This work dealt with the fabrication of novel long glass fibre reinforced aluminum metal matrix composite (LGFRAMMC) material for automotive applications. The composite specimens were prepared by incorporating long glass fibre with different fibre volume percentage (50, 66, 80, and 100 vol.%) as reinforcement in aluminium alloy (Al6061) using the friction stir processing (FSP) method. The mechanical behaviour of the composite materials was investigated for their primary loading conditions such as tensile and Izod impact stress. Microstructural characterization and fractured mechanism of the fabricated composites were carried out by scanning electron microscope (SEM) analysis. The tensile strength and elongation of the developed composite specimens decreased with the incorporation of long glass fibre, whereas the Izod impact strength of the developed composite specimens was significantly improved as compared to the conventional base metal (Al6061) body panels used in automobiles. The low tensile strength of LGFRAMMC specimens compared to base metal was because of tunnel defect, brittle fracture and extreme plastic deformation (EPD) as characterized by fibre pull-out, pits, and micro cracks. The synergetic effects of EPD and reinforcing by long glass fibres lead to a remarkable improvement in the impact strength.
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