Modeling, Optimization and Performance Evaluation of TiC/Graphite Reinforced Al 7075 Hybrid Composites Using Response Surface Methodology.

Mohammad Azad Alam,Hamdan H Ya,Faisal Masood,Ramaneish Sivraj,Bisma Parveez,Mohammad Yusuf,Salit M Sapuan,Mohsin Sattar,Othman B Mamat

doi:10.3390/ma14164703

Abstract

The tenacious thirst for fuel-saving and desirable physical and mechanical properties of the materials have compelled researchers to focus on a new generation of aluminum hybrid composites for automotive and aircraft applications. This work investigates the microhardness behavior and microstructural characterization of aluminum alloy (Al 7075)-titanium carbide (TiC)-graphite (Gr) hybrid composites. The hybrid composites were prepared via the powder metallurgy technique with the amounts of TiC (0, 3, 5, and 7 wt.%), reinforced to Al 7075 + 1 wt.% Gr. The microstructural characteristics were investigated by optical microscopy, scanning electron microscopy (SEM), X-ray diffraction (XRD) and energy dispersive X-ray spectroscopy (EDS) elemental mapping. A Box Behnken design (BBD) response surface methodology (RSM) approach was utilized for modeling and optimization of density and microhardness independent parameters and to develop an empirical model of density and microhardness in terms of process variables. Effects of independent parameters on the responses have been evaluated by analysis of variance (ANOVA). The density and microhardness of the Al 7075-TiC-Gr hybrid composites are found to be increased by increasing the weight percentage of TiC particles. The optimal conditions for obtaining the highest density and microhardness are estimated to be 6.79 wt.% TiC at temperature 626.13 °C and compaction pressure of 300 Mpa.

Highlights

Today’s globe is tormented by environmental pollution and fossil fuel scarcity
The current study explores the synthesis, microstructural characterization, modeling, and optimization of Al 7075-Gr 1 wt.%-titanium carbide (TiC) x wt.%, TiC (x = 3, 5, and 7%) sintered hybrid composites, produced via a powder metallurgy technique
The microstructural characteristics of base materials and synthesized composites were investigated by optical microscopy, scanning electron microscopy (SEM), X-ray diffraction (XRD) and energy dispersive X-ray spectroscopy (EDS) elemental mapping

Summary

Introduction

Today’s globe is tormented by environmental pollution and fossil fuel scarcity. The automotive industry is one of the most significant contributors to these issues. Significant investigations have been focused on the production of AMCs due to their low density, improved strength to weight ratio, and satisfactory hardness and wear resistance [6,7,8,9,10,11,12] These key features of Al/Al alloy composites have led to a great acceptance of AMCs in automobiles, aircraft, offshore structures, and many other applications. The governing factors for the enhanced properties of AMCs are their processing techniques, particle distribution, the alignment nature of reinforcements within the matrix, and the interaction of filler particles at interfaces [11] In addition to these unique properties, the hardness behavior improvement of AMCs has drawn considerable interest in the automotive and aircraft industries. The PM method is economical in large-scale manufacturing because it minimizes expensive machining processes owing to the development of near-net-shaped components

Methods

Results

Conclusion