Alloy Composite Materials Research Articles

Electrochemical machining of aluminium 7075 alloy, silicon carbide, and fly ash composites: An experimental investigation of the effects of variables on material removal rate

The electro-chemical machining process (EMP) is being used to drill super alloys substances into the appropriate design shapes. The current study makes it look at how several common electrochemical holes digging process variables, like voltage source, electrolytic concentration, and pulse on time, affect the material removal rate of Aluminium 7075 alloy, silicon carbide, and fly-ash particle composite materials are cast by the stir casting process. These aluminum metal matrix composites may be utilized to make trusses, frameworks, and vessels which are to hold contaminants, dairy, as well as other acidic substances; it could also be employed to substitute stainless material, which is utilized in salty environments to prevent rusting. In this research, Taguchi’s design of experiment is used to study the influences of each variable on material removal rate.

Fabrication and characterization of N-doped porous carbon Co-Fe alloy composite cathode materials for promoting the electrochemical performance of Li-S batteries

The cathode materials for lithium-sulfur battery, as a hot topic in energy storage research, is an important node for lithium sulfur battery to achieve practical application. Here, we prepared a nitrogen-doped carbon shell structured porous carbon-bimetal alloy composite with a particle diameter of 150 nm. In the shell of the structure, Co-Fe alloy particles as diameter of 20 nm with nitrogen-doped carbon coated were uniformly distributed. This porous nanocarbon materials have a rich surface area that can serve as a site for sulfur load. The uniform Co-Fe alloy catalytic and absorptive site can improve the oxidation-reduction reaction kinetics of LSBs and inhibit the shuttle effects of polysulfides. Meanwhile, the spatial domain restriction of the shell can be helpful to anchor S and polysulfides inside the structure. Because of these synergistic benefits, the Li-S batteries with this material cathode performs an excellent cycling stability with the capacity decay rate of 0.055% per cycle at 0.1 C after 100 cycles (initial capacity is 1226 mAh g−1) and 85.5% of initial capacity at 1 C after 300 cycles (initial capacity is 899.5 mAh g−1). Even with a high sulfur loading of 5.1 mg cm−2, it still achieves a high capacity of 3.43 mAh cm−2 (75% of initial capacity) after 100 cycles. This study provides the potential possibility to achieve large-capacity long-cycle work in lithium-sulfur batteries.

Preparation and compression performance of porous magnesium alloy composite with ceramic hollow spheres

Using two different ceramic hollow spheres (the commercial alumina hollow sphere and the self-made silicon-containing ceramic hollow sphere) as reinforcements, two kinds of lightweight porous magnesium alloy composite materials were successfully fabricated by sintering at 600 °C for 3 h 20 min. The microstructure of samples with the self-made silicon-containing ceramic hollow sphere reveals that an alloy phase containing MgO and Mg2Si was formed by an interfacial reaction at the interface between the magnesium alloy and the self-made ceramic hollow sphere. The formation of the alloy phase is beneficial to improve the mechanical properties of the sample. The influence of different types of ceramic hollow spheres on the apparent density, compressive strength, specific strength, energy absorption, and energy absorption efficiency was studied for these porous products. The results show that the apparent density of these two porous samples is markedly lower than that of the magnesium alloy. The Compression curves of both samples have the elastic stage, the yield platform, and the densification stage, which are the typical compression characteristics of porous materials. The compressive strength and specific strength of the samples made by self-made silicon-containing ceramic hollow spheres are both significantly higher than those made by commercial alumina hollow spheres. Moreover, the energy absorption performance of the sample made by self-made silicon-containing ceramic hollow spheres is better than that of the sample made by alumina hollow spheres. The higher energy absorption capacity and the wider strain range of maintaining the maximum energy absorption efficiency mean the sample made by self-made silicon-containing ceramic hollow spheres can absorb more energy.

EXAMINATION OF THERMAL STRESSES OCCURRING IN CIRCULAR DISCS BY FINITE ELEMENT METHOD

In this study, thermal stress analysis on discs consisting of two different materials was analyzed analytically. Disc materials were selected SiC/6061 Al Alloy composite and Al-7075 respectively. Assuming that the elasticity module does not change with temperature, thermal stress analysis was performed under constant temperature distributions in the area from the inner surface of the disc to the outer surface. Thermal stress analysis was performed under constant temperature distribution. A computer program was developed for the calculation and the ANSYS finite element program was used. The values obtained from the analysis are presented in tables and graphs. There have been differences in radial and tangential stresses that occur because the elasticity modules and thermal expansion coefficients of the materials that make up the discs are different. The radial stress value has always been determined as zero on the innermost and outermost surfaces of the discs. Tangential stresses under constant temperature distribution from the inner surface to the outer surface occurred as pressure on the inner part of the disc and tensile stress on the outer part. It is concluded that the stresses occurring in the SiC /6061 Al alloy composite material are greater than those of AL-7075.

Channel deformation of bilayer material using tool rollers: Part I-Springback

ABSTRACT In this two-part paper, the bilayer material is created by sandwiching the aluminium alloy and carbon fibre composite and then deforming through the conventional channel forming. In both aluminium alloy and polymer, the common problem is the springback due to their lower modulus of elasticity. To reduce the springback mechanically, the patented process is used in this work. In this novel manufacturing process, the die and punch radii are converted in rollers. These rollers can be fixed or rotated depending on the necessity. The first part of this paper involves investigating the bilayer material deformation and springback through the novel manufacturing process. For this the bilayer material was created with equal thickness of aluminium alloy and composite. In one sample the aluminium alloy was the top layer and, in another sample, the aluminium alloy material was bottom layer. From the results it was found that the top layer aluminium alloy composite material with punch roller rotating in counterclockwise and die roller rotating in clockwise direction shows lowest springback. The residual stress graph shows that the rollers rotation changes the stress patterns in the material which results in lower springback.

Comparative structural analysis of CNC milling machine bed using Al-SIC/graphite, al alloy and Al-SIC composite material

The composite materials extensively used in a CNC machine bed have a huge impact on the efficiency and accuracy of the part. Existing materials, such as steel and cast iron are required for higher machine speeds because they have limited stiffness and shift in conventional tools service life, such as manufacturing applications. The current work deal with the comparative structural analysis of Al- SiC, Al alloy graphite and Al-SIC composite materials. To examine CNC milling bed mechanics, lower weight, enhance stiffness, strength, and also find the damping characteristic with a fixed range of natural frequencies. Commercial Solidworks 3D modeling software was used to make the three dimensional model of bed, and ANSYS 14.5 was used to conduct structural analyses. As a result of the higher natural frequency, the vibrative reaction of the Al-SiC composite material is reduced, and the Al-SiC composite material is structurally strong. Al-SiC is incredibly resonant when compared to other composites. The Al-SiC machine bed is protected from harmonic analysis effects caused by resonance phenomena, and damping has an impact on the degree of vibration rather than the effect.

Effect of Graphene Content on the Micromorphology, Microhardness and Micro Frictional Resistance of Co-Ni-Graphene Composite Coating

In order to obtain the alloy composite material with high hardness, good anti-friction property and low friction coefficient, the electrodeposition technology was used to prepare nanocrystalline Co-Ni-graphene composite coating on the surface of low carbon steel by means of ultrasonic dispersion combined with mechanical agitation. The influence of graphene content in electrolyte on composite coating was studied. The surface microstructure, composition, phase structure, micro-hardness and micro-wear properties of composite coating were measured by scanning electron microscopy, energy spectrometer, X-ray diffractometer, micro-hardness tester and UNMT-1 comprehensive mechanical testing system for micro-nanometer materials. The results show that with the increase of the content of graphene in the electrolyte the graphene particles were embedded in the alloy coating, which changes the crystal structure of the alloy coating and improves the microhardness and micro friction resistance of the coating. When the content of graphene in the electrolyte was 0.9g/L the microstructure of the composite coating was fine and uniform, the highest microhardness value was 678 HV, the minimum average friction coefficient was 0.15, and the composite coating had good wear resistance.

Mechanical Properties of a Layered Ti–6Al–4V Alloy Composite Material Fabricated under Low-Temperature Superplasticity Conditions

Mechanical Properties of a Layered Ti–6Al–4V Alloy Composite Material Fabricated under Low-Temperature Superplasticity Conditions

Investigation of mechanical and tribological performance of marble dust 7075 aluminium alloy composites

Investigation of marble dust reinforced Al7075 alloy-based matrix composite fabricated through stir casting technique is done in this study. The different physical, mechanical and wear behaviours of the 0, 2, 4 and 6 wt% reinforced alloy composites are investigated. The void content increase with the addition of reinforcement; the maximum void content was observed at 6 wt% of marble dust-filled Al-7075 alloy composite. The maximum hardness found at 6 wt, % marble dust-filled alloy composites and minimum hardness found in unreinforced alloy. The highest compressive strength is observed for 2 wt% of marble dust and maximum flexural strength observed at 6 wt% of marble dust-filled composites. The maximum impact strength found at 6 wt% of marble dust reinforcement. The wear behaviour is examined in steady-state condition of marble dust mixed Al7075 metal alloy composite material in the dry condition. The specific wear rate decreases with increment in normal load and sliding velocity by keeping two other variable constants. The 6 wt. % marble dust reinforced composites presented in this study has the highest wear-resistant.

COMPARATIVE ANALYSIS OF METHODS FOR DETERMINING THE MASS OF THE SHAFT OF A SPORTS AND AEROBATIC AIRCRAFT, MADE OF TITANIUM AND COMPOSITE MATERIAL

Comparative analysis of an acrobatic aircraft's weight and shaft which is made of a titanium alloy and composite materials. The article contained requirements and specificities of an acrobatic aircraft's landing gear shaft design. The article describes prediction method of an acrobatic aircraft’s weight fraction of shaft which is allows to take into account shaft mass on wing loading upon condition that composite materials will be used in construction. Research objectives include: –Documentation of an acrobatic aircraft’s shaft design. – Analytic dependence conclusions on shaft mass by applying energy absorption of landing impact. – To quantify the algorithm of shaft mass based on strength prediction of shaft construction. –To quantify the mass and construction of shaft based on patterns that are made of titanium and composite materials. – Comparative analysis and references to practical using these methods to quantify shaft’s mass. –To quantify how shaft mass influenced by wing loading. –Designing shaft construction that is made of titanium alloy VT22 and composite material VKU26 by taking into account quantity and ply layup. Comparative analysis shaft mass which is made by different variety of composite materials. The constructive analysis is distinguished for decreasing the shaft mass that is made by composite material and references on ply layup.

Effect of Friction Stir Forming Process Parameters on Mechanical Interlock between A5083Alloy and Ultra-Thin Stainless Steel Strands

Fibre-reinforced materials have gathered attention because of their significant properties such as heat resistance, abrasion resistance and specific strength. The present study proposes a new method of joining stainless steel strands with an aluminium alloy using friction stir forming and analyses the formation of a fibre-reinforced aluminium alloy composite material. Mechanical interlocks between the strands and the aluminium alloy are evaluated based on cross-sectional microstructure observations and EDS analysis. The tensile test indicated an increasing tendency of strength by increasing the number of strands and bending tests showed that higher strength is achieved in rare bend because of inhomogeneous grain distribution after friction stir forming (FSF).

Mechanical and Sliding Wear Performance of AA356-Al2O3/SiC/Graphite Alloy Composite Materials: Parametric and Ranking Optimization Using Taguchi DOE and Hybrid AHP-GRA Method

The novelty of this research work lies in (i) designing and fabrication of hybrid AA356-Al2O3/SiC/Graphite alloy composite materials via semi-automatic stir casting method as per the standard industrial procedure. The ceramic particulates Al2O3/SiC were reinforced in a complementary manner (0–8 wt.%, in the step of 2%) along with constant 3 wt.% of graphite bringing about five alloy composite specimens namely SA-08, SA-26, SA-44, SA-62, and SA-80 respectively. The prepared specimens were explored for any synergistic effect of ceramic combinations on physical (density and void content), mechanical (tensile strength, flexural strength, impact strength and hardness), and sliding wear performance adopting ASTM standards. Simultaneously, optimization of sliding wear process parameters (like sliding velocity, sliding distance, normal load, etc.) using the Taguchi design of experiment and Grey Relational Analysis techniques were explored. Further, surface micrographs were analyzed to understand the underlying wear mechanisms and elemental presence/dispersion over the worn-out surfaces. Thereafter, the ranking of compositions was analyzed using a hybrid AHP-GRA material selection method for optimal selection and recommendations. It has been found that both Taguchi and GRA techniques were effective in parameter optimization and gives an attuned outcome. Composition, SA-44 hybrid alloy composite, having the equal presence of both the ceramic particulates tend to optimize the overall performance criteria. The results of ranking obtained by hybrid AHP-GRA analysis attunes to the subjective analysis.

Revealing the Effects of Microarc Oxidation on the Mechanical and Degradation Properties of Mg-Based Biodegradable Composites.

To overcome the inherent weakness of polylactic acid (PLA), used as scaffolding materials, multiple samples of Mg/PLA alloy composite materials was made by plastic injection molding. To enhance the interfacial interaction with PLA, magnesium alloy was treated with microarc oxidation (MAO) at four different frequencies, resulting in an improvement in mechanical strength and toughness. The microarc oxidation films consisted mainly of a porous MgO ceramic layer on the Mg rod. Based on the phenomenon of micro-anchoring and electrostatic interaction, a change in frequency during MAO showed considerable improvements in the ductility of the composite materials. The presence of the ceramic layer enriched the interfacial bonding between the Mg rod and outer PLA cladding, resulting in the PLA-clad Mg rod showing a higher tensile strength. In vitro degradation test was carried out in Hank’s solution for different time periods. Surface-treated Mg alloy-based composite samples displayed a lower degradation rate as compared to untreated Mg alloy samples. The surface-treated sample at a 800 Hz pulse frequency showed the best degradation resistance and mechanical properties after being immersed in Hank’s solution as compared to other samples. Mg-reinforced PLA composite rods are promising candidates for orthopedic implants.

A comparative study of solid lubricant types on the microstructure and mechanical behaviour of AA7075-zirconium boride aerospace composites

Aluminium alloy is the most favourable material for industrial usage because of outstanding low density, specific strength and resistance to oxidation. In this study, zirconium diboride (5 wt. % ZrB2) as hard ceramic particles and solid lubricants as hexagonal boron nitride (2.5 wt. % hBN) and tungsten disulfide (2.5 wt. % WS2) particles were used for fabrication of AA 7075 hybrid composite. The fabrication of hybrid composites is done through liquid metallurgy technique. The uniform distribution particles on matrix material were analysed through Optical Microscope (OM) and X-Ray Diffraction (XRD) was used to identify the phase of alloy and hybrid composite materials. The Micro Vickers hardness and tensile strength were used to evaluate the mechanical strength of alloy and composites. The microstructure of composites reveals fairly distributed ceramic and solid lubricant particles over the base matrix. The XRD peaks reveals presence of AA7075, ZrB2, hBN and WS2 with low intensity peaks. AA7075/ZrB2/WS2 composite shows an improved hardness and tensile strength as compared to AA7075/ZrB2/hBN composite. It was observed that the influence of WS2 on AA7075/ZrB2 composites have a higher bending strength than hBN composite and hBN particles offers easy grain movement during plastic deformation. Tensile fractured surfaces of alloy and hybrid composites were analysed through Scanning Electron Microscope (SEM). It reveals a ductile fracture in AA7075 alloy whereas ductile-brittle is observed in hybrid composites.

Study on Degradation Behavior and Biocompatibility of Polymethyl Methacrylate/Mineralized Collagen/Mg–Ca Alloy Composite Material

In this study, we composited mineralized collagen and magnesium-calcium alloy by freeze-drying, followed by dip-coating PMMA bone cement to enhance the composite of mineralized collagen and magnesium-calcium alloy. In vitro degradation test was performed to observe the pH and weight loss of the material. The contact angle test was used to detect the hydrophilicity of the material. Subsequently, MC3T3-E1 were used to assess cell biocompatibility In vitro by cell adhesion, cytotoxicity, alkaline phosphatase, alizarin red staining, and cytoskeleton. The results showed that the pH changes of the PMMA/NHAC/Mg–Ca was slower than that of the Mg–Ca , and the weight loss rate at 7 d and 14 d were lower than that of the Mg–Ca (P < 0.05) in degradation test. Wettability experiment showed that PMMA/NHAC/Mg–Ca was a hydrophilic material and Mg–Ca was a hydrophobic material (P < 0.05). In vitro cell experiments, the PMMA/NHAC/Mg–Ca had more cell adhesion than Mg–Ca and more synapses were connected to others. In the cytotoxicity experiment, the cell proliferation lever of PMMA/NHAC/Mg–Ca was higher than that of Mg–Ca at each time point (P < 0.05). In the 7 d alkaline phosphatase experiment, the PMMA/NHAC/Mg–Ca showed higher ALP activity than the Mg–Ca (P < 0.05), and in the alizarin red experiment at 14 d and 28 d, there were more obvious calcified nodules and mineralized area. After 1 day of culture in the PMMA/NHAC/Mg–Ca extract, the cells showed a clearer and more complete cytoskeletal structure and better cell morphology. In conclusion, PMMA/NHAC/Mg–Ca orthopedic implants had a better hydrophilicity, cytotoxicity and osteogenic ability, besides with a slower rate of degradation, and could be implanted in animals for further research, which were expected to be used for the repair of clinical bone defects.

Experimental analysis of aluminium alloy LM25 with carbon in composite material

This paper considers the potential use of Aluminium alloy LM25 with carbon in metal matrix composite with reference to the automobile industry. MMC of Aluminum alloy with carbon is done by appropriate casting process. This Work helps to explore the importance of Aluminium LM25 with carbon in automobile, aerospace industries. Mechanical and Microstructure properties are observed to improve the strength of the Aluminium alloy composite material.

Application of preference selection index method in performance based ranking of ceramic particulate (SiO2/SiC) reinforced AA2024 composite materials

In this research article, ceramic particulate (SiO2/SiC) reinforced AA2024 alloy composite material formulation has been prepared via semi-automatic stir casting technique following industrial standard practice. The samples specimens have been prepared as per ASTM standard dimensions and the physical, mechanical and wear performance test were performed. The obtained test results have higher confidence level (95%) and the same has been used to rank the composite materials of the formulation using Preference Selection Index (PSI) method (a Multi-Criteria-Decision-Making (MCDM) tool) which is simple to compute and understand. This enables a practicing engineer to rank the designed materials via optimizing material properties like tensile strength, flexural strength, impact strength, wear resistance, density etc. It has been observed that the aluminium alloy composite incorporated with an equal presence of both ceramics shows best properties and also ranked highest by PSI method. Hence, such techniques may be used for decision making successfully in the selection of materials.

Basalt Short Fibers Dispersion and Fabric Impregnation with Magnesium Alloy (AZ63): First Results.

Magnesium is one of the lightest structural metals used in different industrial sectors and many works in the literature have studied its reinforcement by filler addition. Basalt fibers are natural fillers that have good mechanical properties, excellent resistance to high temperatures, and lower cost than carbon fibers. Considering this, in recent years, they have been increasingly used in the production of composite materials with polymeric matrices. However, very little information is available in the literature about the use of basalt fibers as reinforcement in metal matrix composite materials. It is well known that the impregnation of fiber reinforcement affects the mechanical behavior of the composite materials. The aim of this study was to investigate the impregnation and the behavior of basalt fibers in a magnesium alloy composite material manufactured by a centrifugal casting technique.

Mechanical performance and microstructural characterisation of titanium alloy-alloy composites built by wire-arc additive manufacture

A first stage study has been performed to investigate the potential for exploiting high deposition rate WAAM to print dual-alloy microstructures. Samples were built using alternating feed wires of commercially-pure Ti and Ti–6Al–4V. A high level of dilution occurred during deposition accompanied by effective liquid-phase mixing, producing a regular distribution of solidified melt tracks of approximate bimodal composition each less extreme than that of their respective constituent feed wires. The yield strength of the dual alloy composite material was approximately midway between that of the two alloys from which it was produced and exhibited a double inflection yield behaviour. Overall, because of the relatively coarse length scale there was not a significant property advantage in tensile loading above that of a chemically homogenous material, thus the main advantage of printing alternate alloys at this length scale is likely to reside more with increasing crack path tortuosity during fracture or fatigue loading. Importantly, the deposited material was found to have a refined β-grain structure suggesting that the composition gradients introduced by dual-alloy printing can disrupt the epitaxial columnar growth normally seen in WAAM deposits.

Laser Welding of Dissimilar Metal Joint of 6061 Al Alloy and Al Matrix Composite

In this paper, dissimilar metal joints of 6061 aluminum alloy and aluminum matrix composite material are investigated by laser welding. TiB2 particles were added into the lap joint. The welding process, microstructure, and the corrosion properties of welding joints are examined. The results demonstrate that the selected optimization process parameters are laser power 6 kW, welding speed 0.6 mm/s, pulse width 11.5 ms, and laser frequency 4.5 Hz. There are a few obvious pores in the molten pool. Al2Ti, Fe2Si, and Al0.5Fe3Si0.5 are present in the microstructure. During the welding process, some TiB2 particles are decomposed and reacted with molten Al. Other TiB2 particles are nucleated and solidified, and the excess TiB2 particles are pushed to the grain boundaries by molten Al. TiB2 particles are wetted well by molten matrix metal. The corrosion resistance of alloys in different conditions decreased in the following order: the weld beam >6061 Al > AMC.