Multifaceted Analysis of Aluminum–Coal Ash–Pumice Composites for Enhanced Brake Disc Specific Heat Capacity
DOI:
https://doi.org/10.11113/jm.v48.509Keywords:
Aluminum-Pumice-Coal Ash Hybrid composite; Specific Heat Capacity; Characterization; Taguchi Optimization.Abstract
The present study investigated the optimization and modelling of some specific process parameters of double stir casting of aluminum, pumice, coal ash (Al-BP-CA) hybrid composites to improve its specific heat capacity for automobile brake disc applications. The constituents were analyzed using X-ray fluorescence (XRF), X-ray diffraction (XRD), thermogravimetric analysis (TGA), and scanning electron microscopy (SEM). The Taguchi approach was utilized to design the experimental runs and optimize the weight composition of reinforcements and stir-casting process parameters. The regression analysis was utilized in developing the mathematical model to forecast the specific heat capacity of the composites. The characterization results revealed that brown pumice and coal ash contained hard and stiff minerals such as SiO2, Fe2O3, and Al2O3, making them well-suited as reinforcement in metal matrixes such as aluminum, titanium, and magnesium. According to the thermogravimetric and differential thermal analyses, the aluminum alloy, brown pumice, and coal ash can endure temperatures up to 264.08, 724 °C, and 606.61°C before any deterioration. The optimal specific heat capacities achieved were 824.85 J/kgK (experimental) and 820.48 J/kgK (predicted) by utilizing 7.5 vol% of brown pumice, 5 vol% of coal ash, 400 rpm stirrer speed, 850 °C pouring temperature, and 20 minutes stirring duration. The developed mathematical model shows an excellent level prediction for the specific heat capacity of the composites based on the process parameters and ceramics reinforcement, with R-Square and adjusted R-Square, and predicted R-Square values of 99.27%, 97.25%, and 88.12%, respectively.
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