Aluminum Alloy Matrix Composites Research Articles

Impact of Boron Nitride(H) reinforcement on the properties of 5.8% copper-based aluminium alloy surface composite done by friction stir processing

ABSTRACT Numerous experiments and research is underway within the realm of aluminium metal matrix surface composites (MMSCs). This material has been applied in various marine, and aerospace industries, on account of its remarkable mechanical properties and desirable weight to strength ratio. The current study is focused on the synthesis of surface composites comprising of BN(H) reinforced 5.8% Cu aluminium alloy matrix composites. Boron Nitride(H) was reinforced on the surface of the Aluminum Alloy by FSP. Grooves were machined on the surface of the matriux and compacted with reinforcement particles. The wear rate, tensile behaviour, and microhardness were evaluated for the fabricated surface composites. The microstructural analysis was done via EDAX and FE-SEM to establish the presence of the reinforced particles. The tensile strength increased marginally with an increase in microhardness and reduction in elongation percenatge. The wear morphology aided in identifying the various wear mechanisms observed.

Finite element modeling of thermal residual stresses in functionally graded aluminum-matrix composites using X-ray micro-computed tomography

Metal-ceramic composites by their nature have thermal residual stresses at the micro-level, which can compromise the integrity of structural elements made from these materials. The evaluation of thermal residual stresses is therefore of continuing research interest both experimentally and by modeling. In this study, two functionally graded aluminum alloy matrix composites, AlSi12/Al2O3 and AlSi12/SiC, each consisting of three composite layers with a stepwise gradient of ceramic content (10, 20, 30 vol%), were produced by powder metallurgy. Thermal residual stresses in the AlSi12 matrix and the ceramic reinforcement of the ungraded and graded composites were measured by neutron diffraction. Based on the X-ray micro-computed tomography (micro-XCT) images of the actual microstructure, a series of finite element models were developed to simulate the thermal residual stresses in the AlSi12 matrix and the reinforcing ceramics Al2O3 and SiC. The accuracy of the numerical predictions is high for all cases considered, with a difference of less than 5 % from the neutron diffraction measurements. It is shown numerically and validated by neutron diffraction data that the average residual stresses in the graded AlSi12/Al2O3 and AlSi12/SiC composites are lower than in the corresponding ungraded composites, which may be advantageous for engineering applications.

Microstructural and wear properties of iron slag reinforced aluminum alloy (LM30) based composite prepared through a stir casting method

Aluminum alloys are widely used in various industries due to their as low density, high strength-to-weight ratio, and good corrosion resistance. However, their wear resistance is often inadequate for certain applications. Utilization of industrial waste materials, such as iron slag, as reinforcement in aluminum alloy matrix composites offers a sustainable approach to material development and waste management. The utilization of industrial waste materials for aluminum alloy matrix composite fabrication offers a waste utilization to material development. The loading of this reinforcement varied from 0 to 15 wt.% and different particle size range (220-140, 140-70, and 70-0 µm). A microscopic analysis indicated that the iron slag particles are spread uniformly inside the metallic matrix. There is also a reduction in the size of primary silicon, as well as morphological changes (acicular to globular shape). The wear behavior was calculated using a pin-on-disk wear set up in accordance with ASTM G99 standard. The composites were employed to dry sliding wear test under various operating conditions such as applied pressure (0.2–1.4 MPa), and sliding distance (0–3000 m). The 15F composite outperformed all other composite samples in terms of wear rate under all working conditions. When compared to the base alloy, it demonstrated a remarkable 67% drop in steady state wear rate. The enhancements in wear performance for the 15F composite were attributed to the effects of Fe slag reinforcement. The inclusion of iron slag particles induced strong interfacial bonding between matrix and reinforcement particles improving the durability of the mechanical mixed layer developed during relative motion. Importantly, the wear rate parameters of the 15F composite were similar to those of the brake drum material used in commercial applications. This emphasizes the composite suitability for usage in a variety of automobile components.

Microstructural and mechanical characterization of AA2124 aluminum alloy matrix composites reinforced with Si3 N4 particulates fabricated by powder metallurgy and high-energy ball milling

Microstructural and mechanical characterization of AA2124 aluminum alloy matrix composites reinforced with Si3 N4 particulates fabricated by powder metallurgy and high-energy ball milling

Tensile Properties of Aluminum Matrix Composites Produced via a Nitrogen-Induced Self-Forming Process

This study compares the tensile properties of commercial aluminum matrix composites (AMCs) with those of AMCs produced via a nitrogen-induced self-forming process. This process is a newly developed AMCs manufacturing process that takes advantage of the price competitiveness and productivity of large-scale products produced via the liquid process. Additionally, this process has the freedom of choice of the reinforcement phase and the homogeneous dispersibility of the powder process. Compared to commercial monolithic 6061 alloys, 6061 aluminum alloy matrix composites exhibit increased Young’s modulus, yield strength, and ultimate tensile strength by 59%, 66%, and 81%, respectively. This study also compares the tensile properties of AMCs with different matrix compositions, including 2009 and 7050 aluminum alloys. The study shows that AMCs produced using the nitride-induced self-forming aluminum composite (NISFAC) process exhibit comparable or superior tensile properties to those obtained using existing commercial powder metallurgy (P/M) processes.

Studies and scientific research analysis of aluminium (Al7075) metal matrix composite surface morphology

A nano-composite is composed of one or more chemically distinct inert phases, and its structural and distinctive qualities are superior to those of the constituent parts acting separately. This review paper focuses on enhancing the mechanical properties of composites through the integration of micro- and nanoparticles into an aluminum matrix. The article provides an overview of Aluminum Alloy (7075) matrix composites. Due to their exceptional strength, metallic matrix composites made from aluminum alloys find frequent applications in aerospace, automotive, defense, marine, and industrial fields. Due to their ease of processing and heat-treatability, heat-treatable alloys such as AA2024, AA6061, and AA7075 have garnered the interest of numerous researchers. This is primarily because these alloys can be readily modified to exhibit properties that are suitable for specific applications. The article discusses the mechanical properties of Aluminum Metal Matrix Composites (MMCs) reinforced with one or more particulates, such as aluminum oxide (Al2O3), zirconium oxide (ZrO2), titanium oxide (TiO2), silicon carbide (SiC), graphite, and titanium diboride (TiB2), among others. AA7075 exhibits remarkable ultimate tensile strength, good corrosion and wear resistance, and enhanced thermal stability.

Fabrication of graphite-reinforced 6201Al matrix composite with simultaneous enhancement of mechanical and electrical properties by multi-pass friction stir processing

In this study, graphite-reinforced 6201 aluminum alloy matrix composites were fabricated by multi-pass friction stir processing. The mechanical properties and electrical conductivity of the composites were tested, the microstructure and composition of the composites were analyzed by scanning electron microscope and Raman spectroscopy. The results showed that the graphite-reinforced 6201Al matrix composite achieved simultaneous improvement of mechanical and electrical properties compared to the base material, with a 19.5 % increase in ultimate tensile strength and a 1.2 % increase in electrical conductivity. Microstructural and compositional analysis revealed that the graphite reinforcement in the composites was significantly fragmented during FSP, and its size decreased while the number of atomic layers reduced with increase in FSP passes. A directly bonded Al-C interface is observed between the graphite reinforcement and the matrix, and no interface products such as Al4C3 were generated. The graphite reinforcement in the matrix simultaneously serves as a hindrance to dislocation motion and the expansion of microvoids during the tensile process, thereby leading to an enhancement in the tensile strength of the composite. The improvement in the electrical conductivity of the composite is attributed to two factors. On one hand, the structure and properties of graphite-reinforced phase is transformed to be closer to graphene after the severe plastic deformation during FSP process. On the other hand, the directly bonded Al-C interface between the matrix and the reinforcement is able to transfer electrons across the interface.

High velocity ballistic performance of ZrSiO4 reinforced aluminum alloy matrix composites

Multi-layered composite structures are a suitable strategy for achieving superior ballistic performance as compared to the monolithic materials. Typically, in the multi-layered structures, high hardness and strength material is configured as a front face and highly deformable material in the back layers. In the present study, ceramic particles ZrSiO4 reinforced Al-Si12Cu (LM13) aluminum alloy composites are investigated for ballistic performance. The 15 wt% ZrSiO4 particles of different sizes 20, 60 and 120 µm are incorporated in the aluminum alloy matrix via stir casting technique. Ballistic impact tests were performed by firing 0.308 calibers bullets with AK-47 rifle from a distance of 10 m. The deformations of the composite plates are predicted by correlating the decrease in the final velocity of the bullet after impact. It was found that composite reinforced with finer size particles offered higher resistance to bullet penetration as compared to the coarse size reinforced particles. The residual velocity as compared to the striking velocity was reduced to ∼34%, ∼29% and ∼22% for composite reinforced with ZrSiO4 particles of 20, 60 and 120 µm, respectively. At exit face the spall diameter is 34, 30 and 17 mm for composite of particle size 20, 60 and 120 µm, respectively. Microstructural analysis of the affected zones is also performed to explore the behavior of composite under the high impact loading.

Characterization, LCA and FEA for an efficient ecodesign of novel stainless steel woven wire mesh reinforced recycled aluminum alloy matrix composite

The production of metal matrix composites generally requires higher energy and raw materials consumption, while generating more waste than conventional material processing. The possibility of reusing recycled aluminum as an alternative in the production of metal matrix composites has led to the interest in this research as it can contribute to aluminum waste and raw reduction as well as to environmental impact mitigation. This paper provides an in-depth investigation of a brand-new metal matrix composite that is produced by gravity casting. In turn, the process is based on recycled aluminum EN AW 6082 for the matrix that is reinforced with stainless steel AISI 304 woven wire mesh that is intended for industrial and commercial use. A detailed description of the production procedure is reviewed, as are the vales of toughness, yield and tensile strengths that were determined by standardized tensile and Charpy tests. Life Cycle Assessment and Finite Element Analysis were used to determine, respectively, the environmental impact and the residual stresses generated during the production of the specimens for the above mentioned tests. Five different opening and wire diameter configurations for the AISI 304 woven wires were studied in this work. In a comparison to recycled aluminum alloy EN AW 6082 without reinforcement, the best results were provided by the 2.177 mm × 0.6 mm configuration. These results were the following: (1) Yield, tensile strength and toughness showed an increase of 245.5%, 13.62% and 175.0% respectively. (2) Life Cycle Assessment increased 8.31% for the highest environmental impact obtained (Human Toxicity). (3) The Finite Element Analysis showed that the residual stresses increased in their compressive values in −10.83 MPa, −9.925 MPa and −3.84 MPa, respectively, for the stainless steel wires, aluminum matrix and wire/matrix interfaces. From the mechanical properties, the environmental impacts and the residual stresses that were obtained, one can conclude that this study has demonstrated a technically feasible practical approach to the use of the recycled aluminum alloy EN AW 6082 using AISI 304 stainless steel woven wires as materials in the metal matrix composites production. This could lead to a substantial reduction in the volume of aluminum used and, consequently, provide environmental and economic benefits.

Subsurface deformation and wear behavior of 15% SiCp/2009Al aluminum matrix composite under cryogenic sliding

Subsurface deformation and wear behavior of 15% SiCp/2009Al aluminum alloy matrix composites induced by sliding wear at room and cryogenic temperature were investigated in the present work. An external cryogenic device was designed to produce a steady cryogenic environment in the course of experiments. Microstructure evolution in the subsurface layer and wear mechanism on the worn surface were analyzed by various characterization methods. The results showed that sliding at cryogenic temperature caused greater plastic deformation in the subsurface layer than that at room temperature. This can be attributed to the increased plasticity of aluminum alloy matrix and increased brittleness of SiC particles at cryogenic temperature, which can reduce the block effect of SiC particles on the deformation of aluminum alloy matrix. Wear rate of the composite material was significantly reduced after cryogenic sliding, whose decrement was much higher under higher applied load. Worn surface presented a lower surface roughness and higher surface evenness after sliding at cryogenic temperature. Wear mechanism was found to be transformed from severe oxidative, adhesive and delamination wear at room temperature, to slight delamination wear and cracking feature under cryogenic sliding. Deformation layer after cryogenic sliding played a role of nanocrystalline work-hardening layer, as the work-hardening rate and dislocation density were increased at cryogenic temperature. This is responsible for suppressing the generation of cracks and correspondingly improving the wear performance of material. This work also offers a new strategy for designing high surface-performance aluminum matrix composites via the method of self-adaptively forming nano hardening layer in cryogenic temperature environment.

Synthesis and mechanical properties of graphene nanoparticles reinforced with aluminium alloy matrix composites

Synthesis and mechanical properties of graphene nanoparticles reinforced with aluminium alloy matrix composites

The influence of carbide reinforcement on the properties of sintered aluminium alloy matrix composites

Based on the commercial aluminium alloy powder blend (Alumix 431D) metal matrix composites reinforced with particles of SiC as well as TiC were produced by conventional powder metallurgy technology and the effect of the type and amounts of reinforced particles on the selected properties and microstructure of sintered composites were investigated. In particular, the densification behaviour, the wear resistance and the corrosion resistance in 3.5% NaCl solution were identified. It was stated that both the type and the weight fraction of carbide used as particulate reinforcement have a great impact on the properties of aluminium alloy matrix composites. It was shown that the introduction of titanium carbide has a more favourable effect on the properties of sintered Alumix 431D matrix composites in comparison to silicon carbide and the optimum content of TiC in composite is 4 wt. % due to the highest hardness, wear resistance (wear rate of 2.86510-3 mm3/m) and simultaneously the best corrosion resistance (corrosion rate of 0.005 mm/year).

Recent findings on mechanical behaviour of stir cast aluminium alloy-matrix composites: An overview

This study examined the previous research on the mechanical properties of reinforced composites of aluminium-matrix, manufactured by stir casting. Stir casting has been reported as the most economical fabrication method currently in use for producing Aluminum Matrix Composites because of its accessibility, portability, adaptability to be utilized for large-scale manufacture, and easy operation of the application to conventional shape casting foundry procedures. Apart from the minority report that recorded a reduction in ductility, yield strength, ultimate tensile strength, and modulus of elasticity but with an increase in hardness of the SiC particulate reinforced aluminium matrix composites following the increase in reinforcing material, the majority of work has shown that the mechanical properties increase with the increase in the addition of the reinforcing material. Reinforcing materials like silicon carbide, tungsten carbide, alumina, boron carbide, and multi-walled carbon nanotubes have been used in various compositions to manufacture aluminium-matrix composites. The highest reported ultimate tensile strength of 489 MPa was obtained after stir casting 10 vol% of SiC - aluminium matrix composite. The maximum tensile strength of 401 MPa was attained with 20% B4C - Al-matrix composite. Various uses of metal-matrix composites have been identified in the making of hypersonic aircraft, sporting equipment, and automobile engine parts.

Effect of laser pulse energy deposition method on nanosecond laser scanning ablation of SiCp/AA2024 composites

The control of the thermal stress and heat accumulation is major issue faced in the laser precision machining, and plays a key role in the laser machining of composite materials. In this pursuit, the present study envisaged the effect of pulse energy deposition method on the processing of particulate reinforced aluminum alloy matrix composites SiCp/AA2024. Specifically, by modulating the combination of the spot overlap ratio (SOR) and the area scanning passes, a variety of pulse energy deposition methods with the same number of received pulses per unit area were designed and applied on a target. The influence of the pulse energy deposition on processing was evaluated by measuring and comparing the ablation depth and surface roughness. The results showed that by using multiple scanning passes with small spot overlap ratios led to a good processing with a high ablation depth. Furthermore, the influence of SOR and scanning passes on the machining was studied using the control variable method. The influence of energy deposition method was studied from the aspect of nanosecond laser ablation mechanism, Fresnel reflection effect and heat accumulation.

Investigations on Mechanical and Wear Properties of Molybdenum Trioxide-Reinforced Aluminum Alloy (AA7075) Matrix Composites Produced via Stir Casting Process

Investigations on Mechanical and Wear Properties of Molybdenum Trioxide-Reinforced Aluminum Alloy (AA7075) Matrix Composites Produced via Stir Casting Process

The third-generation biodiesel blends corrosion susceptibility of oxide particle-reinforced Si-rich aluminum alloy matrix composites

Abstract The study of a stir cast Al356-Nb2O5)P composite immersed in third-generation microalgal-derived biodiesel blends with enhanced plasma electrolyte oxidation surface modification revealed the corrosion susceptibility and possible by-product formation. The effect of (oxide)P reinforcement and mixed-oxide surface coatings were studied separately and cumulatively. Samples were immersed in different biodiesel and petrodiesel blends for up to 3000 h, and their corrosion and electrochemical behavior was studied. Although some weight change was recorded in all samples, the corrosion rates significantly decreased from 1.8 to 1.3 by 10 wt% Nb2O5)P reinforcement, which further decreased 10 times after surface modification. Electron microscopy revealed primary fine-grained microstructure with low porosity content of fine and needlelike dendritic structures in composites and irregular volcanic with scattered micropores and microcracks in surface-modified composites that changed to corrosion spots and flake-covered microcracks after immersion.

Study the effect of stirrer design on the stirring performance of ceramic particle reinforcements in stir casting of Aluminum Matrix Composites

Stir casting is one of the vital methods for making aluminium alloy matrix composites. The main challenge of this technique is getting a homogenous dispersion of reinforcement particles. The uniform distribution of reinforcement particles improves the mechanical properties, so the stirrer must be designed so that it achieves uniform distribution. The main process of stir casting is done in a closed crucible at high temperature with a hidden flow pattern under a variety of various influencing variables; therefore, numerical is more realistic than the analytical approach for forecasting problems. This paper aims to choose the most efficient stirrer design among four different stirrers to attain the best reinforcement particle distribution in the least time in a selected case. ANSYS CFX, the Image process, and visual experiments were conducted to select the optimal stirrer design. This study is unique in that it provides a new methodology for optimizing the stirrer design, and identifying simulation obstacles and future simulation scope for the mixing performance simulation programmers. Finally, any effort to improve mixing efficiency will very certainly result in lower total energy use, fossil fuel consumption, and CO2 emissions, which is the goal of the millennium.

Effect of TaC/Ti/Si3N4 Hard Ceramics on Mechanical and Microstructural Behaviour of AA7075 Processed through Stir Casting Process

A liquid metallurgical stir casting route was utilized for developing aluminium alloy (7075) matrix composites blended with fluctuating wt% of silicon nitride (Si3N4), tantalum carbide (TaC), and titanium (Ti) for sake of generating a profitable composite with enhanced properties. The physical, microstructural, and mechanical characteristics such as density, high temperature tensile, fatigue, and time-dependent creep experiments were conducted and evaluated. SEM microstructural examinations were performed on the composite samples and proved that there was a good interfacial bonding and uniform dissemination among the reinforcement particulates in the matrix. Physical characteristics were analysed and the outcomes showed that AA7075 blended with 1 wt% TaC, 8 wt% Si3N4, and 0.5 wt% Ti proved higher experimental and theoretical densities of 3.2464 g/cm3 and 3.3038 g/cm3, respectively, with maximum porosity of 1.7758%. At 30°C, the tensile properties of the developed MMCs showed improved ultimate tensile strength (UTS) of 137.64 N/mm2. Beyond 100°C, AA7075 reinforced with 0.75 wt% TaC, 6 wt% Si3N4, and 1 wt% Ti proved to have a higher strength of 232.17 N/mm2. Fatigue properties of the developed MMCs discovered were found to be reformed when proportionate to the base alloy by operating at 14 × 103 cycles at the stress of 42.72 MPa. Time-dependent creep analysis of the developed MMCs found to be advanced due to the addition of tough ceramic particulates.

Mechanical and wear properties of SiCp/CNT/Al6061 hybrid metal matrix composites

6061 aluminum (Al6061) alloy matrix composites with hybrid reinforcements composed of both carbon nanotubes (CNTs) and silicon carbide particles (SiCp) were prepared by spark plasma sintering technique. SiCp, CNTs and Al6061 powder were firstly mixed by a tip-sonication mixing, then frozen the suspension in liquid N2, and finally freeze-dried in a vacuum to obtain the uniform dispersion of SiCp and CNTs. The SiCp/CNT/Al6061 hybrid composites containing homogenously dispersed SiCp and CNTs exhibited significantly improvements in hardness, tensile strength and yield strength values of 37%, 38%, and 49%, respectively, compared with those of SiCp/Al6061 composites without CNTs. The improvements in the mechanical properties were attributed to the synergistic strengthening effects of the CNTs and SiC particulates. The coefficient of friction and specific wear rates of the hybrid composites were decreased by the addition of low-friction CNTs due to the self-lubrication effect. The CNTs did not reduce the friction coefficient and specific wear rate of the specimens as significantly with the increase of the applied load. This could be resulted from the transformation of carbonaceous structures of CNTs during the tribological testing process.

An overview of the effect of stirrer design on the mechanical properties of Aluminium Alloy Matrix Composites fabricated by stir casting

An overview of the effect of stirrer design on the mechanical properties of Aluminium Alloy Matrix Composites fabricated by stir casting