Thermomechanical and tribological behaviour of gravity die cast A356 aluminium composites reinforced with date palm seed ash for automotive applications

Lightweight aluminium alloys remain central to the design of modern automotive engine components, yet their limited resistance to wear and thermal instability under service conditions restricts wider structural applications. In this study, date palm seed ash (DPSA), an underutilised agro-waste by-product rich in metal oxides, was introduced as a reinforcing phase into gravity die-cast A356 alloy to improve its multifunctional performance. The DPSA was synthesised by controlled calcination at 500 °C and incorporated into the molten alloy through a semi-solid compo-casting process. Various thermomechanical and tribological assessments were performed to evaluate the enhanced mechanical properties of the composite material, focusing on wear resistance and thermophysical stability under simulated automotive conditions. The results indicate that the incorporation of DPSA significantly improved the wear resistance and thermal stability of the A356 aluminium composites, addressing the limitations of conventional alloys for automotive applications. These findings suggest that using agricultural waste as a reinforcement in metal matrix composites not only enhances material performance but also promotes sustainability through waste valorization.