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Automobile and aviation industries require lightweight solutions in the suspension system to improve overall performance and payload capacity. This can be achieved by materials having high strength to weight ratio. Fiber composites, known for their lightweight and high strength, face a major issue of delamination, which shortens the lifespan of fiber‐reinforced polymer leaf springs. Current researchers are emphasizing the use of functionally graded materials as a promising alternative to tackle this problem. In the present work, a functionally graded leaf spring plate was fabricated using stir casting technique with five layered gradations in the mid portion. The amount of molten material required for each gradation was ensured using a novel experimental technique. On the other hand, the matrix and reinforcement have been adopted from the output of the analysis conducted using CES EduPack 2019 software. Low density and high fatigue strength were primary focal point for the consideration of matrix and reinforcement materials. Aluminium 7075 and boron carbide were considered as matrix and reinforcement materials respectively. Stir casting technique, used in the present work, is simple, suitable and cost effective technique which creates a gradation at central part of the leaf. [ABSTRACT FROM AUTHOR]

The present work is focused on the influences of reinforced particles on mechanical, microstructural, and tribological performances of AA7075 hybrid metal–matrix composites (HMMCs). Al2O3 and coconut shell ash (CSA) were reinforced using two-stage stir casting by varying the wt% (0–5) of reinforcement. Microstructural analysis and various phase identifications were examined with the help of scanning electron microscope (SEM) equipped with EDX and optical microscope. Various mechanical testing such as tensile, hardness, 3-point bend test, and tribological behaviors were carried out to know the HMMCs properties. Microstructural images revealed a homogeneous distribution of reinforced particles in the metal–matrix and EDX confirmed the presence of dispersed reinforcements (Al2O3 and CSA) in the HMMCs. It was seen that mechanical properties and tribological behavior have been increased after addition of Al2O3 and CSA reinforced particles whereas slightly decreased in impact strength. Transgranular cleavage facets, micro-void coalescence, dimples, and crack were shown in SEM images of fractured specimens during impact and tensile testing. [ABSTRACT FROM AUTHOR]