Mechanical and wear characteristics of Al/SiC/ZrO2 hybrid composites synthesized via stir-squeeze casting method for sustainable industrial applications

Aluminium matrix composites (AMCs) reinforced with ceramic particulates have attracted considerable interest in the lightweight engineering sector owing to their superior mechanical strength and tribological performance. The present investigation successfully synthesizes Al–SiC–ZrO 2 hybrid composites via stir–squeeze casting to evaluate the influence of zirconia addition on microstructural, mechanical, physical, and wear characteristics. Microstructural examinations revealed a fairly uniform dispersion of SiC and ZrO 2 reinforcements throughout the aluminium matrix, while XRD and EDX analyses confirmed the successful incorporation of the reinforcing phases. The measured density increased from 2.55 to 3.24 g/cm³ as ZrO 2 was progressively added. The microhardness values increased from 65.67 HVN for AS1–93.33 HVN for ASZ3. Similarly, tensile and compressive strengths increased from 85 to 136 MPa and from 364 to 448 MPa, respectively. Tribological tests indicated a notable decline in the coefficient of friction along with improved wear resistance as the ZrO 2 content increased. Among all compositions, the ASZ3 composite demonstrated the highest overall performance, attributed to the combined strengthening effect of SiC and ZrO 2 reinforcements along with improved particle distribution achieved through stir–squeeze casting, highlighting its suitability for advanced automotive and lightweight structural applications.