Aluminum matrix nanocomposites reinforced with carbon nanotubes have attracted increasing interest for lightweight tribological applications; however, achieving a uniform nanotube dispersion remains a critical challenge. In this study, Al/MWCNT/nanoclay hybrid composites were fabricated via powder metallurgy followed by spark plasma sintering (SPS) to investigate the role of nanoclay as a secondary reinforcement and dispersion aid for MWCNTs. A constant MWCNT content of 1 wt.% was combined with varying nanoclay additions (0.5, 1, and 1.5 wt.%). Microstructural characterization revealed that an optimal nanoclay content of 1 wt.% effectively suppressed MWCNT agglomeration and promoted a more homogeneous reinforcement distribution within the aluminum matrix. The optimized composite exhibited a Vickers hardness of approximately 75.9 HV and achieved about a 2.5-fold improvement in wear resistance compared with pure aluminum. In contrast, excessive nanoclay addition (1.5 wt.%) resulted in reduced hardness and inferior wear performance. Overall, the results demonstrate that controlled nanoclay incorporation provides an effective strategy for enhancing the tribological performance of CNT-reinforced aluminum composites.
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