Fabrication, mechanical characterization, and wear optimization of Al6061-CSAp metal matrix composites using hybrid Taguchi-ARAS-Sunflower Algorithm Approach

The need to develop lighter, stronger, and less expensive engineering materials has compounded the move toward Aluminum metal matrix composites (AMMCs) in a variety of fields. With industries placing more emphasis on the sustainability, waste minimization and enhanced wear behavior, the incorporation of waste-based reinforcements with environmentally friendliness has turned out to be mandatory in the creation of next-generation AMMCs with better mechanical and tribological characteristics. In this direction, the current research explores AA6061 composite with commercially sourced coconut shell ash particulates (CSAp), a low-cost bio-waste substance through a combined experimental and optimization-based method to improve their mechanical and tribological properties and promote the objectives of the circular economy. The 5–15 wt% of CSAp composites were prepared by the stir casting method and tested at different loads and sliding distances with an aim of gaining insight into how the composites wear. Through a Taguchi L27 design, the load was the most dominant independent variable that influenced wear, which was also validated by ANOVA. The Additive Ratio Assessment (ARAS) technique with multiple criteria revealed that the combination of 10 N load, 10% CSAp, and 1000 m sliding distance was the most effective combination in terms of wear, wear rate, and friction responses. In order to optimize this optimum to the levels beyond the discrete experiment levels, the Sunflower Optimization (SFO) algorithm was utilized. SFO rapidly converged to a continuous optimum that was closely aligned and showcased great concurrence with Taguchi and ARAS forecasts. The good convergence emphasizes the consistency of the developed model and the steady and predictable behavior of the utility function of the system. Microstructural analysis verified the same CSAp dispersion and enhanced the bonding between matrices and particles and the reason behind less wear and constant formation of transfer films under low loading conditions. The innovative aspect of this work is that a combined Taguchi-ARAS-SFO framework is applied to a composite reinforced with market-available CSAp to provide a feasible and sustainable solution without involving any steps of processing of the ash. The implications of the findings are also applicable to lightweight automotive, aerospace, and machine components where wear resistance is of great importance. Altogether, this paper shows that CSAp-impregnated AA6061 composites could provide better performance at the same time promoting the economic and environmental-friendly development of the material.