The present experimental study focuses on developing aluminium hybrid metal matrix composites using varying weight percentages of carbonized eggshell powder (CESP) and a fixed 5 wt.% aluminium nitride powder (AlNP) through powder metallurgy (P/M). The influence of CESP content on the microstructure, density, hardness, compressive strength, and wear behaviour was systematically investigated. Field emission scanning electron microscopy (FESEM) revealed uniform dispersion of reinforcements up to 4.5 wt.% CESP, with slight agglomeration observed at 6 wt.%. X-ray diffraction (XRD) confirmed the presence of AlN and CaCO3 phases without any indication of brittle intermetallic compound formation. Increasing CESP content led to a gradual decrease in relative density and an increase in porosity. A significant improvement in microhardness and compressive strength is observed up to 4.5 wt.% CESP, achieving 55.52 HV and 366.04 MPa, respectively, followed by a decline at higher reinforcement levels. Tribological evaluation revealed a reduction in both wear loss and coefficient of friction (COF) with increasing CESP, with optimum performance at 4.5 wt.%. Worn surface analysis indicated a transition from delamination and abrasion in the unreinforced alloy to predominantly abrasive wear in the composites. Overall, 4.5 wt.% CESP was determined to be the optimal reinforcement level for enhancing both mechanical and tribological properties.
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