Aluminum Alloy Composites Research Articles

Experimental Investigation on Microstructural and Wear Behaviour of Dual Reinforced Particles (DRP) Aluminium Alloy Composites

In the present scenario, the automobile industry, and aerospace industries are considerable scuffles to strive for innovative lightweight materials among manufacturing industries. They preserve their place by reducing the cost of their products and services. For this tenacity, the demand for lightweight material, low cost, and high-performance material are needed. Aluminum matrix composite is developed to fulfill and becomes an engineer’s material. Aerospace & Automobile industries are eager to introducing compound aluminum metal matrix composites due to their excellent mechanical & tribological properties which makes a reduction in the weight of the component. In this project the LM13 as the matrix material while SiC and B4C have been considered as dual reinforcement. Stir casting is the modest and inexpensive method of fabricating an aluminum matrix composite. For the Evaluation of Mechanical &Tribological behavior of DRP composite castings (LM13/B4C/SiC) selection for experimentation tests. In this paper different specimens of the MMC with LM13 Al Alloy 2wt% SiC and 2wt% B4C, 2wt% SiC and 4% B4C, 4wt% SiC, 2wt% B4C, 4wt% SiC and 4wt% B4C are taken for carried to invention out the increase in DRP in the composites will intensification the mechanical properties of the LM13 Al Alloy SiC and B4 C composite formed.

The oxide film formation under vibration processing in the high-resource parts manufacture in transport engineering

The results of pilot studies of the possible vibration shock and wave technology processes use when receiving an oxidic covering in aluminum alloys items are presented in the article. The technology of an oxidic covering forming in the course of the vibration shock and wave technology influence reflecting an entity of the process mechanical and chemical components complex impact on forming a surface covering layer is fulfilled. The mechanism of structural and phase impacts on a resource and quality of coverings that allowed to determine consistent patterns of receiving qualitative layers of a vibration chemical and mechanical oxidic coating on micro / a Nano level is installed, the causing obtaining the earlier unattainable quality and operational properties of a surface of the details made of aluminum alloys. The morphology researches of a vibrational chemical-mechanical oxide coating surface at the Nano level showed that the time is 66 nanometers thickness a cell of 600 nanometers consisting of 10 growth layers, at the same time the profile shift on the working environment rotation course is set. This structure of a covering promotes an increase in corrosion resistance as there is no access of an aggressive environment to the base metal. The mechanism of structural and phase influences, influence of granulometric characteristics and a dynamic status of the polymeric working environments used as the mechanical activator of the drawing coverings’ chemical processes is studied. The technological chemical solutions adapted to working conditions when receiving the combined chemical and mechanical oxidic coverings with the lowered maintenance of a silico-fluoride of sodium and chromic anhydride are presented. As a result of the covering surface research with the scanning probe microscope use it is established that the oxidic covering surface is not homogeneous and includes the elements which are in solution and in aluminum alloy composition

Optimal Material Selection for Ship Body Based on Fabricated Zirconium Dioxide/ Silicon Carbide Filled Aluminium Hybrid Metal Alloy Composites Using Novel Fuzzy Based Preference Selection Index

Fabrication and selection of optimal material with diverse properties for ship body is often a troublesome and difficult task, as inadequate selection of materials may result in improper functioning and failure of the components at any stage during its functioning. To this end, this paper presents a novel hybrid fuzzy Preference Selection Method (f-PSI) method for selection of optimal alternative ship body material based on physical, mechanical and corrosion characteristics of a novel hybrid aluminium metal alloy composites. Four hybrids aluminium alloy (AL7075) composites are fabricated through stir casting method by reinforcing varying quantity of zirconium dioxide (2%, 4% and 6%) and silicon carbide (3%, 6% and 9%). The physical characterization results show that void contents and density continuously increases with increase in the wt.% of the reinforcement. The mechanical characterization and fractography analysis results confirms upturn in hardness, ultimate tensile strength, flexural strength and impact strength up to 10% wt. of reinforcement and decreases for 15% wt. of reinforcement. The corrosion characterization and microstructural analysis show that corrosion rate decreases considerably up to 10% wt. of reinforcement and increase after that due to the precipitation of carbide particles along the grain boundary region of hybrid metal alloy composite. For validation and robustness of the proposed method, sensitivity analysis is performed, and comparison is performed with already available fuzzy TOPSIS and fuzzy VIKOR methods. Seven evaluation criteria such as void content, density, micro-hardness, ultimate tensile strength, flexural strength, impact strength and corrosion rate are considered in the study to choose the best material for ship body. From the analysis of results, it was found that A-2 (having 4 wt.% ZrO2 and 6 wt.% SiC as reinforcement) alternative material possesses the best combination of all the properties for the given ship body application.

Study on pitting corrosion behaviour of graphene oxide reinforced metal matrix composites

In this present study, the corrosion behavior of nano graphene oxide reinforced Aluminum alloy metal matrix composites investigated using pitting corrosion methods. The Al/GO composites were fabricated by ultrasonic stir casting technique. The effects of weight fraction of nano graphene oxides on the corrosion behavior of LM 24 aluminium alloy composites were analyzed. The corroded surfaces morphological were evaluated using scanning electron microscope and hardness was examined by microhardness tester. The experimental results were revealed that the corrosion rate was decreased with increases of weight percentage nano particles in the matrix. The microhardness values were gradually increased with increases of weight fractions of reinforcements in the matrix.

Influence of MWCNT Coated Nickel on the Foaming Behavior of MWCNT Coated Nickel Reinforced AlMg4Si8 Foam by Powder Metallurgy Process

This research studies the effect of multi-wall carbon nanotube (MWCNT) coated nickel to foaming time on the foam expansion and the distribution of pore sizes MWCNT reinforced AlMg4Si8 foam composite by powder metallurgy process. To control interface reactivity and wettability between MWCNT and the metal matrix, nickel coating is carried out on the MWCNT surface. Significantly, different foaming behavior of the MWCNT coated nickel reinforced AlMg4Si8 was studied with a foaming time variation of 8 and 9 min. Digital images generated by the imaging system are used with the MATLAB R2017a algorithm to determine the porosity of the surface and the pore area of aluminum foam efficiently. The results can have important implications for processing MWCNT coated nickel reinforced aluminum alloy composites.

Tribological characterization of LM26/SiC/Ni.-Gr. Hybrid aluminium matrix composites (HAMCs) for high temperature applications

In this study, tribological characteristics of the hybrid composite material LM26/ SiC / Ni.-Gr. were studied under different temperature conditions. The LM26 aluminum alloy was reinforced with silicon carbide (SiC) with various weight fractions (0%, 10% and 20%) by keeping nickel-coated graphite (Ni.-Gr.) constant at 2%. Using stir casting setup wear test samples were prepared. Pin on disk equipment was used to assess the tribological performance of both pure aluminum alloy and hybrid composites on the basis of wear loss and friction coefficient. Further, the plan order for performing trials was developed with design of experiments (DOE) and analysis of variance (ANOVA) tools. It was found that the composite's tribological and mechanical performance under high temperature sliding wear conditions was improved because of the hybridization of hard and soft reinforcements. Experimental results revealed that load and temperature primarily affect both pure aluminum alloys and hybrid composites performance. Also low wear loss and friction coefficient were obtained during high-temperature wear tests. The LM26 + 20% SiC + 2%Ni.-Gr.hybrid composite showed the highest improvement in tribological performance. Worn surface analysis using SEM technique showed that hybrid reinforcement significantly increases wear resistance in hybrid aluminum composites. These findings indicate that the proposed hybrid aluminum composites can be considered as an alternative material in which wear-resistant and high-strength components are of primary importance in the automotive industry.

Characteristics of Al-Alloy/Seashell (SESB) Composites in Acidic and Alkaline Environments

The corrosion behaviour of Al-alloy/Seashell (SeSh) composites in the acidic and alkaline environment was investigated in this study. Fifteen Aluminum alloy composites samples were produced using stir casting technology by varying the amount of reinforcement (1.5, 3.0, 4.5, 6.0, 7.5 wt%) and particle size (100, 150, 200 µm) of milled SeSh in the Aluminium alloy matrix. The corrosion rate was determined using a weight loss technique after 18 days of immersion at an interval of 72 hours. It was observed that 6.0 wt% of the 100 µm reinforced Aluminium alloy had the best corrosion resistance in acidic and alkaline environments. In general, the reinforced Al-alloy had better corrosion resistance when compared with the unreinforced samples. Analyses of the results show that aluminum alloy seashell composites exhibited better resistance to corrosion in the alkaline environment than the acidic environment.

Abrasive Wear of Nano-Al2O3 Particles and Cnts Strengthened 2024 Aluminum Alloy Composites Manufactured by Powder Metallurgy

Abrasive Wear of Nano-Al2O3 Particles and Cnts Strengthened 2024 Aluminum Alloy Composites Manufactured by Powder Metallurgy

Study on impact strength, hardness, tensile and yield strength of Copper and Silicon used Al6070 aluminium alloy composites

Here this experimental study based on impact strength, hardness, tensile strength and yield strength of various weight percentages of materials such as Copper and Silicon used base material of Al6070 aluminium alloy composites. For these investigations have four specimens with various combinations of different percentage weight based materials. 92% of aluminium alloy is common for all the specimens. Silicon used as 7%, 6%, 5% and 4% also Copper used as 1%, 2%, 3% and 4% in specimens respectively. Each specimen was tested as per the terms and conditions of the each testing methods. Results of the all individual specimens were studied to identify the best combination of percentage of weight based materials used composite.

Повышение механических свойств композиционных алюминиевых сплавов при вводе карбида бора

The present work is aimed at obtaining a metal composite material based on Al - 5%Cu aluminium alloy by the addition of B 4 C boron carbide and studying the microstructural features and mechanical properties of cast billets based on this material. Aluminium alloy cast billets containing 5%wt. of Cu with a boron carbide content varying from 2-7 wt% were prepared in laboratory die casting machines. Immediately prior to casting, B 4 C particles with a size of 5-7 μm were introduced into the melt under continuous stirring. A tensile test of the samples having an elongation of 0.1-0.5 mm was carried out by Shimadzu tensile testing machines in accordance with ASTM standards. The microstructure of the experimental samples was studied by scanning electron microscopy using an INSPECT S50 microscope (FEI, Netherlands). In terms of the aluminium matrix microstructure following the introduction of boron carbide, the composite was established to contain inclusions of the Al 2 Cu intermediate crystallisation phase and B 4 C particle inclusion matrices distributed throughout the entire sample volume. Porosity zones were detected in the form of weak contact of the matrix material with the embedded surface of the boron carbide reinforced particle. A high level of wetting by the matrix melt was observed, leading to a uniform distribution of particles in the matrix. The best indicators of hardness (113 HV) and tensile strength (~180 MPa) are characteristic of the samples with the addition of boron carbide in an amount of 5%. At this content, due to the low observed particle segregation in the volume of the Al-Cu matrix, a uniform fine-grained billet structure for the selected composition of the alloy was obtained. According to the research results, the composition of the alloy obtained by die casting based on Al-5%Cu alloy with the addition of boron carbide in amount of 5% can be recommended as a suitable material for the manufacture of products with due to its attractive hardness and strength properties.

A microstructural and mechanical property investigation of a hot upset forged 2xxx series aluminum powder metallurgy alloy reinforced with AlN

Abstract Metal-matrix composites (MMC) of a 2000-series aluminum alloy coupled with AlN were fabricated through a commercially-relevant aluminum powder metallurgy (APM) approach. Cylindrical preforms containing 0–5 vol% AlN were produced to investigate the mechanical properties and microstructure evolution through hot upset forging. Specimen were deformed to a maximum strain of 0.15–1.55 mm/mm at rates of 0.1–1.0 s−1. TEM observations of forged products indicated the Al–AlN interfaces were free of defects and of high quality. Near-full (>99.5% theoretical) densities were observed at 1.40 mm/mm. At this strain, a substantial increase in all tensile properties was observed. An elastic modulus of 77 GPa was realized in a forged product with 5% AlN, accompanied by a 0.2% offset yield strength of 325 MPa and a UTS of at least 400 MPa. Versus an undeformed sample, forged MMC’s exhibited up to a five-fold increase in tensile ductility. Likewise, improvements of up to 98 MPa (57%) in fatigue strength were recorded. Mechanical gains were a result of densification and residual oxide disruption, as well as the enhanced dispersion of the AlN phase.

Mechanical and Tribological Behaviors of WAl<sub>12</sub> Reinforced 2024 Aluminum Alloy Matrix Composites

WAl12 reinforced 2024 aluminum alloy matrix composites were prepared by powder metallurgy with tungsten particles and W50Al50 alloy particles. The effects of WAl12 on the mechanical properties of 2024 aluminum alloy composites at room temperature and high temperature were studied, and the friction behavior was characterized. The results show that intermetallic WAl12 phase forms in the composite by 2024 aluminum alloy and tungsten. The mechanical properties and friction behavior can be improved by the formation of intermetallic WAl12 phase. The tensile strength of 2024 aluminum alloy at room temperature and 180 °C can be improved by adding tungsten less than 1.5 at.%. Adding 2.0 at.% tungsten can reduce the friction coefficient by 20 % and the scratch width by 40 %. The tensile fracture surface of the sample was analyzed by scanning electron microscopy (SEM), indicating that WAl12 intermetallic phase is closely connected with the aluminum matrix.

Mechanical and tribological characterization of industrial wastes reinforced aluminum alloy composites fabricated via friction stir processing

Abstract The fabrication of particulate reinforced metal matrix composites via melt based processes poses issues like aggregation, wettability and formation of detrimental phases which may severely affect their performance. Recently developed solid-state process i.e., friction stir processing (FSP), is an efficient fabrication technique to counter the limitations of melt based processes. However, the incorporation of industrial waste in the metal matrix by using friction stir processing is rarely reported. Thus, the present investigation was carried out to reinforce the particulate type industrial waste in cast A356 alloy by friction stir processing. The performance of the fabricated composites as well as the as-cast A356 alloy was assessed through mechanical and tribological characterization. It was observed that FSP resulted in the eradication of porosity, fragmentation of α-Al dendrites, breakage and redistribution of Si particles, and grain refinement. A fair homogeneous distribution of reinforcement was observed in stir zone (SZ) with negligible aggregation of particulate reinforcement. The particle/matrix interface was free from any detrimental phase. The improvement in strength, ductility, and wear resistance was observed as compared to as-cast A356 alloy which was attributed to the microstructural changes that occurred during FSP, and the efficient reinforcement of particles via FSP.

Surface nanostructure and wettability inducing high bonding strength of polyphenylene sulfide-aluminum composite structure

Light-weight, high-strength polyphenylene sulfide (PPS) - aluminum alloy (Al) composite was favored for many engineering applications. The flexible injection technology was employed to fabricate the polymer-metal composite structures. After pretreating the Al surface with anodization and plasma processing, the injected bonding strength between Al and PPS were significantly improved. The effect of the nanostructure size and porosity on the bonding performance of the PPS-Al composite parts were discussed. It reveals that when the diameter of the nanostructure increases to 160 nm and the porosity reaches 0.281, the bonding strength and fracture work of the PPS-Al composite parts reach the highest. Furthermore, the effect of chemical bond (–OH) amount on the metal surface wettability and bonding strength was first analyzed. After plasma treatment, the relative contents of chemical bond (–OH) obtained on Al surface were calculated. When the –OH bond content reaches 0.431, the largest bonding strength and fracture work of the composite structure were found to be 24.8 MPa and 20.1 KJ/m2 respectively, improving by 16% and 17% compared with non-plasma treated sample. These results proved that the nanostructure and chemical functional group formed on the Al surface played vital role on the bonding strength of the PPS-Al composite structures.

Microstructural Characteristics and Mechanical Behaviour of AA7075/TiB<sub>2</sub> Composite

Titanium Boride (TiB2) particles reinforced with aluminum alloy (AA 7075) composites were developed using the two-step stir casting method. TiB2 with aluminium alloy was varied in 5, 10, 15 weight percentages (wt.%) . The mechanical properties of the composites were assessed through density, hardness, tensile and impact. Factography observations were also evaluated with Scanning Electron Microscopy (SEM) and phase identification of the composite was carried out through X-ray diffraction technique (XRD). The XRD pattern of alloy and composites revealed peaks of Al and TiB2 particles and the intensity of TiB2 particles increased with increase in wt. %. Compared to the base matrix, the density and hardness of composites increased with the wt. % of TiB2. Addition of TiB2 particles exhibited grain refinement, thereby improving the mechanical properties. Composite materials exhibited high load bearing capacity due to the strong bonding of TiB2 and matrix material resulting in increased impact energy. The tensile strength of the composite increased with increasing wt. % of reinforcement. The failure in the composites observed were dimpled structure and ridges, voids, and cracks.

Effect of particle size of rice husk ash on aluminium/graphene composites

Aluminium/graphene (Al/G) composite has gained wider engineering applications because of its unique properties such as lightweight, excellent corrosion resistant, improved strength and enhanced thermal conductivity. However, difficulty in dispersing graphene in molten aluminium remains one of the major optimization challenges. This study developed, by stir casting technique, composites of aluminium alloy from recycled aluminium can, 0.4 wt. % graphene (G) and 1.6 wt.% rice husk ash (RHA) with particle sizes of 150, 300 and 600 μm. The tensile, hardness, impact and fatigue properties were analyzed using Instron Extensometer, Vickers hardness tester, Charpy Impact machine and rotating fatigue machine respectively. Furthermore, the cast samples were characterized using scanning electron microscope (SEM) and X-ray diffractometer (XRD). The morphology of the microstructure of all composites showed the retention and uniform distribution of G and RHA particles in the Al matrix devoid of presence of harmful aluminium carbide with improved mechanical properties. The study established a new approach of dispersing graphene in molten aluminium through a stir cast method with 150 μm particle size of RHA given the best mechanical and morphological properties.

The effect of alumina on mechanical behavior of Al 6064 alloy

Need in the development of new materials with excellent properties are growing day by day. Composite materials are the simple and better way to accomplish materials with superior properties. Aluminium metal matrix composites due to their high strength to weight ratio, low cost, improved electrical conductivity and good tribological properties are broadly produced and used in various engineering applications in the area of automobile, aerospace and military engineering. In the present paper an attempt has been made to fabricate MMC of an alloy of aluminium 6064, reinforced with alumina particles through stir casting with vortex technique. Three aluminium alloy composites with alumina (2.5-5-7.5 wt. %) were fabricated. Different mechanical tests for hardness, tensile strength and toughness were carried out for the samples. Addition of alumina to aluminium alloy shows an increase in mechanical properties of aluminium metal matrix composite. The results showed that the stir casting could produce uniformly distributed reinforced particles of Al2O3 in Al 6064 alloy.

Phase composition of deformable D16 and B95 aluminium alloys with the quantitative assessment of overburning of different stages of development

This paper covers new overburning monitoring methods for D16 and V95 aluminum alloys based on use of a method of an energydispersive X-ray spectral analysis (EDS analysis). It is known that lowered performance of aluminum-based materials is often connected with overburning in their structure. Because the structural changes caused by overburning (flash-off of eutectics and excess low-melting phases and the subsequent crystallization of melted-off microvolumes) are followed by developing porosity, have negative impact on physical and chemical, mechanical and processing properties. The ability to reveal overburning at early stages allows to reject the defective metal. Characteristics sensitive to an early overburning stage are offered based on EDS analysis. A degree of the induced overburning in a D16 sheet is identified. B95 alloy structural components determining the alloy tendency to overburning are revealed. It is found that the EDS analysis makes it possible to reveal changes in the chemical composition of the structural elements of D16 and V95 aluminum alloys and identify an overburning stage quantitatively based on oxygen content. Overburning development leads not only to the higher content of oxygen in the chemical composition of aluminum alloys, but also lowers the electrical conductivity of the material. The paper considers a correlation relationship between the D16 alloy electrical conductivity with overburning induced in it, and oxygen content. The applicability of this method is caused by the method simplicity and a possibility to quantify the defect development in the heat-strengthened deformable aluminum alloys after process heatings. Also this method can be used as an additional research method when metallographic analysis gives no definite answer at identification of early overburning stages.

Effect of the aluminum alloy composition (Al-Cu-Li or Al-Mg-Li) on structure and mechanical properties of dissimilar laser welds with the Ti-Al-V alloy

This paper presents the results of the studies of dissimilar Ti-Al-V/Al-Cu-Li and Ti-Al-V/Al-Mg-Li laser welds. The main variable parameter was the laser offset towards the titanium alloy. It was found that strength properties of the welds were significantly affected by alloying elements (copper or magnesium) in the aluminum alloys. The presence of copper improved kinetics and thermodynamics of the welding process due to the formation of specific phases in the fusion zone. Also, it increased the strength of the dissimilar welds by 2.5 times compared with the Ti-Al-V/Al-Mg-Li joints.

Prediction of hardness of stir cast LM13 aluminum alloy ‐ copper coated short steel fiber reinforced composites using response surface methodology

AbstractCopper coated steel fibers reinforced LM13 aluminum alloy composites have been prepared using stir casting process. Experiments have been designed using response surface methodology (RSM) by varying wt % of reinforcement (0–10), stirrer speed (350 min−1–800 min−1) and pouring temperature (700 °C–800 °C). Microstructure and hardness of composites have been investigated. Analysis of variance, significance test and confirmation tests have been performed and regressions model has been developed to predict the hardness of composites. Response surface plots reveal that hardness of composites increases with increasing wt % of reinforcement and stirrer speed. The optimum stir cast process parameters for obtaining higher hardness are found to be the wt % of reinforcement of 8.2, pouring temperature of 748 °C and stirrer speed of 708 min−1.