This study focused on developing an aluminum alloy 6063 (Al 6063) based composite reinforced with kaolin clay powder using the stir casting method. The research investigated the effects of varying kaolin clay content (0%, 6%, 12%, 18%, and 24% by weight) on key mechanical and tribological properties, including wear resistance, coefficient of friction, Rockwell hardness, tensile strength and compressive strength, density, and microstructure. The results demonstrated that the wear rate decreased with an increase in the weight fraction of kaolin clay up to 18 wt.%. The coefficient of friction, Rockwell hardness, tensile strength, and compressive strength increased with an increase in the weight fraction of kaolin clay powder up to 18 wt.%. The density of composites decreases with an increase in the weight composition of kaolin clay. Based on these findings, sample C4 (18% Kaolin clay, 81% Al 6063, and 1% Mg powder) was identified as the optimal composition for motorcycle brake disc rotor applications due to its balanced mechanical and tribological properties. Experimental analysis was also involved to measure the thermal conductivity of the selected kaolin-Al 6063 metal matrix composite and conducted finite element analysis to compare its thermal performance with conventional materials such as cast iron, stainless steel, and pure Al 6063 alloy. The results revealed that the kaolin-Al 6063 MMC exhibited superior thermal characteristics, with 57.8% higher heat flux than cast iron and more efficient heat distribution. A prototype brake disc rotor was manufactured, and it achieved a remarkable 49.29% reduction in material weight.
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