Assessment of mechanical properties and microstructure of AA6061 reinforced with nano-sized chicken feather powder and cow-bone ash

The demand for lightweight and sustainable engineering materials has increased interest in aluminum metal matrix composites (AMMCs) reinforced with low-cost alternatives to conventional ceramics. This study investigates the microstructural and mechanical properties of AA6061 aluminum alloy reinforced with hybrid nano-sized chicken feather powder (CFP) and cow bone ash (CBA). CFP and CBA were produced from poultry and abattoir wastes through controlled combustion and high-energy ball milling, and characterized using SEM, and EDS. Composites containing 0 to15 wt.% CFP and 0 to 2 wt.% CBA were fabricated via stir casting. Hybrid nano CFP–CBA reinforcement significantly improved mechanical performance. Hardness increased from 62 BHN for the unreinforced alloy to a maximum of 79 BHN at higher reinforcement levels, indicating enhanced resistance to plastic deformation and tensile strength reached approximately 162 MPa due to effective load transfer and grain refinement. Impact energy decreased to about 16 J with increasing reinforcement content, indicating reduced ductility, while density slightly reduced to approximately 2.69 g/cm³. SEM analysis confirmed uniform particle dispersion and good interfacial bonding. The results demonstrate that hybrid CFP–CBA reinforced AA6061 composites offer a lightweight, low-cost, and sustainable alternative for automotive and structural applications.