Fabrication, Mechanical Characterization & Statistical Optimization

This project focuses on the fabrication and mechanical characterization of Aluminium 7075 metal matrix composites reinforced with copper, silicon carbide, and fly ash using the stir casting technique. Aluminium 7075 is selected as the base material due to its high strength-to-weight ratio and good mechanical properties, while copper, silicon carbide, and fly ash are used as reinforcements to improve strength, hardness, and wear resistance. The composites are fabricated by varying reinforcement combinations and cast into flat plate specimens. After casting, machining is carried out to obtain standard test specimens. Mechanical properties such as tensile strength and hardness are evaluated. Design of Experiments using the Taguchi method is applied to optimize process parameters, and Analysis of Variance (ANOVA) is used to identify the significant factors affecting the mechanical properties. The results demonstrate that the addition of reinforcements significantly enhances the mechanical performance of Aluminium 7075 composites, making them suitable for lightweight structural and automotive applications.