Microstructural Investigation of Tensile Fractography and Wear Properties of Scrap Aluminium Engine Head (SAEH) Reinforced with Fresh and Spent Catalysts from Petrochemical Industries using Stir Casting Method

Abstract This study examines the microstructural properties, tensile fractography, and wear characteristics of scrap aluminum engine head (SAEH) composites reinforced with different types of alumina catalysts. Four composite variants were created using the stir casting method: SAEH + spent alumina catalysts (SAC), SAEH + fresh alumina catalysts (FAC), LM25 + SAC, and LM25 + FAC. Scanning electron microscopy (SEM) was utilized to analyze the microstructural features, while pin-on-disk wear testing was performed to assess wear properties. The results indicate that the SAEH + SAC composite demonstrates superior mechanical and wear properties compared to the other variants. The SAEH + FAC composite exhibits the second-best performance, followed by the LM25 + SAC and LM25 + FAC composites. SEM analysis confirms the presence of cohesive and uniform microstructures in composites containing SAC and FAC. These findings emphasize the potential of utilizing waste materials, specifically SAEH from automotive scrap yards matrices and SAC as reinforcement materials from petrochemical industries. This approach offers enhanced mechanical and wear properties, making it suitable for various applications.