Experimental Testing and Fabrication of Metal Matrix Composite for Automotive Applications

Abstract

Cold compaction behaviour, hardness, and micro-structural behavior of aluminium–boron carbide composites with variable boron carbide content for several composite systems, including Al-5 percent B₄C, Al-10 percent B₄C, Al-15 percent B₄C, and Al-20 percent B₄C, were all evaluated. Powder metallurgy was used to create the particle reinforced composite, with aluminum particles measuring 75 microns and boron carbide particles measuring 150 microns. The compacts were made using a universal testing machine (UTM) with a 60-ton capacity and the appropriate punch and die set assembly. After the green compacts were prepared, they were sintered in an electric furnace at 550°C for 120 minutes. The compacts are then allowed to cool in the furnace to room temperature. Cold compaction and axial pressing were used to study densification tendencies. The link between applied pressure and density, as well as between applied pressure and relative density, was established. The percentage of B₄C reinforcement was used to boost the hardness and compressive strength of various composite samples. Scanning electron microscopy (SEM) images were used to investigate microstructural phenomena. The final solution was compared to that of Cam, an existing car component. It's made of a metal matrix composite of Al-SiC. Because the Al-B₄C composite has a lower density than the Al-SiC composite, it allows for the most weight reduction in the product. The samples' weights have been reduced, resulting in a higher strength-to-weight ratio. In both cases, the material cost evaluations were substantially identical. It's simple to automate the fabrication process.