Microstructural and Elemental Characterization of Aluminium Alloy A356/Cow Horn Particle Composite Using SEM and EDX Techniques

Research into substitute reinforcements for metal matrix composites has increased due to the engineering and automotive sectors' increasing need for lightweight, strong, and reasonably priced materials. Despite their effectiveness, conventional reinforcements like silicon carbide and alumina are costly and harmful to the environment. To examine the machining behavior of aluminum alloy A356 reinforced with cow horn particles (0–20%), the study used an experimental methodology. To guarantee structural integrity, spark plasma sintering was used to create the composites at 550°C and 30 MPa under vacuum. Using HSS and HCS tools, machining experiments were carried out on a Universal Turning Machining Center. Response Surface Methodology was used to improve parameters such as cutting speed, feed rate, and depth of cut. Using a Phenom ProX model, scanning electron microscopy (SEM) was used to analyze surface morphology, and energy dispersive X-ray spectroscopy (EDX) was used to characterize the ideal composite sample's elements and composition. Scanning Electron Microscope (SEM) results revealed reduced wear in CHp composites, as larger particles improved interfacial bonding, toughness, and resistance to plastic deformation compared to the unreinforced alloy. The study demonstrates that CHp reinforcement offers an eco-friendly and economical approach to enhancing the performance of aluminum alloys for industrial applications.