High-Performance Aluminium Hybrid Composited Reinforced with Zn, Sn and Ti for Lightweight Automotive and Advanced Structural Applications

This study focuses on the fabrication and characterization of high-performance aluminium hybrid metal matrix composites (AMMCs) reinforced with zinc (Zn), tin (Sn), and titanium (Ti) for lightweight automotive and advanced structural applications. Using the stir casting process, three hybrid composite formulations were developed by varying reinforcement ratios to optimize mechanical performance. Comprehensive tests, including tensile strength, Brinell hardness, and Charpy impact, were conducted, alongside scanning electron microscopy (SEM) and energy-dispersive spectroscopy (EDS) for microstructural analysis. The results revealed significant enhancements over pure aluminium, with the highest tensile strength of 292 MPa, maximum hardness of 67 BHN, and improved impact toughness of 2.4 J/cm². Microstructural observations confirmed uniform particle distribution in the optimally reinforced sample, contributing to superior mechanical properties. Owing to their high strength-to-weight ratio, these hybrid composites are highly suitable for engine blocks in automotive systems and aircraft seat frame structures, where weight reduction and structural integrity are critical. The outcomes demonstrate that combining Zn, Sn, and Ti reinforcements provides a synergistic enhancement in mechanical performance, offering a sustainable pathway for developing next-generation lightweight structural materials in automotive and aerospace engineering.