Al Nanocomposites Research Articles

Structural and Electrochemical Properties of Binary ZnO:Al Nanocomposites as Anode for Lithium-ion Batteries

In conventional lithium-ion batteries (LIBs), carbon compounds are commonly utilised as the anode owing to their great performance, low cost, and abundance. However, due to the limited storage capability of pure carbon materials that restrict further improvement of LIBs, zinc oxide (ZnO) has been one of the promising anode materials to be used as an alternative to strengthen the electrochemical performance of LIBs due to its high theoretical capacity of 987 mAh g-1. This study aims to synthesise ZnO:Al nanowires using the hot-tube thermal evaporation method. Three types of samples are made using this method by varying the concentration of 0 wt% (S1), 3wt% (S2), and 6 wt% (S3) of aluminium (Al) during the Al deposition process. The EDX findings indicated that the sample has a high proportion of zinc (Zn) and oxygen (O), with the S3 sample having the highest Al concentration after being deposited. The most substantial diffraction peak for XRD of all samples was found at (101), exhibiting a single crystalline hexagonal structure with optimum growth direction on the c-axis. For EIS analysis, the S3 sample has the lowest bulk resistance and maximum ionic conductivity. In conclusion, the ZnO sample with 3 wt% of Al as a dopant was selected as the optimum result to synthesise a homogenous surface of ZnO:Al with good crystallinity by using a hot-tube thermal evaporation process and giving the best conductivity in electrochemical performance.

Mechanical Performance and Corrosion Behaviour of Aluminum7075 Reinforced by Nano-Titanium dioxide

في هذه الدراسة ، تم تطبيق تقنية الصب بالتحريك (SCT) لتكوين مركب الألمنيوم (Al) النانوي مع نسب وزنية مختلفة من مسحوق ثاني أكسيد التيتانيوم النانوي (TiO2). تم فحص الخصائص البنائية ,الميكانيكية والتآكل لمتراكبات النانو. دراسة البنية المجهرية تمت عن طريق المجهر الإلكتروني الماسح (SEM) ، بينما تم الحصول على التركيب البلوري للعينات باستخدام حيود الأشعة السينية (XRD). بالإضافة إلى ذلك ، تم غمر المركبات النانوية في محلول 0.5 مولاري من حمض الهيدروكلوريك لقياسات معدل التآكل والديناميكية الفعالة. أظهرت النتائج أن أفضل عينة كانت 0.03٪ ، حيث زادت الصلابة بنسبة 23٪ ، لكن قوة الشد زادت إلى 52٪. حيث أظهرت صور SEM للعينات المعززة بالجسيمات النانوية تجانسًا وانتشارًا واضحًا للجسيمات النانوية في المصفوفة. لذلك ، فإن إضافة جزيئات TiO2 النانوية إلى معدن الألمنيوم أدى إلى تحسين صلابة وقوة الشد للمركبات النانوية بشكل ملحوظ. بالمقابل أظهرت نتائج التآكل أن المواد المركبة النانوية لديها مقاومة تآكل أعلى من المواد المركبة القائمة على Al7075.

Dislocation extension in coarse–grained Al reinforced by SiC nanowires under complex stress condition

Stacking faults (SFs) could be generated in aluminum (Al) via full dislocations extension under extreme stress. However, the extension behavior of the dislocations related to the stress conditions have not been studied comprehensively. In this study, SFs were generated solely under extreme stress condition in coarse–grained Al nanocomposites, where high content of Silicon Carbide nanowires (SiCnw) was introduced as reinforcement. Dislocation extension behaviors under normal and shear stress were predicted using an atomistic approach comparing with experiment methods. The extension ability of full dislocations was studied in terms of complex stress forced on partial dislocations and the relationship between stress condition and the SF width was established by stress analysis. The generated SFs were further proved to offer superb additional strengthening effect for the composites. This study provides a new idea and theory for designing of SF generation in coarse–grained Al based nanocomposites.

Synthesis and characterisation of calcium-iron-aluminium nanocomposites for electromagnetic radiation shielding application.

Electromagnetic shielding parameters are crucial to investigate unexplored nanoparticles and their nanocomposites. Herein, calcium-iron-aluminium (Ca: Fe: Al) nanocomposites are synthesised using the simple solution combustion technique. The as-synthesised nanocomposites with various doping concentrations of Al nanoparticles are characterised to study the structural and surface parameters and to confirm the successful formation. Further, the procured Ca: Fe: Al nanocomposites along with various doping concentrations are utilised for electromagnetic shielding applications, and various shielding parameters are calculated. It was confirmed that Ca: Fe: Al nanocomposites are suitable for electromagnetic shielding applications.

Eco-friendly and efficient sulfamic acid functionalized MIL-53 (Al) nanocomposite for removal of hazardous pollutants from wastewater and catalytic synthesis of 3,4-dihydropyrimidinone pharmacological moiety

This study proposed the facile synthesis of sulfamic acid functionalized MIL-53 (Al) (SA@MIL-53(Al)) nanocomposite for dual-functional pollutant removal and catalytic synthesis. The composite was synthesized through a facile, straightforward, and one-step solvothermal process. Furthermore, different analysis techniques like XRD, SEM, XPS, FT-IR, and TGA were applied to examine the prepared composites' structure properties, confirming the successful preparation of functionalized frameworks. Several factors, including the initial concentration of pollutants, adsorbent dosage, pH, and pHpzc, have been established to optimize the suitable parameters for adsorption. 25 wt.% SA@MIL-53(Al) has the greatest adsorption capacities of 146.5, 97.7, and 35.5 mg g−1 for removing MB, CR dyes, and Pb (II), respectively. The rate-limiting steps were also discussed, and the experimental adsorption measurements obeyed the Langmuir and the pseudo-second-order kinetic models. Moreover, the fabricated composites were used as catalysts to produce 3,4-dihydropyrimidinone (3,4-DHP). 50 wt.% SA@MIL-53(Al) demonstrated the highest efficiency, nearly 92.0 %, with great durability and stability.

Molecular dynamics simulations of tensile and creep-ratcheting behaviour of CNT reinforced columnar nanocrystalline Al nanocomposites

High-temperature cyclic loading is a major factor affecting the life of a structural component. In this study, the tensile and creep-ratcheting behaviour of three volume fractions of CNT-reinforced columnar nanocrystalline aluminium has been studied using hybrid potentials (EAM, AIREBO and LJ potentials) at two different stress ratios (R = 0.4, 0.6) and three different temperatures (T = 300 K, 467 K and 653 K). The aim is to determine the stress-strain curve, strain-time curve, overall dislocation density, dislocation types, and mainly the underlying deformation mechanisms of CNT-based NC Al matrix nanocomposites. Increasing the CNT volume fraction in the matrix has shown improved UTS values, enhanced dislocation annihilation rate, dissipation of the hysteresis loop energy, lower strain accumulation and higher time to fracture. The specimen fails quickly at higher temperatures which is depicted by the widening of the hysteresis loop. The predominant deformation mechanisms like grain boundary diffusion, widening, merging, sliding and rotations have been observed. Grain boundary diffusion drives the creep-ratcheting deformation behaviour under three temperatures and the misalignment has been noticed at the interaction of CNT-NC Al nanocomposite during the creep-ratcheting deformation at high temperature. The Shockley-partial and perfect dislocations have been determined to control the underlying deformation mechanism. The current work can serve as a keystone in the creep-ratcheting analysis of structural materials employed in high-temperature loading environments.

Advance processing of cluster-free CNT reinforced 6082 Al matrix nanocomposites: influence of mechanical milling and cryomilling

ABSTRACT In the present study, lightweight high-strength carbon nanotubes (CNTs) reinforced aluminium-based composite was fabricated through powder metallurgical processing. The effect of planetary milling and cryogenic assisted milling on the structure, morphology, mechanical properties, phase composition, and thermal stability of CNTs reinforced Al6082 Al nanocomposites powders was investigated using X-ray diffraction (XRD), scanning electron microscope (SEM)- Energy dispersive spectroscopy (EDS), transmission electron microscope (TEM), and indentation techniques. The CNTs in the Aluminium (AL) matrix were distributed uniformly after 50 h of milling. Further, the cryomilling of 50 h milled Aluminium matrix composites (AMC) decreases agglomeration even more and was successful in cleaving the nanotubes as well as minimising entanglements. The broadening of diffraction peaks suggests a reduction in the crystallite size (from ~36 to ~20 nm) and an increase in induced strain. Milled powders were consolidated through the hot-press and spark plasma sintering technique. The mechanical properties of these AMCs were evaluated through indentation for hardness (>250 HV) and compressive testing techniques. SPSed samples reported better properties in comparison to hot-pressed samples. It is discovered that post-CM of Mechanical Milling (MM) powder aids in overcoming issues related to the agglomeration of Al/CNT composites, and the goal to fabricate tangle-free CNT reinforced composite was achieved. Moreover, it showed enhanced mechanical properties with a maximum yield strength of 210 MPa and good synergy between strength and ductility.

Construction of novel CoFe2O4/h-BN/MIL-53 (Al) magnetic nanocomposites for the removal of hazardous antibiotics from water

In this study, the CoFe2O4/hexagonal boron nitride (h-BN) nanocomposite prepared via the microwave irradiation method, was hybridized with the MIL-53 (Al) metal–organic framework. The structure and morphology of the magnetic CoFe2O4/h-BN/MIL-53(Al) nanocomposite were investigated using Fourier transform infrared spectroscopy (FTIR), powder X-ray diffraction (XRD), Raman spectroscopy, scanning electron microscopy (SEM), energy dispersive X-ray analyzer (EDX), Brunauer-Emmett-Teller (BET) surface area analysis, vibrating sample magnetometry (VSM) and zeta potential analysis. The adsorption performance of the CoFe2O4/h-BN/MIL-53 (Al) nanocomposite as a magnetically recyclable adsorbent for removing tetracycline (TC) and ciprofloxacin (CIP) antibiotics in aqueous solutions was investigated under different influence factors, including contact time, initial drug concentration, adsorbent dosage, pH conditions, temperature and ionic strength. The results indicated that the nanocomposite adsorbed 100 % of drugs within a short time (20–––30 min), with a maximum adsorption capacity of 625.00 mg g-1and 270.27 mg g−1, respectively. Additionally, the adsorption mechanism was also discussed based on the obtained results. After the drug absorption and removal process, the nanocomposite can be easily separated and reused several times without losing its absorption activity, therefore making it an appropriate choice for removing drugs from polluted water.

Machine learning aided design of Bi2WO6/MIL-53(Al) nanocomposites

It is a very rewarding work to quickly develop a new type of visible-light photocatalyst Bi2WO6/MIL-53(Al) (BWO/MIL) nanocomposites with desired property in enormous material synthesis space. In the work, the BWO/MIL predictor based on machine learning method was established by using the synthetic parameters to accelerate the design of BWO/MIL nanocomposites. The forward feature selection, genetic algorithm based on support vector regression (SVR), and genetic algorithm based on gradient boosting regression (GBR) were employed to screen the key features from candidate features related to synthetic parameters of BWO/MIL nanocomposites. The correlation coefficients (R) of the SVR model with radial basis function (RBF) were 0.904 and 0.929 for ten-fold cross validation and the external test, respectively. The two R values of the GBR model were slightly lower than the SVR model. The potential BWO/MIL nanocomposites with desired property were discovered by the SVR-RBF model and virtual screening from the huge synthesis space of BWO/MIL nanocomposites. An online web service (http://1.14.49.110/online_predict/BWO1) was developed to quickly predict photocatalysis activity of BWO/MIL nanocomposites. The methods mentioned here can accelerate the design of BWO/MIL nanocomposites and cut the cost of BWO/MIL synthesis.

Nanomechanical analysis of friction welded similar PEEK/aluminum nanocomposites: Effect of metal particle reinforcement

AbstractAluminum (Al), poly(etheretherketone) (PEEK) thermoplastics, and their individual composites have widely been used in many industries, including aerospace and biomedical fields. However, the joining process of those composites has not been explored much to date. In this context, the friction welding process (FWP) could be used as an alternative since it has the ability to join high‐strength components with minimal distortion. Therefore, the present study aimed to develop PEEK/Al nanocomposites with varying Al concentrations of 10, 20, 30, and 40 vol% using powder metallurgical technique and further joined the similar composition composites by FWP. Then, the effect of reinforced particle concentrations on the physical, morphological, structural, thermal, and micromechanical behaviors of the joined nanocomposites has been characterized by microscopy, X‐ray diffraction, differential scanning calorimetry, and nanoindentation tests. The concentrations of the reinforcement were found to have a significant effect on the crystallinity, melting temperature, glass transition temperature, and thereby micromechanical properties. The results were analyzed and correlated precisely for all the welded nanocomposites systematically. The interdiffusion mechanism was found to be involved in improving the mechanical properties of the present nanocomposites. The highest elastic modulus (13.91 GPa) or nanohardness (0.31 GPa) was obtained for the rotatory part of the PEEK/Al40 nanocomposites at 80 mN load. But, the applied load of 40 mN was the best loading condition due to the uniform change in modulus and nanohardness of all the nanocomposites. Therefore, the present alternative joining method of the PEEK/Al nanocomposites might be used for aerospace components.Highlights Development of PEEK/aluminum with 10, 20, 30 and 40 vol% Al nanocomposites. Friction welding of similar composite material, PEEK/Al‐PEEK/Al nanocomposites. Microstructural, thermal, and nanomechanical analyses. Effect of metal particle reinforcement on the friction welded nanocomposites. FW PEEK/Al40 nanocomposite is found to be the best.

Physical, electrochemical, and catalytic attributes of Mx–Bi–V–O (Mx = Al, Fe, Co, and Ni) nanocomposites for the fabrication of chromene derivatives

Physical, electrochemical, and catalytic attributes of Mx–Bi–V–O (Mx = Al, Fe, Co, and Ni) nanocomposites for the fabrication of chromene derivatives

Fabrication of high-content hybrid-reinforced Al nanocomposites by in-situ reaction of TiO2-decorated CNTs and matrix

The idea of intragranular in-situ reactions results in the proliferation of nanoreinforcements in a metal matrix composite. In this regard, high-content multi-component hybrid-reinforced 6061Al composites were synthesized in-situ from template reaction between TiO2-decorated carbon nanotubes (CNTs) and the matrix by flake powder metallurgy. TiO2 nanoparticles were introduced with the help of low-amount of CNT as carrier. The total content of reinforcements increased from 3.4 wt% to ∼17.35 wt% when TiO2-decorated CNTs were completely reacted with the matrix, producing Al4C3/Al4O4C/Al3Ti/Al2O3 compounds during high temperature sintering/extrusion. The as-fabricated hybrid composite exhibited outstanding mechanical properties of high tensile strength (570 MPa) and high Young's modulus (98.6 GPa) at room temperature, which were 105 % and ∼33 % higher than those of 6061Al matrix. Furthermore, the tensile strength of the hybrid-reinforced composite reached 211 MPa at 300 °C, which is about 270 % higher than the matrix. The remarkable mechanical properties were attributed to the in-situ formation of multi-components/nanophases with superior mechanical properties and high thermal stabilities. The results indicate that uniform incorporation of high-content nanophases through the in-situ reaction of nanoparticle-decorated CNTs is a promising path to produce high-performance nanocomposites and can be applied to other composite systems.

Investigation on the high strength and improved creep behavior of in-situ (Al2O3+ZrB2)/7055 Al nanocomposites

In this paper, 7055 Al composites reinforced by Al2O3 and ZrB2 nanoparticles were fabricated by in-situ reaction. The adhesion (Wad) of the ZrB2/Al interface was 3.91 J/m2 while the adhesion at the Al2O3/Al interface was 3.69 J/m2. At room temperature and high temperature up to 523 K, yield strength (YS), ultimate tensile strength (UTS), and elongation (EI) in (Al2O3+ZrB2)/7055 Al composites reached up to 595 MPa, 710 MPa, 19% and 371 MPa, 435 MPa, 24%, respectively. The combined strengthening effect produced by Al2O3 and ZrB2 nanoparticles was found to be stronger than that of the individual ZrB2 particles and the matrix. In addition, the steady creep rate of the (Al2O3+ZrB2)/7055 Al composites were the lowest, constituting only 3∼14% of the matrix and 5∼68% of the ZrB2/7055 Al composites. The true stress exponents in the matrix and composites were 5, indicating a dominative dislocation climbing mechanism. Both the promotion of precipitation nucleation and the precipitation-coarsening inhibition during the creep process at the interfaces between the matrix and nanoparticles were discussed. Additionally, deformed and fragment mechanisms and the creep resistance mechanism were elucidated.

Investigating microstructural features of the carbon nanotube-aluminum hybrid active plate on diffusion induced stresses in the bilayer electrode with initial stretching

Various types of batteries are produced to support years of service for implantable medical devices. Evaluation of internal stresses in nanoparticle-contained electrodes for lithium-ion batteries (LIBs) is a fundamental step toward enhancing their durability. In this research, diffusion induced stresses (DISs) in the bilayer electrode consisted of the carbon nanotube (CNT)-aluminum (Al) nanocomposite active plate bonded to the current collector are investigated. Modeling the DIS is performed by applying the initial stretching on the CNT-Al active plate. Effective properties of CNT-filled Al nanocomposites are calculated using micromechanics models in which the formation of interfacial carbide between the Al and CNT is considered. The role of important microstructural features including amount, length, diameters, curved structure and dispersion type of CNTs, and the thickness and property of interphase in DISs is examined to provide design insights for LIB electrodes. The blending of straight CNTs with a high aspect ratio significantly reduces the tensile stress in the current collector, both compressive and tensile stresses in the nanocomposite active plate and especially the stress drop at the collector/plate interface. Moreover, the DISs can be alleviated by the formation of a stiff and thick interphase between the Al and nanotubes. The CNT-contained electrode with a stretched active plate exhibits lower internal stresses.

Microstructures and mechanical properties of Al nanocomposites hybrid-reinforced with B4C, carbon nanotubes and graphene nanoplatelets

To improve the mechanical properties of Al-30%B4C composites, modified carbon nanotubes (CNTs) and graphene nanoplatelets (GNPs) were added. The Al/B4C composites with different content of CNTs and GNPs were fabricated via ball milling and hot press. The B4C particles were homogeneously distributed, and the B4C/Al interface was tightly bonded due to AlB2 and Al3BC. With increase of CNTs content, the composites strength increased. The compressive strength of the Al-30%B4C-0.75%CNT-0.25%GNP composite was enhanced by 46% compared with that of the Al-30%B4C composite. The interface bonding and strengthening mechanisms of CNT-GNP hybrid were studied in detail. The reinforcements mainly reinforced the nanocomposites by Orowan, dislocation, grain refinement strengthening and load transfer. After calculation, CNT-GNP hybrid has lower contribution in thermal mismatch and Orowan strengthening due to the larger size. The load transfer efficiency of the CNT-GNP hybrid was significantly higher than that of the CNTs and GNPs, as the optimised interface structure and interconnected structure of the hybrids contributed to its high strength.

Microstructural and Mechanical Characterization of Al Nanocomposites Using GCNs as a Reinforcement Fabricated by Induction Sintering

High-energy ball milling is a process suitable for producing composite powders whose achieved microstructure can be controlled by the processing parameters. Through this technique, it is possible to obtain a homogeneous distribution of reinforced material into a ductile metal matrix. In this work, some Al/CGNs nanocomposites were fabricated through a high-energy ball mill to disperse nanostructured graphite reinforcements produced in situ in the Al matrix. To retain the dispersed CGNs in the Al matrix, avoiding the precipitation of the Al4C3 phase during sintering, the high-frequency induction sintering (HFIS) method was used, which allows rapid heating rates. For comparative purposes, samples in the green and sintered state processed in a conventional electric furnace (CFS) were used. Microhardness testing was used to evaluate the effectiveness of the reinforcement in samples under different processing conditions. Structural analyses were carried out through an X-ray diffractometer coupled with a convolutional multiple whole profile (CMWP) fitting program to determine the crystallite size and dislocation density; both strengthening contributions were calculated using the Langford-Cohen and Taylor equations. According to the results, the CGNs dispersed in the Al matrix played an important role in the reinforcement of the Al matrix, promoting the increase in the dislocation density during the milling process. The strengthening contribution of the dislocation density was ~50% of the total hardening value, while the contribution by dispersion of CGNs was ~22% in samples with 3 wt. % C and sintered by the HFIS method. Atomic force microscopy (AFM) and scanning electron microscopy (SEM) were used to analyze the morphology, size, and distribution of phases present in the Al matrix. From the analyses carried out in AFM (topography and phase images), the CGNs are located mainly around crystallites and present height profiles of 1.6 to 2 nm.

Effect of Heat Treatment on the Mechanical and Tribological Properties of Dual-Reinforced Cold-Sprayed Al Coatings

The aluminum cold spray feedstock powder was single- and dual-reinforced with no greater than 2 vol% boron nitride nanoplatelets (BNNP) and/or nanometric boron carbide (nB4C). These powders were cold sprayed onto Al-6061 substrates and then heat-treated in an argon environment. In addition, micro- and nano-indentation hardness and wear testing were performed on the heat-treated samples. Further microscopy and optical profilometry were used to characterize the microstructure and wear track volumes. Minimal changes to the splat structure were observed after heat treatment. However, when compared to the pure Al coating, microhardness improved with reinforcement after treatment at 500 °C, while nanohardness improved only in the dual-reinforced coatings, again after treatment at 500 °C. The elastic modulus generally decreased for the reinforced coatings after treatment; however, indentation test results were mixed. The wear testing done on samples heat treated at 500 °C for one hour showed increases in the specific wear rate for single-reinforced coatings but decreases in the dual-reinforced coatings. These results indicate that both dual-reinforcement and heat treatment are required for improvements in the mechanical and tribological properties of Al nanocomposites.

A machine learning-based nano-photocatalyst module for accelerating the design of Bi2WO6/MIL-53(Al) nanocomposites with enhanced photocatalytic activity.

It is a great challenge to acquire novel Bi2WO6/MIL-53(Al) (BWO/MIL) nanocomposites with excellent catalytic activity by the trial-and-error method in the vast untapped synthetic space. The degradation rate of Rhodamine B dye (DRRhB) can be used as the main parameter to evaluate the catalytic activity of BWO/MIL nanocomposites. In this work, a machine learning-based nano-photocatalyst module was developed to speed up the design of BWO/MIL with desirable performance. Firstly, the DRRhB dataset was constructed, and four key features related to the synthetic conditions of BWO/MIL were filtered by the forward feature selection method based on support vector regression (SVR). Secondly, the SVR model with radical basis function for predicting the DRRhB of BWO/MIL was established with the key features and optimal hyperparameters. The correlation coefficients (R) between predicted and experimental DRRhB were 0.823 and 0.884 for leave-one-out cross-validation (LOOCV) and the external test, respectively. Thirdly, potential BWO/MIL nanocomposites with higher DRRhB were discovered by inverse projection, the prediction model, and virtual screening from the synthesis space. Meanwhile, an online web service (http://1.14.49.110/online_predict/BWO2) was built to share the model for predicting the DRRhB of BWO/MIL. Moreover, sensitivity analysis was brought into boosting the model's explainability and illustrating how the DRRhB of BWO/MIL changes over the four key features, respectively. The method mentioned here can provide valuable clues to develop new nanocomposites with the desired properties and accelerate the design of nano-photocatalysts.

Reaction pathways of in situ ZrB2 nanoparticles during flux-assisted synthesis in Al melt

Based on the Al-K 2 ZrF 6 -KBF 4 system, in situ ZrB 2 /Al nanocomposite was fabricated using flux-assisted synthesis in Al melt at 850 °C. A time-quenched technique was utilized to reveal the reaction mechanisms and particle evolution processes. Microstructural observations reveal that ZrB 2 generates through three parallel pathways, i.e., molten Al reacts with salt droplets (type I), K 2 ZrF 6 -dominated (type II), and KBF 4 -dominated (type III) powders, respectively. As for type I and type II, the initial appearance of lamella and flocculent agglomerates enrich supersaturated [Zr] and [B] solute atoms, upon which high-density ZrB 2 nuclei spontaneously nucleation and grow over time. While in type III, Zr-diffusivity and surface tension dissolution drive the transformation of the rod-like AlB 2 phase into ZrB 2 nanoparticles. It is noteworthy that all of these reactions are basically complete within 15 min, and hereafter the multiply melt stirring has a significant shearing effect, resulting in relatively dispersed particle agglomerates with sizes of 5–20 μm. • Time-quenched technique helps to trace synthesis processes of salt-metal reactions. • Three parallel reaction pathways and associated reasons are clarified. • ZrB 2 nanoparticles form mainly through the nucleation-growth mechanism. • Reaction pathways and melt stirring affect particle cluster configurations.

Microstructure-Based Modeling and Mechanical Characteristics of Accumulative Roll Bonded Al Nanocomposites with SiC Nanoparticles

This research work aims to fabricate the Al-4 wt.% SiC nanocomposite using the accumulative roll bonding (ARB) technique. Moreover, a finite element model based on real microstructure representative volume element representation and cohesive zone modeling was developed to predict the mechanical response of the produced composites. The results demonstrated that SiC particles were homogenously distributed inside the Al matrix after five passes. The tensile strength and hardness were improved by increasing the number of ARB passes. The microhardness of an Al-4%SiC composite subjected to five ARB passes was increased to 67 HV compared to 53 HV for Al sheets subjected to the same rolling process. Moreover, owing to greater bonding and grain refinement, tensile strength was increased by a factor of three compared to pure Al. The result of the proposed micro-model successfully predicts the experimentally obtained results of the Al–SiC macro composite. The numerically obtained stress–strain curve was comparable with the experimental one. The results also showed that the size of the used RVE was significantly influential in the prediction of the stress–strain behavior.