Sustainable synthesis and optimization of aluminium matrix composites reinforced with laboratory waste borosilicate glass for resource sustainability circularity

This study presents the synthesis and optimization of AA8011 aluminium matrix composites reinforced with waste borosilicate glass particles using stir casting. Reinforcement levels of 0–15 wt.% were evaluated for tribological performance under varying operating conditions. A Taguchi L16 design integrated with Grey Relational Analysis (GRA) was employed to optimize wear rate, friction force, and coefficient of friction. The results show that the incorporation of borosilicate glass reduces wear by approximately 30–35% compared to the base alloy. Optimal performance was achieved at 5 wt.% reinforcement, 60 N load, 1.5 m/s sliding speed, and 2250 m sliding distance, corresponding to a maximum Grey Relational Grade of 0.8210. ANOVA indicates that applied load is the most influential factor (56.56%), followed by sliding distance (17.20%) and sliding speed (14.41%). The prediction error between experimental and model results was 3.47%, confirming the robustness of the optimization approach. The use of waste borosilicate glass contributes to material reuse and improved component life, supporting sustainable material development. In general, the resulting composites have considerable potential in terms of sustainable and energy-efficient use in the automotive and industrial engineering segments.