Abstract
In the modern era, the need for new products with novel processing and multipurpose materials is increased. The current market requirements for engineering applications are lightweight, high strength and low-cost materials. This paper explores the novel development process of high-performance nano cermet material for aerospace applications. Herein, lightweight aluminium 6061 + 2% of SiC (40 nm) nano cermet was fabricated through the casting method. The effects of ultrasonication, double stir casting or rheocasting, and squeezing pressure on nano cermet fabrication were successfully investigated by comparing their physical, thermal and mechanical properties. Scanning electron microscopy was employed to analyse the morphology of the cermets, and the presence of reinforcements was verified through EDS. The reinforcement of SiC into Al 6061 improved density, hardness, and reduction in porosity and grain refinement. This study reveals a novel fabrication process of ultrasonic-aided rheo-squeeze casting technique which enhanced the mechanical properties of the cermets compared to Al 6061 alloy due to nanoparticles homogeneous distribution, nominal agglomeration and porosity.
Highlights
Aluminium and its alloys are widely used in the aviation industry in the areas such as wings, rudder, exhaust pipes and fuselage due to its high strength to weight ratio, high creep and chemical resistance, loadbearing stability, rapid and low-cost manufacturing process [1]
The morphology of Al 6061 base material (Fig. 2a & b) indicates voids and cavities around the surface with reduced cavities in the squeeze technique. These voids in the Al 6061 could have been due to the followed fabrication process and heat treatment
This study intends to bring out the effects of casting, rheocasting, squeezing pressure and ultrasonication processes associated with the physical, mechanical and thermal properties of the cermets
Summary
Aluminium and its alloys are widely used in the aviation industry in the areas such as wings, rudder, exhaust pipes and fuselage due to its high strength to weight ratio, high creep and chemical resistance, loadbearing stability, rapid and low-cost manufacturing process [1]. The development of high-performance nano cermets through this method is very challenging owing to the floating of nanoparticles on the molten liquid due to heterogeneous distribution, agglomeration and cluster formation [10] To overcome this problem, double stir casting (rheocasting) strategy along with a vortex technique was combined to enhance the nanoparticle distribution [11]. Squeeze casting led to the defect-free surface with improved toughness along with improved mechanical properties and grain refinement, leading to reduced porosity and cavities [20,21] This investigation explored the development of a highperformance cermet through a novel strategy of ultrasonication-aided rheocasting
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