This study investigates a novel aluminum-based hybrid composite, incorporating 10 wt.% SiC and varying WS2 concentrations (0–12 wt.%). WS2 addition reduces friction, enhancing engine efficiency and lifespan. The structural and morphological features with mechanical behavior of the hybrid composites manufactured via powder metallurgy were examined. X-ray diffraction (XRD) and scanning electron microscopy (SEM) analysis reveals the phase identification with topographical features. Microstructural analysis reveals uniform SiC distribution and WS2 clustering at aluminum grain boundaries. Microhardness increases from 52.86 ± 1.264 HV to 71.12 ± 2.175 HV with increase in WS2 (1–9 wt.%). Wear decreases from 70.56 to 8.48 μm, indicating better lubrication. After 120 h, corrosion rates drop from 0.041 to 0.013 mm a−1 with WS2 (up to 9 wt.%). The research findings suggest that with addition of WS2 and SiC improves corrosion resistance and hardness, minimizing wear.