Alloy Metal Matrix Composites Research Articles

Enhanced mechanical properties of magnesium alloy reinforced by layered Ti3AlC2 MAX phase fabricated by SPS at a near solidus temperature

Powder metallurgy stands out as a highly promising and versatile method for manufacturing particle-reinforced metal matrix composite (MMCs) as compared to other fabrication processes. This method ensures excellent binding between the matrix and reinforcement, uniform microstructure, and effectively prevents the formation of undesirable phases. In this study, magnesium alloy (AZ91) metal matrix composites (MMCs) reinforced with 0–30 vol% of Ti3AlC2 MAX phase were prepared by Spark Plasma Sintering (SPS) from powders at temperature close to the solidus. Ti3AlC2 is a member of the MAX phases which are known for their layered structure, machinability and being ternary carbides. The latter was synthetized from pure components (Ti, TiC and Al) using insulated SPS technology at high temperature. Sintered composites reached quasi-full density, as measured by Archimedes’ method. Their microstructure has been assessed by SEM and X-ray diffraction (XRD) respectively. Mechanical properties in relationship with the microstructure of all composites were carefully investigated. The experimental compressive tests data were extracted to obtain true strain-true stress curves. Vickers hardness (HV1), ultimate compressive strength (UCS) and conventional yield strength (0.2%YCS) increase with an increasing fraction of Ti3AlC2 in the composites and compare favorably with literature. SEM observations of fracture surfaces after compression tests seem to show that cracks initiate in both Ti3AlC2 clusters and α-Mg/MAX interfaces.

Optimization on stir casting process parameters of Al7050 based composites using Taguchi technique

Aluminium Alloy Metal Matrix Composites (AAMMCs) are broadly used for various applications such as aerospace, military, marine, transport and automobile applications. Aluminium alloys are not sufficient for satisfying the needs of the fastest growing industries. The more combination of properties are needed for fulfil the need of fastest growing countries. The input process parameters of fabrication methods of composites are more important in connection with mechanical and tribological properties. In this research, optimization on stir casting input process parameters of AA7050/4wt.%WC composite was done by utilizing the Taguchi technique. The melting temperature (650, 700 and 750 °C), stirring speed (150, 200 and 250 rpm) and stirring duration (10, 20 and 30 min)were selected as input parameters to optimize the stir casting input process parameters. The chosen response parameter for the investigation was wear loss. The wear test was conducted by using pin on disc setup at the condition of 2500 m sliding distance, 25 N applied load and 1.5 m/s sliding velocity. The optimized input process parameters of stir casting is high level of melting temperature (750 °C), low level of stirring speed (150 rpm) and low level of stirring duration (10 min). The increasing of melting temperature decreases the wear loss and increasing of stirring duration and stirring speed enhances the wear loss due to accumulation of reinforcements in the matrix AA7050. The contribution percentage of melting temperature, stirring speed and stirring duration is 81.02 %, 12.4 % and 6.4 % respectively. The high strength MgZn2 precipitate was formed while using optimized stirring temperature, stirring duration and stirring speed and it was confirmed by XRD. The SEM image of AA7050/4wt.%WC confirmed that uniform distribution of WC in matrix AA7050 material and it caused to offer higher wear resistance. The obtained low wear loss for confirmation test specimen is 16 mg.

Fabrication and Sliding Wear Characterization of Eggshell Particulate Reinforced AA6061 Alloy Metal Matrix Composites

In this work, AA6061 aluminum alloy composites reinforced with industrial wastes, i.e., eggshell particles are fabricated. The stir casting technique was used to fabricate the Al6061 metal matrix composites. The AA6061 matrix contains 3, 5, and 7 wt.% eggshell particles as reinforcement. Mechanical characterization i.e., hardness, toughness, and tensile strength was examined of the eggshell particle-reinforced composites. According to the experimental findings, adding eggshell particles significantly increased the material's hardness, tensile strength, and toughness. Moreover, the sliding wear resistance improved by adding eggshell particles as reinforcement. ANNOVA results predict that sliding velocity and load are the dominant factors for the sliding wear of composites.

Tensile and Hardness behaviour of AlMg1SiCu alloy reinforced with SiC/ MoS2 metal matrix composite

The current work examines the AlMg1SiCu alloy material through the stir casting process, where the Molybdenum Disulphide (MoS2 ) using three different variations of weight percentage (3 MoS2%, 6% MoS2, 9% MoS2) and 10% uniform proportion silicon carbide (SiC). The distribution of reinforcements such as Hard particle Silicon Carbide (SiC) and Soft particleMolybdenum Disulphide in the matrix was studied by looking at the microstructure of the composites before Tensile and Hardness test using Backscattered Secondary Electron image (BSE). A Brinell hardness tester was employed to determine the hardness of samples made of AlMg1SiCu alloy and hybrid metal matrix composites. Tensile test carried out using a Universal test Machine for AlMg1SiCu alloy and HMMC Samples. With an increase in MoS2 particle percentage, hybrid composites' tensile strength improves. With a AlMg1SiCu hybrid composite containing 10% SiC and 9% MoS2, the maximum tensile strength has been achieved.

Influence of marble waste reinforcement on mechanical properties and sliding wear behavior of an aluminium alloy metal matrix composite

This study thoroughly analyse the effects of waste marble dust reinforcement in a metal matrix composite made of AA6061 aluminium alloy. The 3-weight percentage, 5-weight percentage, and 7-weight percentage of waste marble dust particles are used as reinforcement. The stir casting technique is used to fabricate the AA6061 based metal matrix composites. Marble dust was preheated at 200 °C before being used as reinforcement. Mechanical properties (tensile strength, micro-hardness, and impact strength) and sliding wear characteristics of the fabricated composites are studied. The sliding wear characteristics of composites were simulated under the pin-on-disc tribometer with varying control parameters. The selected control parameters are sliding velocity (150 rpm, 300 rpm, 450 rpm, 600 rpm), normal load (5 N, 10 N, 15 N, 20 N), and temperature (25 °C, 40 °C, 60 °C, 80 °C). Taguchi design is also used for an optimization of control parameters. Results indicate that a composite reinforced with 5-weight percent marble dust has good mechanical and sliding wear resistance properties compared to 3-weight percent and 7-weight percent marble dust reinforced composites.

Reinforcement of micro and nano material with aluminum alloy (Al7075) metal matrix composite: a review

The characteristics and structural performance of a composite material’s properties are better than those of its component parts because It comprised of a pair or more insoluble, chemically separate stages. functioning alone. ‘Metal-Matrix’ composites materials that have been produced from metals and ceramics had fibers or particles incorporated into them to enhance their physical characteristics. The fabrication of several parts and components in the aircraft and aerospace industry regularly uses aluminium 7075 alloy, a significant technical material. Its high strength to density ratio makes metal matrix composites very desirable. We provide an overview of Al 7075 Metal Matrix Composites in this study.

Investigation of Mechanical and Tribological Properties of Al–7 Wt.% Si alloy Metal Matrix Composites Reinforced with SiC

Investigation of Mechanical and Tribological Properties of Al–7 Wt.% Si alloy Metal Matrix Composites Reinforced with SiC

Influence of hybrid nanoparticles on the wear behavior of aluminum alloy composites for aerospace applications

PurposeEngineers and scientists are searching for novel materials with high performance on all aspect points of view for the applications including marine, aero and automobile fields. AA8090 aluminum alloy is one of the materials used in aero industries for aircraft construction because of its weight reduction ability. However, the AA8090 alloy has a drawback such as low wear resistance that affects the life time of material; hence, it should be addressed. The purpose of this investigation is to improve the wear resistance of AA8090 alloy.Design/methodology/approachIn this investigation, AA8090 aluminum alloy metal matrix composite was fabricated using different types of carbide nanoparticles such as vanadium carbide (VC), Cr3C2 and Mo2C by stir casting method and tribological and mechanical behaviors were studied.FindingsMechanical studies showed that the S1 sample displayed the maximum hardness of 142 HV and maximum tensile strength of 857 MPa because of the inclusion of hard VC particles. Tribological studies revealed that S1 sample showed high performance. A least wear rate of 0.003915 × 10–3 mm3/m was noted for S1 sample, which is 71% lower than the wear rate of S0 sample. Further, a least mass loss and lower coefficient of friction of 0.00152 g and 0.2, respectively, were observed for S1 sample because of its high hardness and high wear resistance because of the stuffing of high-hardness VC particles. Hence, it is concluded from this study that S1 sample, i.e. AA8090/VC, could be a better candidate for aerospace applications as it showed good tribological and mechanical properties.Originality/valueTo the best of the authors’ knowledge, this work is original and novel in the field of metal matrix composite which deals with the effect of hybridization on the wear performance of the aluminum alloy composites.

Microstructural Evolution and Mechanism of Strengthening in Al-Zn/fly ash/ ZrO2 Composites Fabricated Through a Vortex

This paper describes the fabrication of aluminum-zinc (Al-Zn) alloy (AZ91E) metal matrix composites augmented with Fly Ash (FA) and zirconium dioxide (ZrO2) particulate utilizing the vortex method and a stir casting process. The researchers introduced composites with ZrO2and fly ash at varied weight % ranging from 0 to 10 with 53 μm particle sizes. The inclusion of ZrO2 particle reinforcement increased the hardness significantly, whereas the ultimate yield and tensile strengths increased somewhat. As the weight % of ZrO2 particles was increased, the permeability and density of Al-Zn alloy based composites increasing. When compared to the comparable alloy, composite densities were lower, which might be attributed to the low density of the FA. Additionally, the compressive and tensile crack properties of the composites produced were investigated. Microstructural analyses confirmed the presence of evenly dispersed FA and ZrO2 particles throughout the matrix, but an EBSD study revealed that this led to the diminished reduction. The inclusion of FA particles enhanced the material’s tensile properties and hardness including ultimate yield and tensile strengths. The strengthening mechanisms underlying the enhanced properties were discussed. At the point when ZrO2 and FA fortifications were applied, a definite tensile and yield strengths raised in contrasted with the basic compound. As revealed by the aftereffects of the examination, the grain size of the Al-Zn composite built up with FA and ZrO2 particulates is a lot of lower than the grain size of the lattice compound.

Empirical Modelling and Multi-Objective Optimisation of Laser Micro Machining on Magnesium Alloy AS21-SiC Metal Matrix Composite

Micromachining techniques are now being used more frequently as a result of miniaturization. This technique has been supported by the requirement for material processing at an affordable cost and microatomic resolution in numerous sectors. Laser micromachining is a precise, non-contact method of machining that is used to create tiny, up to 500 m, components. The small elemental areas are the focus of laser ablation, which helps absorb a high amount of energy. In this micro-machining, metal removal rate and surface finish are represented by the deepness of the groove and the height of the recast layer. While machining, a layer called a recast layer forms on the work piece surface as a result of the tremendous heat generated, and this layer is damaging to the component's surface quality. For accurate applications, the recast layer must be as tiny as possible. As a result, the objective functions are the height of the recast layer and the deepness of the groove. Experiments designed by the DOE are used to generate empirical models. For each experimental run present in the matrix, the specified input parameter combination is set and the work piece is machined accordingly. The response surface methodology based on mathematical modeling and analysis of the machining properties of a pulsed Nd: YAG laser during micro-grooving operation on a work piece of Magnesium Silicon Alloy metal matrix composite is the focus of this research study. Initially, magnesium alloy AS21-SiC metal matrix composites are manufactured with Ultrasonic pro assisted stir casting. For the machined samples, the deepness of the groove and the height of recast layer will be measured by an optical measuring microscope. Consequently, the measured data is used by the GP to develop the mathematical models. In this work, an efficient GA-based genetic algorithm (NSGA-II) is applied to obtain the optimal parameters. As the chosen objectives are conflicting in nature, the problem is formulated as a multi-objective optimization problem.

Studies on tribological behaviour of AA8050-Si3N4 composites

Aim of this work intense to find tribological behavior of the AA8085 composites fabricated through stir casting technique. Experiments were carry out using wear test (pin on disc) by controlling different parameters namely sliding speed (m/s), load (N) and sliding distance (m). Aluminium alloy Metal Matrix Composites (AA8050) considered for this work as base material with reinforced of AA8050 and 5 wt% and 10 wt% of Si3N4. Wear rate of AA8050 matrix composites are improved by the occurrence of different weight percentage of reinforcements. Taguchi optimization route with orthogonal array is involved to this work for evaluates the parameters influence. This work concentrates on priority of factors which affects and enhances the tribological behavior of the fabricated composites. Increasing of Si3N4 reinforced percentage moderately reduced the wear arte of the composites.

An experimental investigation of wire breakage and performance optimisation of WEDM process on machining of recycled aluminium alloy metal matrix composite

Abstract In this research, a novel aluminium metal matrix composite (AMMC) was developed using recycled aluminium alloy as a matrix with 5% alumina as reinforcement. The machining experiments were conducted by varying the input parameters such as voltage (V s ), wire feed rate (F w ), current (I p ), pulse on time (ON T ) and pulse off time (OFF T ), on wire breakage. The effect of voltage level and wire breakage frequency was analysed. The parameter combinations for machining the slot of size 5 mm width and 10 mm height with high machining rate (MR) and less surface roughness (R a ) were analysed using the CRiteria Importance Through Intercriteria Correlation (CRITIC) and simple additive weighting (SAW) methods. The wire breakage frequency is lesser at minimum peak current. The optimal parameter combination for higher MR and lower R a is found to be at 30 V, 7 mm/min, 30 A, 120 μs (ON T ) and 70 μs (OFF T ). Analysis of variance (ANOVA) is performed to understand the significant factors affecting the WEDM process. ANOVA results predict that wire feed rate and voltage contribute 47.82% and 21.23%, respectively, to MR; and pulse on time shows a 23.06% influence on surface roughness. Scanning electron microscopy (SEM) was used to ascertain the pattern of wire breakage in WEDM, and based on the results obtained from employing this technique, it is inferred that the erosion and breakage of the wire are not instantaneous and that a cone shape is formed on the either portion of the wire.

Impact of AlN-SiC Nanoparticle Reinforcement on the Mechanical Behavior of Al 6061-Based Hybrid Composite Developed by the Stir Casting Route

The enhancement of composites’ mechanical characteristics (tensile, compressive, and hardness) is a constant demand for technological advancement. The stir casting process is used to make the hybrid aluminium alloy metal matrix composites Al 6061-SiC-AlN in our present study. To create mechanical qualities such as tensile, compressive, and hardness, silicon carbide and aluminium nitride (both 3% and 6%) were utilized as the reinforcement. The tensile strength, compressive strength, and hardness of the Al 6061-SiC-AlN hybrid composites samples were determined. The tensile, compressive, and hardness parameters of Al 6061-SiC-AlN hybrid composites are estimated and evaluated to those of the matrix Al 6061 alloy. With the inclusion of silicon carbide and AlN nanoparticles, the tensile strength, compressive strength, and hardness increased from 328 to 385 MPa, 145 to 178 Mpa, and 302 to 724 VHN, respectively.

Surface roughness and microstructure analysis on drilling of titanium diboride in-situ aluminium metal matrix composite

Aluminium and its alloys are widely used for fabricating components are used in aircraft, automobile, defence and structural applications. Due to its light weight and high strength, it is applied in the various commercial purposes such as window, doors, construction member etc. However, machining of aluminium alloys using conventional machining methods is difficult. In this present investigation, an endeavour has been made to drill TiB2 in situ aluminium metal matrix composite alloy developed using stir casting method. During the casting two different salts namely K2TiF6 and KBF4 are added with matrix materials to form TiB2. The paper is studied the surface roughness (SR) of drilled TiB2 in situ aluminium metal matrix composite viz speed, feed rate and TiB2 addition. Empirical relationship is developed for SR in order to identify the dominating factors. The percentage contribution of SR is 96.35% that showed the empirical model is adequate. The normal probability plot showed the points of residuals are equally distributed over the straight line. The lack of fit value was 3.65 which is less than the standard point. Therefore, the SR model is satisfactory. SR increased with increasing of speed, feed rate and addition of TiB2. The removal of TiB2 particles causes small pits and voids due to the inclusion of reinforcement. The minimum SR was achieved at lowest speed (1260 rpm), feed rate (0.05 mm rev−1) and TiB2 addition (2%). As speed and feed increased, the surface hardness increased.

Effect of heat treatment and ageing on microstructure for hypoeutectic Al-7Si alloy and hybrid metal matrix composites

In the present investigation on fabrication and microstructure of aluminium based hybrid composites. A356 based aluminium matrix material with varying reinforcement percentage from 0 to 9 wt. % in steps of 3 wt. % silicon carbide (SiCp) and fixed quantity of 3 wt. % of graphite (Gr) particles were used in fabrication. The specimens were fabricated by stir-cast method. Heat treatment was carried out for the cast specimen at 540oC for 12 hours and further ageing was carried out at 155ºC for 3, 6, 9 and 12 hours durations. The specimen after heat treatment and ageing were quenched in water at 60oC. The prepared specimens (ascast and aged) were examined using optical microscope to know the particle distribution in the matrix. Hardness and tensile were carried out for as-cast and aged specimen. The results were compared with as-cast and aged specimens. There was a significant improvement in hardness and tensile properties due to increase in the weight percentage of SiCp. The specimen A356-9SiCp-3Gr aged at 9 hrs showed improved hardness, and tensile when compared to other tested specimen. The presence of reinforcements (SiCp and Gr) significantly affects the solid state transition kinetics that improves the properties of composites. The presences of reinforcements in the specimens are evident from the electron dispersive spectroscopy (EDS) analysis.

Influence of micro graphite particles on the microstructure and wear behaviour of aluminium 6061 alloy composites developed by two step casting process

In the present research, the effect of micron sized graphite addition on the microstructure and wear behaviour of Al6061 alloy has been studied. The Al6061 alloy metal matrix composites reinforced with 6, 9 and 12 varying wt.% of graphite particles were fabricated by novel two step stir cast route which helps in improving the wettability of Al6061 alloy matrix with graphite particles. The created composites were exposed to microstructural studies and wear properties evaluation. Microstructural characterizations of achieved samples were carried out by SEM microscopy, EDS and XRD patterns. The occurrence of graphite particles were confirmed by the XRD patterns. The wear behaviour of Al6061 alloy with 6, 9 and 12 weight percentages of graphite composites were evaluated using pin on disc wear apparatus. All the experiments were conducted by varying applied loads of 1, 3 and 5 kg at 400 rpm sliding speed and varying sliding speeds of 100, 200, 400 and 600 rpm at 5 kg constant load. Wear mechanisms were studied by using SEM micrographs of worn surfaces and wear debris.

Influence of SiC reinforcement content and heat treatment on the corrosion behavior of pulsed electrodeposited Ni-W alloy metal matrix composite

The influence of SiC content and heat treatment on the corrosion behavior of pulsed electrodeposited Ni-W/SiC composite coatings was studied by electrochemical polarization and impedance spectroscopy in 0.6 M NaCl. Structural and compositional analysis was carried out using X-ray diffraction, differential scanning calorimetry, transmission electron microscopy and depth profiling XPS analysis. It was observed that as deposited composites coatings demonstrated better corrosion resistance than heat-treated coatings. A higher corrosion and passive current density in the heat treated composite coatings was attributed to the defective nature of the passive film as indicated by Mott-Schottky analysis. A suitable corrosion mechanism is proposed and the results are rationalized based on mixed potential theory and a point defect model. This study indicate that heat treatment of coatings does not always result in better corrosion resistance.

Investigation of the abrasive wear behavior of an aluminum alloy and its Al2O3 particle reinforced composite by statistical analysis

Abstract This experimental investigation deals with the evaluation of abrasive wear behavior of Al alloy and Al2O3 particle reinforced Al alloy metal matrix composites on a pin-on-disc test rig, where the specimens were slided against a 600 grade SiCP emery paper. The specimen preparation and experimentation have been carried out according to the ASTM G-99 standard. A plan of experiments based on the Taguchi design of experiments was developed to acquire data in controlled way. An orthogonal array and the analysis of variance were employed to investigate the percentage of contribution of various process parameters like sliding speed, applied load, sliding distance and their interactions affecting the abrasive wear volume loss of the materials. The correlations between the various factors affecting the abrasive wear behavior of composites were obtained by using multiple linear regression equations. The experimental results showed that the sliding distance has more contribution on the abrasive wear followed by applied load for both materials. The predicted volume loss of the specimens was found to lie close to that of the experimentally observed ones.

Analysis of Mechanical Behavior of Al6061 Composites Reinforced with Titanium Dioxide

Aluminum alloys are used low density good mechanical properties, better wear resistance as compared to predictable metals and their alloys. The industries are continuing in demand to develop light weight material, inexpensive and strong material which has led to the growth of aluminum alloy metal matrix composites. The aluminum based metal matrix composites have been moulded using TiO2 as reinforcement materials using the stir casting process. The hardness and tensile strength have been calculated addition to the TiO2 in Aluminium matrix improves the hardness of the material. The tensile strength and hardness increases above 4% of titanium oxide particles in the matrix.

Effect of sliding speed on tribological behaviour of heat treated hypoeutectic Al-7Si alloy and hybrid metal matrix composites

In the present paper, effect of sliding speed on wear behaviour of as-cast and heat treated hypoeutectic Al-7Si alloy and hybrid metal matrix composites have been investigated. Aluminium is used as matrix and Silicon Carbide (SiC) and graphite (Gr) particles are used as reinforcements. The proposed Aluminium Metal Matrix Composites (AMMCs) was fabricated by stir-cast method. Aluminium A356 matrix and reinforcements of SiCp was varied from 0 to 9% by weights in steps of 3%, and addition of fixed quantity of 3% by weight of Gr particles. The castings were machined as per ASTM standard and T6-heat-treatment was carried out. Specimens were aged at different durations from 3 to 12 hrs in steps of 3 hrs at a temperature of 155 ºC. The pin-on-disc wear testing machine was employed to evaluate the wear rate of the composites. As per the results, addition of reinforcement and aged at T6-9 hrs shows most wear resistance in all sliding tests. The increase in sliding speed with increase of wear rate was observed. The wear tested samples were examined using scanning electron microscope (SEM) and energy dispersive spectrum (EDS) and analysed.