Fly ash coal combustion dust from thermal power plants is one of the world's largest non-hazardous solid wastes. Effective utilization of fly ash as a secondary reinforcement in metal matrix composites significantly enhances properties and is highly appreciable for waste management systems. Present experimental scrutiny primarily spotlights on the mechanical, morphology, and wear behaviour of AA7075/Fly ash composites. The stir casting technique with regular feeding method was utilized for the fabrication of 4 wt.%, 8 wt.%, 12 wt.%, 16 wt.%, and 20 wt.% fly ash reinforced AMFAR (Aluminum matrix fly ash reinforced composites). Tensile, hardness, and low velocity impact behaviour of the samples, along with the sliding wear and morphology analysis, were carried out to study the material behaviour under different operational conditions. The results show that fly ash as a secondary reinforcement improves the mechanical performance of the samples significantly. At the same time, 20 wt.% fly ash content exhibits better mechanical, wear performance and reasonable particle distribution. The proposed hybrid composites are preferred for high-strength automobile applications as well as their industrial machine counterparts

Keywords: AA7075, Stir casting, Hardness, Sliding wear, Wear rate