Investigating the influence of ferric oxide grade alumino‐silicate cenosphere particulates and heat treatment on the microstructural evolution and mechanical properties of Al6061/ferric oxide alumino‐silicate cenosphere (x weight %) composite

Abstract The main aim of this investigation is to fabricate aluminum 6061 composites with three different weight percentages of ferric oxide grade alumino silicate cenosphere (1 wt.%, 3 wt.%, and wt.%) by the stir‐casting process. The fabricated cast composite and T6 heat‐treated composite is used to obtain a fundamental understanding of various weight percentages of the cenosphere and the influence of heat treatment on the microstructural changes, mechanical characteristics, the mechanism of fracture, and the interface between the aluminum‐matrix and ferric oxide grade alumino‐silicate cenosphere particulates. Tensile and compressive tests with a constant strain rate (0.5 mm ⋅ min −1 ) were carried out to study the strength and to find a correlation between the various weight fractions of cenosphere and heat treatment. Investigations of the changes in the microstructure of the aluminum ferric oxide grade alumino silicate cenosphere composite and the fractography of the fracture surface are investigated using optical and scanning electron microscope. X‐ray diffraction was utilized to confirm the results obtained from optical and scanning electron microscope analyses for phase characterization validation. A maximum of 30 % increase in hardness value, 20 % increase in tensile strength value, 33 % increase in maximum compressive strength value, and 2 % increase in elongation values are observed in heat‐treated composite when compared to cast composite.