High-Performance Aluminium Hybrid Composited Reinforced with Zn, Sn and Ti for Lightweight Automotive and Advanced Structural Applications

Md. Shahriar Islam; Paban Barua Nishan; Pritom Barua Shuvo

doi:10.38032/scse.2026.4.104

Authors

Md. Shahriar Islam Department of Mechanical Engineering, Chittagong University of Engineering & Technology, Chattogram-4349, Bangladesh
Paban Barua Nishan Department of Mechanical Engineering, Chittagong University of Engineering & Technology, Chattogram-4349, Bangladesh
Pritom Barua Shuvo Department of Mechanical Engineering, Chittagong University of Engineering & Technology, Chattogram-4349, Bangladesh

DOI:

https://doi.org/10.38032/scse.2026.4.104

Keywords:

Aluminium Hybrid Composites, Zn-Sn-Ti Reinforcements, Stir Casting, Lightweight Design

Abstract

This study focuses on the fabrication and characterization of high-performance aluminium hybrid metal matrix composites (AMMCs) reinforced with zinc (Zn), tin (Sn), and titanium (Ti) for lightweight automotive and advanced structural applications. Using the stir casting process, three hybrid composite formulations were developed by varying reinforcement ratios to optimize mechanical performance. Comprehensive tests, including tensile strength, Brinell hardness, and Charpy impact, were conducted, alongside scanning electron microscopy (SEM) and energy-dispersive spectroscopy (EDS) for microstructural analysis. The results revealed significant enhancements over pure aluminium, with the highest tensile strength of 292 MPa, maximum hardness of 67 BHN, and improved impact toughness of 2.4 J/cm². Microstructural observations confirmed uniform particle distribution in the optimally reinforced sample, contributing to superior mechanical properties. Owing to their high strength-to-weight ratio, these hybrid composites are highly suitable for engine blocks in automotive systems and aircraft seat frame structures, where weight reduction and structural integrity are critical. The outcomes demonstrate that combining Zn, Sn, and Ti reinforcements provides a synergistic enhancement in mechanical performance, offering a sustainable pathway for developing next-generation lightweight structural materials in automotive and aerospace engineering.

Downloads

PDF

Downloads

Download data is not yet available.

References

[1] Cheah, L.W., 2010. 2010. Cars on a diet: the material and energy impacts of passenger vehicle weight reduction in the US (Doctoral dissertation, Massachusetts “Lightweight Materials for Cars and Trucks Institute of Technology).

[2] Singh, J., Srivastawa, K., Jana, S. and Dixit, C., 2024. Advancements in lightweight materials for aerospace structures: A comprehensive review. Acceleron Aerospace Journal, 2(3), pp.173-183. DOI: https://doi.org/10.61359/11.2106-2409

[3] Pooja, K., Tarannum, N. and Chaudhary, P., 2025. Metal matrix composites: revolutionary materials for shaping the future. Discover Materials, 5(1), p.35. DOI: https://doi.org/10.1007/s43939-025-00226-6

[4] Gupta, P.K., Trivedi, A.K., Gupta, M.K. and Dixit, M., 2024. Metal matrix composites for sustainable products: A review on current development. Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications, 238(10), pp.1827-1864. DOI: https://doi.org/10.1177/14644207241238197

[5] Samal, P., Vundavilli, P.R., Meher, A. and Mahapatra, M.M., 2020. Recent progress in aluminum metal matrix composites: A review on processing, mechanical and wear properties. Journal of Manufacturing Processes, 59, pp.131-152. DOI: https://doi.org/10.1016/j.jmapro.2020.09.010

[6] Agbeleye, A., Durowaye, S., Oladoye, A. and Bolasodun, B., 2021. Effect of Zinc Addition on the Mechanical and Corrosion Characteristics of Aluminium Matrix Composites. Acta Materialia Turcica, 5(1), pp.30-37.

[7] Sonker, P.K., Singh, T.J. and Yadav, N.P., 2023. Experimental research and effect on mechanical and wear properties of aluminium based composites reinforced with Zn/Sic particles. Discover Materials, 3(1), p.9.

[8] Abdelhakim, N.A. and Shalaby, R.M., 2021. Microstructures and mechanical properties of Al-Zn-Sn bearing alloys for high performance applications. World Journal of Engineering and Technology, 9(3), pp.637-652. DOI: https://doi.org/10.4236/wjet.2021.93045

[9] Farahany, S., Hamdani, M.K., Salehloo, M.R., Krol, M. and Cheraghali, E., 2024. Synthesis and Characterization of Novel Aluminum Composites: A Compo-Casting Approach with ZrO2, Al2O3, and SiC. Archives of Foundry Engineering, pp.88-97. DOI: https://doi.org/10.24425/afe.2024.149274

[10] Alaneme, K.K., Ojomo, A.M. and Bodunrin, M.O., 2022. Structural analysis, mechanical and damping behaviour of Al-Zn based composites reinforced with Cu and SiC particles. Manufacturing Review, 9, p.5. DOI: https://doi.org/10.1051/mfreview/2022005

[11] Sonker, P.K., Singh, T.J. and Yadav, N.P., 2023. Experimental research and effect on mechanical and wear properties of aluminium based composites reinforced with Zn/Sic particles. Discover Materials, 3(1), p.9. DOI: https://doi.org/10.1007/s43939-023-00045-7

[12] Tian, C., Singh, K., Wakai, A., Dass, A., Bustillos, J., Chuang, A.C. and Moridi, A., 2025. Tunable TiAl3-reinforced aluminum matrix composites via in-situ reactive printing: insights from operando synchrotron analysis and microstructural characterization. npj Advanced Manufacturing, 2(1), p.3. DOI: https://doi.org/10.1038/s44334-024-00014-9

[13] Lei, D., Xu, S., Yang, X., Lu, X., Qin, X., Zhou, L., Chen, J. and Li, M.V., 2025. Transformation mechanism of microstructure and mechanical properties of wire arc additive manufacturing TiC/Ti reinforced Al-Zn-Mg-Cu alloy under different heat treatment processes. Journal of Alloys and Compounds, p.180718. DOI: https://doi.org/10.1016/j.jallcom.2025.180718