An attempt has been made to develop aluminum metal matrix composite (AMC) by utilizing waste from coal mines. By suitable thermal treatment in plasma reactor the waste colliary product containing mainly Al_2O_3, SiO_2 and carbon has been converted to a useful in-situ composite Al_2O_3 - SiC - C. The in-situ ceramic composite so developed is added to an aluminum melt for the preparation of AMC. For comparison purposes, a few more AMCs are prepared using Al_2O_3 and a mechanical mixture of Al_2O_3 and SiC particulates from indigenous sources. AMC developed by reinforcing aluminum with novel Al_2O_3 - SiC - C in-situ formed composite exhibits superior mechanical, tribological and machining properties. Tensile properties of the cast AMC prepared with in-situ composite at 15 vol %, Al_2O_3 15 vol % added singly, and Al_2O_3 and SiC in combination (15 vol %) registered 92, 80 and 62 MPa respectively. Additionally, the ceramic composite produced through plasma synthesis of colliary shale has been gainfully utilized to produce AMC amenable to hot working, both hot forging and rolling. The wrought product has superior mechanical and tribological properties.
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