DEVELOPMENT OF ALUMINIUM ALLOY (AA6061) COMPOSITES FOR AUTOMOBILE EXHAUST PIPE

Abstract

This research addresses the limitations of aluminium alloy AA6061 in withstanding the harsh conditions of automotive exhaust systems. The study aims to develop a composite material with enhanced mechanical strength and corrosion resistance by reinforcing AA6061 with kaoline ore and masquerade leaves. Using the stir casting method, the alloy was combined with the reinforcements and cast into molds. The results revealed that the developed composites showed improved properties compared to the base alloy. Hardness increased from 95.4 HBW to 102.7 HBW, tensile strength rose to 270 N/mm², and yield strength to 240 N/mm². Corrosion resistance was significantly enhanced, with potential ranging from -300 mV to -550 mV, compared to -90 mV to -250 mV for the unreinforced alloy. Microstructural analyses confirmed uniform reinforcement distribution. The study recommends further optimization of reinforcement ratios and casting parameters to maximize performance for automotive applications, particularly in exhaust systems.