Aluminium Based Metal Matrix Composites Research Articles

Mechanical properties of silicon nitride fortified aluminium based metal matrix composites – A review

Aluminum metal matrix composites (AMMCs) are in potential demand in numerous field such as automotive, defence and sports recreation sectors owe to important properties compared to traditional aluminium alloys. AA7055 is generally embraced and it is the ideal composite between Al7XXX series arrangement mainly used for different vehicle applications. AA7055 metal matrix composites properties can be improved by incorporating suitable reinforcement. The motivation behind this assessment is to give an outline of silicon nitride in the AA7055 MMC as a base material and to clarify changes in mechanical properties due to the inclusion of reinforcements that can be further improved in combination with the addition of appropriate reinforcement materials to the base matrix.

Development of Aluminium based metal matrix composites by stir casting method

Aluminium 7050 is a predominant alloy that is used for various engineering applications such as aircraft, marine components. Metal matrix composite possesses improved characteristics such asstrength and hardness. Aluminium based MMC’s are receives attraction because of their exceptional characteristics. In this present investigation, an endeavour has been taken to develop aluminium-based (AA7050) metal matrix composite with Titanium dioxide(TiO2) as reinforcement. The composite is fabricated with the help of a stir casting process which exhibits better and improved properties than base materials.The composite is fabricated by varying the reinforcement (1–4%) weight combination. The fabricated composite is testedfor determining the mechanical properties as per ASTM standards. The tensile test and wear test have been performed on the fabricated metal matrix composite to identify the better mechanical properties.

Study of fabrication methods and various reinforcements with aluminium for automotive application – A review

In the today’s modern world, the demand of composite material has been increased gradually. At current scenario aluminium-based composites are commonly used in engineering applications especially in automotive sectors because of its novel quality of properties. Whenever there is requirement of changes and improvements in property of material, at that time, the property is improved by mixing reinforcement components into the basic material. In the present study there are several kinds of reinforcement particles are used with the aluminium as a base material. This literature review aims to provide an overview of various types of fabrication methods of composite metal matrix and shows their potential of this technology in different fabrication methods. This literature review also presents that various reinforcement particles such as SiC, TiC, B4C, Al2O3, SiO2, MgO etc. can be used to improving properties of Al based composite by using different methods. This study concludes that among the various matrix, aluminium is most used matrix because of its internal characteristics and processing potentiality for fabrication of composite material. It also concludes that among the reinforcement particles which are the most used because of their capability to provide good mechanical properties to the fabricated composite material. This literature review is beneficial to study the various fabrication methos of composite metal matrix and different reinforcement particles which are enhancing the properties of aluminium-based metal matrix composite.

Development of predictive models for wire electrical discharge machining of aluminium metal matrix composites by using regression analysis and neural network

Metal Matrix Composites (MMC) play a major role in numerous engineering uses such as aerospace, automobile and structural industries due to their exceptional characteristics such as lightweight, improved strength and resistance to wear. Amongst numerous contemporary approaches of machining, Wire Electrical Discharge Machining (WEDM) attracts attention due to its performance, especially in the machining of hard materials with complex shapes. In this present exploration, an endeavour was done to evolve predictive models for WEDM of aluminium-based metal matrix composites reinforced with Boron Nitride (BN). Pulse on time, pulse off time and peak current are considered independent parameters. Taguchi’s approach has been adopted for planning the experiments and to analyze the influence of process variables on desirable performance measures such as dimensional deviation and form/orientation tolerance errors. Neural network and multiple regression approaches were adopted for forecasting the aforementioned process variables. A comparison has been made among the predicted values from regression and neural network methods. The outcome of the comparative analysis proves that the neural network precisely predicts the desired performance.

An Investigation on the Mechanical Properties of Aluminium 6061 Alloy Reinforced with Boron Carbide and Silicon Carbide

Abstract: Aluminium alloys are widely utilised in the aerospace and automobile industries due to their low density and strong mechanical qualities, as well as their superior corrosion and wear resistance and low thermal coefficient of expansion as compared to traditional metals and alloys. These material’s superior mechanical qualities and inexpensive production costs make them an appealing alternative for a wide range of scientific and technical applications. In this study, we strive to present a literature review on the overall performance of reinforced composites created by the stir casting method, as well as the effect of process factors on the properties of Aluminium-based MMC. The literature review framework in this paper provides a clear overview that the process parameters play important role for optimum properties of Aluminium based Metal Matrix Composites. As reinforcing elements in Metal Matrix Composites, Boron Carbide and Silicon Carbide play an important role. The MMCs were successfully produced using the liquid metallurgy process. Scanning electron microscopy was used to examine the morphology and microstructure of Al-B4C and Al-SiC composites. The addition of 2, 4 and 6 wt% B4C and SiC particles increased several mechanical parameters such as ultimate tensile strength and hardness. It was also discovered that the mechanical behaviour of B4C particulates AMC is superior to that of SiC particulates AMC. Keywords: Aluminum, Metal matrix composite, SiC, B4C, Tensile test, Hardness test and SEM Analysis.

Compressive behavior of CNT-reinforced aluminum matrix composites under various strain rates and temperatures

Carbon nanotubes (CNTs) have been attractively used as reinforcement in metal matrix composites (MMCs) for advanced mechanical properties. However, the effects of loading rate and temperature on such materials are still to be resolved. In the present study, aluminum-based MMCs reinforced with CNTs of different contents were investigated under various loading rates and temperatures, along with microstructural examination by electron microscopy. It is found that the strengthening capability of CNTs/Al in comparison to PBM Al decreased with the temperature increasing and loading rate decreasing. However, microstructure characterization showed that CNTs played an essential role on hindering dislocation movement and stabilizing the microstructure, thus yielding an increased strength in Al-based MMCs at temperatures up to 603 K, regardless of the loading rate. A constitutive model that takes into the effect of temperature and microstructures account is then established to illuminate the role of CNTs. In addition, experimental results showed that the CNTs-reinforced Al composites exhibited an enhanced value of strain rate sensitivity and a reduced activation volume than the Al counterpart under all the tested temperatures. It is also found that the increased temperature softened the matrix and reduced the amounts of interactions of mobile dislocations with CNTs and forest dislocations, which led to the enhanced thermal activation volume of the CNTs/Al with temperature.

Application of TOPSIS Method for Prediction of Optimum Design Parameters of Micro Hole Textured Cutting Inserts in Turning of Al-MMC

Metal Matrix Composite (MMC) has better mechanical properties and it is possible to produce near net shape. Aluminum-based MMC (Al-MMC) has challenges in terms of machinability studies and estimation of its optimum process parameters. Alternative cutting fluid research is a challenging area in machining. To avoid, existing hydrocarbon oil-based cutting fluid, textured inserts embedded with a solid lubricant are one of the alternative solutions. Micro hole textured inserts make a hole on the rake face of the cutting tool inserts. Texture includes various important design parameters namely hole diameter, hole depth and pitch between the holes. These optimum parameters influence the machining process. In this work, the Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) method is used to find the optimum design parameters (hole diameter, hole depth and pitch between holes) during turning of Al- MMC. The objective parameters considered are minimization of surface roughness, power consumption and tool flank wear. The optimum combination of these design parameters is obtained by the higher relative closeness value of the TOPSIS method. The result of the investigation revealed that these design parameters are important to obtain improved machining performance. Also, it is understood that the TOPSIS method has an appropriate procedure to solve multiple objective optimization problems in manufacturing industries.

Finite element modeling of sub-surface damage while machining aluminum based metal matrix composites

Sub-surface damage during machining of aluminum-based metal matrix composites (MMCs) has been modeled using finite element models. These models are based on reinforcement particles size and volume fractions and particles are distributed uniformly in the metal matrix. In order to simulate particle debonding cohesive zone elements (CZE) have been incorporated along the parting line. In addition, failure criteria based on brittle fracture have been added for ceramic particles to simulate particle fracture. To reduce computational time and simplify the model both CZE and particle fracture is limited to the reinforced particles along the parting lines facing the tip of the cutting tool. The damage depth beneath the machined surface is measured by using the non-zero plastic strain values in the equivalent plastic strain contours obtained from the FE models. The results were compared against published experimental data and found to be in good agreement.

Experimental investigation of nano reinforced aluminium based metal matrix composites

The objectives of this work is to create an aluminum-based hybrid composite using the stir casting technique. Aluminium alloys are frequently utilised in the marine, concrete, transportation, and aircraft sectors due to their excellent strength-to-weight ratio. Stir casting was used to create particles strengthened metal matrix composites. The samples were characterised using optical microscopy and hardness testing. The results showed that the stir casting technique can advance the mechanical properties of samples by ensuring a uniform distribution of CNT/ Alumina elements in the A6061 matrix. As a result, simulating the mechanical characteristics of a newly generated raw sample is critical for assessing the structure's durability.

Aluminum Based Metal Matrix Composites Behavioral Studies with Different Reinforcements- A Review

Abstract: Aluminum alloy’s widely employed in transportation applications like: aerospace, aviation, marine and automobile sector due to their good mechanical properties, wear properties, corrosion behavior and high strength to density ratio. The current review article mainly highlights the effects of various reinforcements on mechanical and tribological properties of aluminum based metal matrix composite materials and focuses on the types of different reinforcements. Review revealed that, there is significant improvement in mechanical properties of AMMC’s with different reinforcements as compared to traditional base alloys. The reinforcements may be SiC, TiO2 , Al2O3 , fly ash, B4C, fiber, Zircon are incorporated in the stir casting or other methods. Keywords: AMMC, Reinforcements, Mechanical properties, Stir casting etc.

Ultrasonic pulsed waterjet surface peening of an industrial aluminum-based metal matrix composite

Peening is used across a wide range of materials to improve fatigue response. Recently, a new approach to peening has been developed using an ultrasonic-pulsed waterjet (UPWJ). In the present work, UPWJ peening has been conducted on a powder metallurgy derived aluminum-based metal matrix composite (Al-MMC), containing 5 wt% aluminum nitride (AlN) additions. Traverse speed is one of the most important parameters in UPWJ peening, which primarily modulates the mechanistic interaction between the waterjet and the target surface. In the current study, a focus was placed on assessing the effects of traverse speed (which was varied from 150 to 1000 mm/s), while the other primary process parameters, including the pressure, frequency and standoff distance were kept constant. Confocal laser scanning microscopy and scanning electron microscopy were used to evaluate the surface roughness and microstructure of the Al-MMC samples, in both un-peened and UPWJ peened states. The induced residual stress generated by UPWJ was also determined, with profiles obtained by electropolishing to remove micro-layers of material until an attenuation of the residual stresses was realized. It is shown that the Al-MMC was generally responsive to UPWJ peening. The surface roughness increased due to UPWJ processing, though the extent of increase was lower for increasing traverse speed. Mass losses were recorded at UPWJ traverse speeds lower than 500 mm/s due to material removal. Generally, the UPWJ peening process produced significant increases in compressive stresses, with the best combination of low surface roughness and high compressive stress obtained at a traverse speed of 700 mm/s.

Study on Dry Sliding Wear Characteristics by Taguchi Analysis of Al-Mg-Si-Cu-SiC Composite Prepared by Powder Metallurgy Method

There is a growing attention among researchers to the production of new composites with low-density and low-cost processes. Aluminum based metal-matrix composites (AMMC) offer solutions for new product development. In this paper, a newly developed Al-Mg-Si-Cu-SiC composite was manufactured by powder-metallurgy, and the wear mechanism of aluminum composite materials was carried out using the pin-on-disk method. The purpose of the experimental plan was to correlate the factors that influenced the wear operations in order to execute them with a minimal rate of wear and co-efficient of friction (COF). The experiment was based on the Taguchi design with OA (orthogonal arrays) to correspond to the effects of load applied, sliding speed, and distance. The design features are distinctive and integral attributes of the method, affecting and determining the wear characteristics of composites.The predictive models developed for various machining performance characteristics employing response surface methodology are effective in terms of adequate, statistically significant, and probabilistically validate because of their higher R2-values, P-values less than 0.05 and larger AD-test p-values. The data generated for the Al-Mg-Si-Cu-SiC AMMC will be useful for the industry. HIGHLIGHTS Preparation of AMMC through powder metallurgy method The WR decreases with the rise in wt% of SiC reinforced particles Taguchi orthogonal design model is best suited to examine dry sliding wear characteristics of an Al-0.5Si-0.5Mg-2.5Cu-10SiC composite Using the Taguchi-optimization method, it is more expedient to obtain the minimum WR of the composites GRAPHICAL ABSTRACT

Composites Based on Aluminium Metal Matrix Prepared by Varies Methods with Their Mechanical and Tribological Properties – A Review

Abstract: Aluminum based metal matrix composites (AMCs) are very useful and demanded in space and vehicle sector because they carry excellent properties like light weight, ductility, great strength, and toughness apart from this they can be handled by predictable methods. Melt casting and powder metallurgy methods are widely adopted for fabricating the compounds as compared to other technique. Casting methods is used for prepare the complex shapes because powder metallurgy technique is not able to prepare such type of complex shape though it is further cost effective than the melt casting techniques. Casting with stirring has certain advantages over powder metallurgy because it allows for better matrix particle adhesion, easier matrix structure control, low cost, simplicity, and the formation of precise shapes. The Casting process can be utilised with a wide range of materials. Aluminium metal matrix composites, on the other hand, have been found to have superior wear resistance and mechanical qualities. The tribological and mechanical properties of aluminium based alloy matrix composites manufactured using various casting processes are summarised in this review paper. Keywords: Metal Matrix based on aluminium, Manufacture methods, mechanical and tribological characterization.

Recovery of Cr from chrome-containing leather waste and its utilization as reinforcement along with waste spent alumina catalyst and grinding sludge in AA 5052-based metal matrix composites

The present investigation deals with the development of AA 5052-based metal matrix composites (MMCs) by utilizing industrial wastes, spent alumina catalyst, chrome-containing leather waste, and grinding sludge as a reinforcement material. The chrome-containing leather waste has been utilized to extract the collagen powder, which is a form of chromium oxide. The presence of Al2O3, Fe2O3, and SiO2 phases in the spent alumina catalyst and grinding sludge ball-milled powder encourages its utilization as reinforcement material (in the form of Cr) for the development of MMCs. The stir-casting technique has been used to develop the aluminum-based MMC with waste spent alumina catalyst, chrome-containing leather waste, and grinding sludge. Further, results revealed that the matrix material mechanical properties compressive strength, tensile strength, and hardness were significantly increased by 12.93%, 5.34%, and 31.81% after adding spent alumina catalyst, Cr, and grinding sludge with the weight percentage (wt.%) of 4.5%, 1.5%, and 4.5%, respectively, but the toughness was reduced. The microstructural investigation indicated the uniform distribution of reinforcing elements spent alumina catalyst (4.5 wt.%), GS (4.5%), and Cr (1.5%) in the aluminum matrix material. Further, the influence of given reinforcement elements on the thermal expansion and corrosion weight loss properties of aluminum alloy matrix material has also been investigated.

Tribological analysis of Al-Si alloy based MMCs at elevated temperature

In the current study, investigates the tribological behaviour of aluminium-based metal matrix composites (MMCs) and aluminium-based hybrid metal matrix composites (HMMCs) fabricated through the stir casting process. Reinforcements like Al2O3 and SiC are vastly used to enhance the quality of metal facets and reduce the rate of wear. In this work, the matrix metal Al alloy (LM6) is reinforced with 10 wt% of (Al2O3), 10 wt% of (SiC) & (5%SiC + 5%Al2O3) to manufacture MMCs & HMMCs respectively, and 1 wt% of Mg mainly used for wettability of composites. The whole tribological experiment carried out through a computerized pin-on-disc setup by varying the input parameters like elevated temperature (T) i.e. 50,100,150 °C, sliding distance (D) i.e. 500, 1000, 1500 m, and sliding velocity (V) i.e. 1,2,3 m/s with a constant load of 24.5 N. The outcome response is considered as wear rate (WR) (mm3/m) and coefficient of friction (COF). The observations are designed based on one of the robust methods i.e. taguchi (L9) orthogonal array. Analysis of variance(ANOVA) revealed that both elevated temperature and sliding distance are the most regulating factors compared to sliding velocity. All the observations are conducted at a persistent load of 24.5 N and ANOVA revealed that elevated temperature is an outrageous regulating factor followed by sliding distance, sliding velocity. Elevated temperature is the most influencing factor in HMMCs (Al2O3 & SiC) whereas both sliding distance and elevated temperature are the regulating factor for MMCs (Al2O3/SiC). Finally, worn-out areas of specimens were analysed through scanning electron microscope (SEM) and Regression equations value by a confirmation test.

Development and analysis of SiC, TiO2, and Biochar hybrid reinforced aluminium-based metal matrix composite

ABSTRACT In the present work, SiC, TiO2, and Biochar were reinforced in Aluminium Alloy 5083 O by stir casting technique. The SiC particle was kept at a constant volume percentage of 2.5% and TiO2 was varied from 2%, 2.5%, and 3%, and Biochar was varied in the range of 2.5, 5, and 7.5 volume percentage. The cast samples were subjected to tensile, microhardness, and wear tests. The UTS was 8% more than the base metal. The elongation revealed the increase in the ductility of the reinforced composites. There was an increase in the tensile strength also. The micro-hardness was lesser in the highest reinforcement of biochar. The wear tests were carried out. A reduction in wear rate was observed. FESEM analysis was carried out which revealed the particle distribution in the metal matrix.

Effect of tool diameter ratio on the microstructural characteristics of a solid-state processed aluminum based metal matrix composite

Abstract Stir cast aluminum based metal matrix composites (MMCs) with silicon carbide (SiC) reinforcement particles consist of cast product dendrites and large agglomerated reinforcements. The agglomeration of SiC particles creates a difference in properties in the composite system. Friction stir processing (FSP) is used to overcome the uneven distribution of SiC particles in the aluminum matrix. The friction stir processed (FSPed) microstructure is significantly influenced by the process parameters used for processing. In FSP, the effect of the tool diameter ratio (tool shoulder diameter to pin diameter) on material flow, material mixing, material consolidation is more predominant than other parameters. Hence, a perfect combination of shoulder diameter to pin diameter is required to produce sufficient material flow. In this investigation, the tool diameter ratio is varied from 2.0 to 4.0 for processing composite material and thus FSPed zones were subjected to micro structural characterization. It was concluded that a tool diameter ratio of 3.0 yielded a defect free stir zone with higher hardness compared to other ratios.

Experimental Investigation of Tool Wear in Machining of SiC Based Al-MMC

ABSTRACT The machining of hard particle reinforced metal matrix composite material is always challenging. The machining behaviour of aluminium-based metal matrix composites (Al-MMCs) can be entirely different from conventional materials. This paper presents an experimental study of the effect of cutting parameters like cutting speed on surface quality and tool wear. Even the matrix material can be ductile, but hard particles and their binding with matrix material can bring a difference in the machinability of composite materials, specially MMCs. Three different MMC compositions, i.e. MMC reinforced with 15%, 20% and 25% SiC, were machined at various cutting speeds and feed rates. Tool wear and surface roughness of the machined surface of MMC were examined. Increased content of SiC increases the mechanical properties like hardness and compressive strength but was found detrimental to tool and surface quality. Tool wear was found increasing with both increasing feed rate and cutting speed. Application of image processing for measurement and prediction of tool wear is attempted by capturing the images of tool insert and processing using a MATLAB® based algorithm. Results are in line with many other research and establish the scope of future work for non-contact measurement of tool wear in real-time.

An Investigation of corrosion of friction welded and post-weld heat-treated AA6061/SiC/graphite hybrid composites

The aluminium-based hybrid metal matrix composites have noteworthy applications in sub-sea installations, structures of deep-sea crawlers, submarine parts, engine cylinders, drum brakes etc., as they possess high strength, corrosion resistance, chemical, and dimensional stability. In this investigation, the pitting corrosion behaviour of friction welded and post-weld heat-treated AA6061/SiC/graphite hybrid composites were analysed. The corrosion rates of AW (as welded), ST (Solution treated), STA (Solution treated and Aged), and AA (Artificially Aged) weld joints were experimentally determined. The corrosion behaviour has been discussed in light of microstructure. The experimental results revealed that the STA joints exhibited better corrosion resistance characteristics as compared to AW, AA, and ST joints. The corrosion rate was high for AW joints, followed by AA and ST joints, respectively. Taking into account the corrosion rates of AW and STA joints, the STA joints have a corrosion rate 34.6% lesser than that of AW joints. A comparison of AA and ST with STA joints reveals that the rate of corrosion for STA joints was 31.1% lesser than that of AA joints and 28.8% lesser than that of ST joints. A lower corrosion rate was observed for STA joints as compared to AA, AW, and ST joints.

Corrosion Resistance of Al-CNT Metal Matrix Composites.

The design of aluminium–graphite metal matrix composites (MMCs) with advanced mechanical properties and high corrosion resistance is in demand for aerospace, transportation, and industrial applications. Breakthroughs in this field are limited due to the tendency of aluminium–graphite MMCs to corrode. In the present research, aluminium-based MMCs were produced by a relatively novel combined two-staged method. Multiwall carbon nanotubes (MWCNTs) were added into molten Al1070 and processed by high-pressure die casting followed by cyclic extrusion. For the composites produced by this method, it was previously demonstrated that mechanical properties are improved in comparison with pure aluminium alloys. In the current study, the manufactured Al–MWCNT composites were investigated by electrochemical tests (such as open circuit potential), potentiodynamic tests, linear polarization tests, and electrochemical impedance spectra to understand the corrosion resistance of the obtained composite material. The experimental testing of the corrosion resistance of Al–MWCNT MMCs showed that due to the advantages of the fabrication method, the addition of CNTs to aluminium does not cause a radical decrease of corrosion resistance.