Several components are made from Al-Mg-based composites. MoS₂ is used to increase the composite’s machinability. Different weight percent (3, 4, and 5) of MoS₂ are added as reinforcement to explore the machinability properties of Al-Mg-reinforced composites. The wire cut electrical discharge machining (WEDM) process is used to study the machinability characteristics of the fabricated Al-Mg-MoS₂ composite. The machined surface’s roughness and overcut under different process conditions are discussed. The evaluation-based distance from average solution (EDAS) method is used to identify the optimal setting to get the desired surface roughness and overcut. The following WEDM process parameters are taken to determine the impact of peak current, pulse on time, and gap voltage on surface roughness, and overcut. The WEDM tests were carried out on three different reinforced samples to determine the impact of reinforcement on surface roughness and overcut. The surface roughness and overcut increase as the reinforcement level increases, but the optimal parameters for all three composites are the same. According to EDAS analysis, I₃, Ton₂, and V₁ are the best conditions. Furthermore, peak current and pulse on-time significantly influence surface roughness and overcut.

In this study, powder metallurgy process has been utilized to produce the composite materials. Pure aluminium (Al) has been selected as the matrix material for the preparation of composite materials. 4% of magnesium (Mg) has been added as the alloying element, whilst molybdenum disulphide (MoS₂) is reinforced with a varying wt.% (2, 4 & 6). The intent of this work is, to evaluate some basic mechanical properties (density, microhardness, compression strength and toughness), surface degradation properties (corrosion and wear), and electrical conductivity of the fabricated composite materials. Moreover, SEM mapping and EDAX analysis have been conducted to confirm the presence of reinforcement particles with homogenous distribution in the matrix material and to do the fractographic study of the compressive strength tested samples. The density of the composite material Al-4% Mg-6%MoS₂ has been increased compared to the density of pure Al material. Micro Vickers hardness test shows that Al-4% Mg-6%MoS₂ composite has 32.86% more hardness as compared to that of pure Al material. Compressive strength of the composite material with the higher wt.% of MoS₂ is found to be 181.81 N/mm², while Al material has only 167.52 N/mm². The buckling formation during the compression test is avoided in the composite material owing to the existence of MoS₂ particulates. The wear loss of composite materials is found low as compared with the unreinforced Al material, owing to the solid lubricant property of MoS₂ particles, and hence, coefficient of friction (COF) is also lessened with the increase in the MoS₂ wt.%. Also, the MoS₂ reinforced materials show good resistance to corrosion due to the presence of molybdenum, which acts as a consistent layer obstacle to prevent the surface from further degradation.

The research article addresses the reciprocating wear behaviour of hybrid AA7075 reinforced with boron carbide and boron nitride through a stir-casting technique. The experiment involved varying wt.% of the secondary particle boron carbide (3, 6 and 9) while boron nitride (3) was kept as constant. The hybrid composites were characterised using scanning electron microscopy coupled with energy dispersive spectroscopy. The hardness and tensile behaviour of the hybrid composites were evaluated. Reciprocating wear behaviour of the hybrid composites were examined using a tribometer by varying the wear parameters such as load and sliding distance. The results revealed that AA7075/6boron carbide/3boron nitride had better hardness, tensile and wear properties. The surface morphology of the wear samples was analysed using SEM.