International Journal of Materials Engineering Innovation (21 papers in press)

Regular Issues

• Formability Analysis of AA3003O by Optimizing Processing Parameters in Single Point Incremental Forming  
  by Ankita Pandey, Yogesh Kumar 
  Abstract: Incremental sheet forming (ISF) is a die-less process and has various advantages like low tooling cost, part flexibility and higher formability over the conventional sheet forming process. In this work, a robot based single point incremental sheet forming is carried out. During the forming process, by varying the forming angle from 60
  Keywords: Robot-based Incremental sheet forming; Formability; Forming angle; Step sizes; Optimization.
  DOI: 10.1504/IJMATEI.2025.10069298
   
  
• Review on recent trends in sustainable biocomposites: materials, manufacturing, application  
  by Hiral H. Parikh, Viren K. Parikh, Jitendra M. Mistry 
  Abstract: Growing environmental awareness and the limitations of conventional resources have spurred a greater interest in biocomposite materials across diverse applications. Researchers are increasingly turning to natural fibres and binders as sustainable alternatives to traditional, petroleum-based materials. This shift towards eco-friendly materials aims to address the demand for lightweight, environmentally responsible solutions. However, the manufacturing of biocomposite materials has many concerns regarding the high cellulose contain of nature of the fibres, bonding between fibre and matrix, strength, manufacturing constraints, surface modification of fibres, long-term durability, poor electrical properties and low thermal stability. Recently, exclusive research has been carried out to address issues like durability, biodegradability, sustainability and sustainable manufacturing. This review article broadly covers the different types of fibres obtained through plants and animals and discuss the surface modification processes to enhance the adhesion. It also covers the different types of biopolymers, their advantages and limitations in developing biocomposites. Also, the review article discusses the various manufacturing techniques used to create the biocomposite with highlighting on advanced manufacturing techniques to produce lightweight composites. Finally, the detailed application areas, scope and challenges of biocomposites are briefly discussed.
  Keywords: biocomposites; biopolymers; biofibres; advanced manufacturing processes; fibre reinforced polymer matrix composite.
  DOI: 10.1504/IJMATEI.2025.10071256
   
  
• Investigation of thermal properties of sisal/glass fiber hybrid composite with inclusion of graphane nano platelets  
  by Amrita Maddamasetty, Prathyusha Mathi, Jayasree Gudivada, Malavika Koneti, Rohith Battina Venkata Satya Sai Narasimha 
  Abstract: Hybridisation of natural and synthetic fibres results in leverage of the complementary strengths of each type of fibre resulting in enhanced properties. The work aims to create natural fibre composite (sisal), synthetic fibre composite (glass), and hybrid fibre composite (sisal/glass) to take advantage of both natural and synthetic fibres. To further enhance the properties of the composites different weight percentages of graphene nanoparticles (0.25wt%, 0.50wt%, 0.75wt%, 1wt%) are incorporated into the hybrid composite. The thermal properties of composites are evaluated using thermogravimetric analysis (TGA), differential thermal analysis (DTA) and differential scanning calorimetry (DSC) tests. 1.0wt% hybrid composite showed improved thermal stability with 13.89%, 10.03% and 10.46% decrease in weight loss% compared to hybrid composite without graphene at temperatures 250 C, between 250 C and 450 C and above 450 C respectively. It also showed a 53.5% improvement in char yield value over hybrid composite.
  Keywords: graphene; nano platelets; thermal analysis; glass transition temperature; crystallisation temperature; melting temperature; weight loss; char yield; degradation temperature; thermal stability.
  DOI: 10.1504/IJMATEI.2025.10071302
   
  
• A study on properties of particle board from waste tyre rubber crumb and glass fibre  
  by Bidyut Prava Jena, Suchismita Satapathy, Bijaya Bijeta Nayak 
  Abstract: In this work, suitability of waste tire rubber crumb (WTRC) and glass fibre (GF) as alternate material for particle board manufacturing was investigated. Composites with different weight percentages (5%, 10%, 20%, 25% and 30% wt) of WTRC incorporated with three layer of glass fibre mat using epoxy (LY556) resin by compression moulding were made. Mechanical properties like modulus of rupture (MOR), modulus of elasticity (MOE), interlaminar shear stress (ILSS), impact strength and physical property like density was determined. Their morphological property was checked by XRD and SEM analysis. Addition of WTRC greatly improved the mechanical property of the panels. The novelty of these composites lies in utilisation of WTRC as suitable filler in PMCs. This research work seeks to offer information and growing public responsiveness on importance of waste minimisation, value addition to the waste through recycling and improve the quality of life in the usages of particle board materials.
  Keywords: particle board; waste tyre rubber crumb; WTRC; epoxy; compression moulding; characterisation.
  DOI: 10.1504/IJMATEI.2025.10071388
   
  
• A review on casting and reinforcement methods for enhancing mechanical characteristics of aluminium alloys  
  by Manas Ranjan Sahoo, Rasmi Ranjan Behera, Sudesna Roy 
  Abstract: The aim of this survey is to explore studies related to advancements in aluminium composites over the last two decades. Thus, previously undertaken studies on aluminium composites between 2000 and 2023 are explored, and their findings are summarised. As a result, various fabrication and reinforcement techniques are identified from the literature in order to explore the full potential of the composite. Among those methods, the ceramic particles reinforced aluminium composites fabricated through the stir casting method have shown notable improvement in both the physical and chemical properties of aluminium alloys. Additionally, because the majority of the manufactured composites need to be machined before being used, the challenges faced during the process of machining the developed composites are also highlighted. This review is expected to clarify a few existing issues and offer a comprehensive foundation for future studies in the manufacturing of aluminium alloy composite.
  Keywords: aluminium composites; reinforcements; fabrication techniques; machining behaviours; wear characteristics.
  DOI: 10.1504/IJMATEI.2025.10071784
   
  
• Assessment of Si3N4 reinforced Al6061 matrix mechanical properties and heat treatment impact for protective structures  
  by J. Prabhakaran, V. Vinoth, S.A. Divyadharshini, G. Bharathiraja, S. Sukumar, M. Suresh Chinnathampy, H. Mohamed Suhail 
  Abstract: This study investigates the effect of heat treatment on the mechanical properties of an aluminium metal matrix composite (MMC) using Al6061 alloy (T6 tempered) reinforced with 5% Silicon Nitride (Si3N4). Two samples are fabricated using the stir casting method: one with pure Al6061 and the other with Al6061 + 5% SiN. The samples undergo a heat treatment process at 600 C for 6 hours, followed by rapid quenching in distilled water and artificial ageing at 180 C for 24 hours. After heat treatment, mechanical testing is conducted to evaluate tensile and impact strength. The study compares the mechanical behaviour of the reinforced and non-reinforced samples to understand the effects of SiN and heat treatment. Since aluminium is extensively used in modern vehicle structures, enhancing its strength improves vehicle safety and performance. Fuzzy logic is also used to predict intermediate mechanical property values based on the experimental data.
  Keywords: aluminium heat treatment; moulding; mechanical properties; Al6061; Si3N4.
  DOI: 10.1504/IJMATEI.2025.10071908
   
  
• Application of fuzzy TOPSIS and fuzzy VIKOR approaches for ranking friction-based additive manufacturing processes: a case study  
  by A. Ranjith Raj, S. Vinodh 
  Abstract: This study presents a comprehensive assessment of friction-based additive manufacturing (FBAM) processes with the focus on friction stir additive manufacturing (FSAM), friction additive solid welding (FASW), and additive friction stir (AFS). Fuzzy-based MCDM tool technique for order preference by similarity to ideal solution (fuzzy TOPSIS) is used to evaluate these processes based on relevant criteria. These criteria include structural, operational, material, and environmental factors, as well process efficiency and output quality. The method includes expert opinion from decision-makers, utilising linguistic terms and corresponding fuzzy numbers to capture inherent uncertainties in the assessment process. The results revealed FSAM as optimal FBAM process, depicting superior performance in key areas such as structural integrity and dimensional precision. AFS shows promise in certain aspects, while FASW, despite some advantages, lags in several performance indicators. The result is validated using fuzzy VIKOR. This research provides insights for additive manufacturing industry practitioners for process selection.
  Keywords: additive manufacturing; friction-based additive manufacturing; FBAM; multi-criteria decision making; fuzzy TOPSIS; fuzzy VIKOR.
  DOI: 10.1504/IJMATEI.2025.10072342
   
  
• Development and characterisation of Mg-based hybrid composite for biomedical applications  
  by Manmeet Singh, Sandeep Singh, Neeraj Sharma, Guru Prakash 
  Abstract: The enhancement in the mechanical characteristics of Mg alloys are required to use in medical industries successfully. A lot of Mg-alloys were developed and used in medical application. But the work on the development of composite for medical applications is underway. Thus, in present research, AZ31 alloy was used as base alloy reinforced with TiO2 and HA particles. The composite was fabricated at a temperature of 850 C in a graphite crucible. The micro-structural behaviour of magnesium composite was investigated using scanning electron micrograph. The yield strength and percentage elongation of all composites were investigated using universal testing machine. The grain size of the composites was reduced with the increase in yield strength of the composites at different percentage of reinforcement. The yield strength, microhardness, wear rate and elemental maps were investigated for developed composites.
  Keywords: AZ31/TiO2/HA; stir casting; composites; SEM; MMC.
  DOI: 10.1504/IJMATEI.2025.10072472
   
  
• Exploring machining scrap as reinforcement in composites a sustainable approach  
  by Ganesh S. Kadam 
  Abstract: Local machine shops often face challenges in disposing of machining scrap, making its reuse an environmentally and economically sustainable alternative. This study investigates the feasibility of using turning and milling chips as reinforcing fibres in epoxy-based composites. Composites were fabricated using the hand lay-up method, and their flexural strength and moisture absorption properties were evaluated. Results showed that composites with machining chips achieved strength levels comparable to those with natural fibres. The inherent strain-hardened nature of the chips enhanced mechanical performance. Optimal strength was observed at 40% fibre content for turning chips and 50% for milling chips, with milling chip composites showing a 27.42% increase over turning chip ones. All formulations demonstrated excellent resistance to water absorption, indicating their suitability for humid environments. The findings confirm that metal machining scrap can be effectively utilised as reinforcement in polymer composites, offering a practical, cost-effective and sustainable solution for waste management and material innovation.
  Keywords: composite; fibres; matrix; machining; chips; scrap; resin; strength; recycling; sustainable.
  DOI: 10.1504/IJMATEI.2025.10072768
   
  
• 3D printed bone implants using PLA polymer composite materials  
  by Jeevanandham Narayanan, R. Velmurugan, Shankar Krishnapillai 
  Abstract: Recent advances in three-dimensional printing have significantly advanced the development of bone implants. Using computed tomography scans, customised patient-specific designs can be created for bone repair and replacement. Fused deposition modelling is used to manufacture these implants with a composite filament made of polylactic acid (PLA), hydroxyapatite (HAp) nanoparticles, and carbon nanofibres (n-Cf). This combination leverages PLAs biocompatibility, HAps osteoconductivity, and the enhanced mechanical strength provided by carbon nanofibres. For filament fabrication, PLA pellets are mixed with the composite materials through a modified mixing process and then extruded using a twin-screw extruder. The mechanical and material properties of the 3D-printed PLA composite samples are thoroughly tested. Tensile and compression tests evaluate their strength, while dynamic mechanical analysis assesses their mechano-thermal behaviour. SEM analysis reveals the distribution of particles within the filament and the material properties, determined through fractographic studies. Additionally, FTIR and EDAX are used for molecular and elemental characterisation.
  Keywords: 3D printing; bone implants; nano composites; filament fabrication.
  DOI: 10.1504/IJMATEI.2025.10073507
   
  
• An analysis of mechanical and machinability study of eco-friendly jute/cotton non-woven fabric composites  
  by Srinivasan Rajaram, N.S. Balaji, Marxim Rahula Bharathi Boopathi Rajan, Venkatesan Kamalakkannan 
  Abstract: The present study investigates the mechanical and machinability properties of eco-friendly jute-cotton-epoxy hybrid composites (JCEHC) developed with varying fibre and resin weight fractions. Among the fabricated composites, JCEHC2 demonstrated superior mechanical performance, achieving a tensile strength of 78.32 MPa, impact strength of 38.2 J/m, flexural strength of 52.32 MPa, and ILSS of 9.6 MPa. Water absorption was found to be lowest in JCEHC3 due to its higher jute content, which serves as an effective barrier to moisture. SEM analysis revealed common fracture features such as fibre pullout, breakage, and matrix cracking. Drilling studies were conducted to evaluate machinability, where thrust force, torque, and delamination were assessed under varying input parameters, including drill bit diameter, spindle speed, and feed rate. Maximum thrust and torque were observed using an 8 mm drill bit at higher speeds, confirming the significant influence of these parameters on drilling-induced damage.
  Keywords: hybrid composite; mechanical properties; drilling; delamination; thrust force; torque.
  DOI: 10.1504/IJMATEI.2025.10073556
   
  
• Optimised HDPE-MoS2 composites for enhanced mechanical performance using the TOPSIS method  
  by Veeranaath Vetry, Hariharan Thiyagarajan, Madapati Phani Raghavendra 
  Abstract: The paper investigates the production technique of HDPE and MoS composite materials through blending methods before injection moulding. A comprehensive investigation of mechanical properties related to MoS2 reinforcement is generated through studies of varying reinforcement amounts at various injection temperatures based on the L9 orthogonal array design system. The assessment approach detected that the improved interfacial component bond strength and the distribution quality of fillers within matrix frameworks. The developed composites are tested for their density, hardness, and strength. The TOPSIS approach enabled process condition optimisation and regression analysis to deliver predictive information about property alterations. The examined HDPE-MoS2 composite showed enhanced mechanical properties, which qualify it as an attractive material for various high-performance engineering uses, including wear-resistant designs and lightweight structural segments, and tribological components. The research establishes a new polymer-based composite that brings adjustable properties to increase HDPEs potential within advanced engineering frameworks. The density of the composites was increased marginally to 0.9997 g/cm3, which represents a 4.88% increase. Shore D hardness increased by 27.33% to 64.38, and compressive and tensile strength increased to 6.45 MPa and 44.19 MPa.
  Keywords: HDPE composites; MoS2; injection moulding; optimisation; TOPSIS.
  DOI: 10.1504/IJMATEI.2025.10075025
   
  
• Experimental and numerical analysis of graphite reinforced polypropylene/epoxy composite beam  
  by R. Santhanakrishnan, K. Jegadeesan, C. Shravankumar, M. Kamaraj, A. Johnny Varghese 
  Abstract: Composite materials are being increasingly commonly used in all disciplines of technical applications. The purpose of this research is to evaluate the mechanical and dynamic properties of a composite laminate made from polypropylene bags that are already used for packing consumer products. To reinforce the composite, graphite powder in varied quantities (5, 7.5, and 10 wt.%) was added to the resin, and the composite laminates were hand layup. Tensile and flexural tests on the composite were performed to determine its mechanical properties. The mechanical characteristics improved after adding 5 wt.% graphite powder, but declined after adding more graphite powders. The dynamic characteristics of the laminated composite were determined using an impact hammer. Finally, finite element studies were done with ANSYS to compare the impact hammer test results. It was observed that the experimental findings closer to the numerical results for 5 wt.% graphite powder.
  Keywords: polypropylene; graphite; hand layup; mechanical properties; dynamic properties; ANSYS.
  DOI: 10.1504/IJMATEI.2025.10075257
   
  
• Design, fabrication and FEA analysis of hybrid composite leaf spring for light vehicle  
  by Vinay Kal Math, Prasanna Kumar Mukunda Das, Mantesh Basappa Khot 
  Abstract: The present study investigates the design, fabrication, and finite element analysis of hybrid composite leaf springs (CLS) for light vehicles using glass fibre and viscose staple fibre (VSF) reinforcements. Five hybrid composite variants were produced through hand lay-up and epoxy resin processing, followed by hydraulic hot pressing. Both experimental and numerical evaluations were carried out to determine their structural performance. Among the tested samples, the composite containing 40% epoxy, 45% E-glass fibre, and 15% VSF demonstrated the best results. It exhibited a maximum natural frequency of 258.94 Hz in the sixth mode, significantly higher than the 207.43 Hz recorded for a conventional steel leaf spring. Under a 3,052 N load, it showed a maximum von Mises stress of 323.18 MPa, comparable to steel (308.43 MPa). Moreover, the hybrid CLS achieved a substantial weight reduction of 76.37%. Overall, these findings highlight the potential of glass-VSF hybrid composites as efficient, lightweight alternatives for medium to high load vehicle applications.
  Keywords: viscose staple fibre; VSF; leaf spring; finite element analysis’ FEA; natural frequency.
  DOI: 10.1504/IJMATEI.2026.10076492
   
  
• Mechanical characteristics of hybrid metal matrix composites  
  by Tharmaraj Ramakrishnan, Thiruneelakandan Balasubramaniyan, Anand Rajkumar Ramesh Kumar, Dinesh Kumar Manokaran, Subburaj Mada Samy 
  Abstract: Aluminium and its alloys are attractive for lightweight structural applications because of their good characteristics. In this work, AA6061 is selected as the matrix, and graphite (Gr), aluminium oxide (Al2O3), boron carbide (B4C), and silicon carbide (SiC) are selected as the reinforcements. The hybrid metal matrix composite (HMMC) with various percentages of Gr, Al2O3, B4C and SiC is prepared by using the stir casting technique. The influence of the reinforcements on tensile, impact, bending, and hardness is examined. The results showed that the HMMC with 5% of SiC and 5% of B4C in the AA6061 permits to increase in the tensile, bending and impact properties. The hardness of the HMMC is higher in the 5% of SiC, 5% of B4C and 5% of Al2O3.
  Keywords: mechanical characteristics; HMMC materials; hybrid metal matrix composite materials; stir casting; reinforcement materials.
  DOI: 10.1504/IJMATEI.2026.10076493
   
  
• Performance analysis on hybrid composites leaf spring with natural fibres reinforcement  
  by Unmesh Pawar 
  Abstract: Integration of natural fibres, such as jute, flax sisal, etc, with glass fibre composites has gained attention in many engineering applications. Natural and Synthetic fibres are progressively being utilised as fortifications in different applications. The present work aims is to examine the impacts of natural fibres on some mechanical properties of the composites. This exploration was completed by strengthening the network with natural fibres and synthetic glass fibre. Natural fibres like jute, flax and, sisal were delivered utilising Vacuum assisted resin transfer moulding. After manufacturing of composite material, mechanical properties like tensile and flexural strength were considered. It was discovered that the tensile and flexural strength of jute, flax and sisal fibre has good strength because of the VARTM process. The examination indicated that the jute-glass fibre exhibited superior properties over the other prepared composites. The glass fibre leaf spring is manufactured and physically tested in the laboratory. From the experimental findings, it is observed that the presented leaf spring shows much-closed results over the traditional steel spring.
  Keywords: natural fibre reinforced hybrid composites; glass; jute; flax; sisal; fibres; leaf spring; tensile strength; flexural strength; VARTM.
  DOI: 10.1504/IJMATEI.2026.10077801
   
  
• Dual surface treatment of 18/8 austenitic stainless-steel (AISI 304 SS) for bipolar plate utilisation  
  by Pankaj Kumar Singh, Rajeev Kumar Gupta, Siddharth Singh, Gurpreet Saini Saini, Gajendra Prasad Singh 
  Abstract: Surface properties of 18/8 austenitic stainless-steel (ASS) (AISI 304 ASS) specimens were improved through a two-step modification process involving plasma nitriding at three different temperatures, followed by a titanium nitride (TiN) nanocrystalline coating. The modification process was confirmed through diffraction patterns showing the presence of expanded austenite, CrN, TiN, and -phase characteristics. TiN depositing fragments have a mean size of approximately 20 nanometres (nm), in accordance to the dispersion pattern. The nitrogen diffusion layer was measured as 10-50 m thick with TiN thickness was approximately 200 nm. The nitrogen diffusion enhanced the surface hardness maximum 4-fold (6.83 GPa) whereas the nanocrystalline TiN coating enhanced about 7-fold (9.03 GPa) compare to untreated specimen (1.67 GPa). The interfacial contact resistance (ICR) reduced significantly from 72.26 m cm2 in the untreated steel to 9.9 mcm2 after plasma nitriding and 8.77 mcm2 after TiN coating. These results indicated that the TiN coating improved conductivity by providing a pathway for electron transportation due to the existence of conductive TiN nanoparticles in the form of inert oxide layers surface.
  Keywords: austenitic stainless steel; plasma nitriding; titanium nitride; TiN; hardness; interfacial contact resistance; ICR.
  DOI: 10.1504/IJMATEI.2026.10077908
   
  
• Experimental evaluation on the mechanical and thermal performance of graphene and hexagonal boron nitride reinforced polypropylene nanocomposites  
  by Aamir M. Shaikh, Pravin R. Kubade 
  Abstract: Incorporation of nanofillers in polymer matrices has shown a potential route for enhancing their multifunctional properties. In this study, polypropylene (PP) nanocomposites with graphene (G) and hexagonal boron nitride (hBN) reinforcements were synthesised using twin screw extruder and injection moulding. Mechanical (tensile, flexural, impact strength) as well as thermal (TGA, DSC, DTG) characterisation of nanocomposites with 0.5 wt.%, 1.0 wt.% and 1.5wt.% concentration of fillers was investigated. Morphological characterisations using SEM, XRD, and FTIR were done for filler distribution as well as interface interactions study. Results indicate an improvement of mechanical characteristics along thermal stability with incorporation of nanofillers due to reinforcement as well as uniform distribution inside the PP matrix. The paper signifies a future prospect for G, hBN systems for use as advanced fillers for lightweight PP nano-composites for engineering applications. Seven nanocomposite compositions were prepared in a set of experiments involving single fillers (0.51.5 wt.% G or hBN).
  Keywords: polypropylene; graphene nanoparticles; hexagonal boron nitride; hBN; morphological characterisation.
  DOI: 10.1504/IJMATEI.2026.10078006
   
  
• Tailoring the microstructure and corrosion resistance of Sn-9Zn solder through Ce and Cr alloying  
  by Niranjan Kumar, Ambrish Maurya 
  Abstract: The demand for lead-free solders has positioned Sn-Zn alloys as promising alternatives to conventional Sn-Pb systems. Study explores the influence of Ce-Cr micro-alloying onto the microstructure, intermetallic compound (IMC) formation, and corrosion resistance of Sn-9Zn solders. The alloys Sn-9Zn-0.05Ce, Sn-9Zn-0.1Cr, and Sn-9Zn-0.05Ce-0.1Cr were fabricated via conventional casting and tested in 3.6 wt.% NaCl solution using potentiodynamic polarisation, SEM, EDS, and XRD. The Ce-Cr co-doped alloy exhibited superior performance, characterised by the noble corrosion potential (1.139 V), the lowest corrosion current density (29.788 A/cm2), and a dense protective film. While Ce-only and Cr-only alloys formed porous, partially protective layers. Phase analysis confirmed the presence of CeSn3 and Cr2Sn3, which refined Zn distribution, suppressed dissolution, and stabilised Cu-Sn IMCs. Findings highlight the synergistic role of Ce and Cr in improving corrosion resistance and interfacial reliability compared to lead-free materials.
  Keywords: LFS; corrosion; intermetallic compound; IMC; Sn-9Zn solder.
  DOI: 10.1504/IJMATEI.2026.10078164
   
  
• Multi-response optimisation of TiB2-reinforced aluminium composites fabricated by FSP using Taguchi-GRA integrated approach  
  by Yogender Chauhan, Vikas Kumar, Ram Niwas Singh 
  Abstract: The present study focuses on fabrication of composites reinforced with nano-sized TiB2 particles AA2014 alloy using the friction stir processing (FSP) and optimisation of input parameters for enhanced mechanical and microstructural characteristics was done. Taguchi approach and grey relational experimental analysis technique (GREAT) was employed for multi-response optimisation. Taguchi L9 orthogonal array, considering tool rotational speed (rpm), transverse speed (mm/min), and tilt angle (degrees) as input process parameters. The responses evaluated were tensile strength, hardness, and grain size. The optimal combination of process parameters was identified as a tool rotational speed of 1,300 rpm, a transverse speed of 100 mm/min and a tilt angle of 2 . At this optimised setting, the maximum hardness achieved was 147 HV, which represents an improvement of 11.5% over the base metal hardness of 132 HV. The highest recorded ultimate tensile strength (UTS) was 452 MPa, representing a 28.4% enhancement over the BM.
  Keywords: friction stir processing; FSP; AA2014; L9-orthogonal array; ANOVA; GREAT; micro-hardness; grain size.
  DOI: 10.1504/IJMATEI.2026.10078520
   
  
• Effect of nickel as an alloying element on grain morphology, mechanical and wear properties of Al-Sn alloy  
  by Jayarama Bhat, Satyanarayan 
  Abstract: Al-Sn alloys are widely used in bearing and tribological applications, but their load-bearing capability and high-temperature durability remain limited. In this work, Al-Sn-xNi (0, 1, 3, 4, 5 wt.%) alloys are developed to address these constraints, and the influence of Ni on microstructure, mechanical properties, and thermal wear behaviour is systematically investigated. Microstructural analysis revealed that Ni promoted the formation of Al3Ni and Ni-Sn intermetallics, transforming the continuous Sn network into a refined, heterogeneous distribution that enhanced matrix reinforcement. The modification resulted in a monotonic hardness increase from 51 RHN to 68 RHN, while impact toughness peaks declined due to increased intermetallic fraction and brittleness. Pin-on-disc measurements up to 90 C show that Ni markedly improved wear resistance and stabilised friction through a synergistic mechanism of load bearing intermetallics and Sn-assisted solid lubrication. Machine-learning-assisted mapping of wear trends confirmed an optimal performance from 3 to 5 wt.% Ni, where hardness-toughness and high-temperature tribological stability were maximised. The findings demonstrated that Ni-modified Al-Sn alloys are strong Pb-free candidates for next-generation high-load, thermally demanding bearing applications in automotive and industrial systems.
  Keywords: Pb-free bearings; Al-Sn-Ni alloys; intermetallic strengthening; high-temperature wear; tribological performance.
  DOI: 10.1504/IJMATEI.2026.10078847