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This study investigates the Tensile, Corrosion and Wear characteristics of Aluminum - Tungsten Carbide - Fly ash - Zirconia Composites for automotive applications. Two different compositions, 90% Aluminum- 5% Tungsten Carbide-5% Fly Ash (Al90-WC5-FA5) and 92% Aluminium-4% Tungsten Carbide-4% Fly Ash (Al92-WC4-FA4), were prepared using the sand casting process. Zirconia was also incorporated into both composites. Samples were prepared according to ASTM standards, and tests were conducted to evaluate mechanical properties, corrosion resistance using the salt spray method, and wear characteristics using a pin-on-disc apparatus. The results demonstrated that the Al90-WC5-FA5 composite exhibited higher tensile strength and significantly improved wear resistance compared to the Al92-WC4-FA4 composite, attributed to the higher content of Tungsten Carbide and Fly Ash. Both composites showed comparable corrosion resistance to standard aluminum alloy. These findings suggest that the Al90-WC5-FA5 composite, with its superior mechanical properties and wear resistance, is a promising candidate for automotive applications, providing enhanced performance and durability.

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