Aluminum Content Research Articles

Revealing the environmental-assisted degeneration mechanism of an Al-containing dual-phase high entropy alloy in supercritical water

A dual-phase high entropy alloy (DP-HEA) containing 7.82 wt% Al was synthesized to withstand corrosive supercritical water. The long-term corrosion and quasi-static tensile tests reveal superior resistance to such environmental-assisted degeneration. The outstanding corrosion resistance can be attributed to the high aluminum content in B2 phase, which forms a continuous Al2O3 layer for protection, while the FCC phase is selectively corroded. Under external stress, stress corrosion cracking (SCC) initiates from surface oxide and penetrates uncompact mixed Cr/Al-rich oxide in deteriorated FCC regions or corroded phase interface, though network-shaped B2 can inhibit SCC propagation, which supports the brittle film rupture model.

Synergistic mechanism of pH control by CO2 and CaO2 pre-oxidation to enhance algae dehydration

This study investigated the improvement of algal dehydration efficiency through CO2 pH adjustment and moderate pre-oxidation with CaO2 to enhance coagulation. Adjusting the pH of algal water to 6.0–9.5 with CO2 significantly affected zeta potential and photosynthesis, enhancing aluminum hydrolysis product aggregation. At pH 6.5, the composition of algal organic matter closely matched the original water, indicating minimal impact on algae and optimal cell activity. CaO2 pre-oxidation effectively reduced residual aluminum content and DOM release after coagulation. The DOM removal rate reached 44.50 % at pH 6.5, with the highest dehydration efficiency of 44.34 % and the lowest cell rupture rate of 5.55 %. Small molecular aromatic proteins decreased, while humic substances increased significantly. The chemical bonding between the EPS membrane and CaO2 improved system density and elasticity, enhancing dehydration performance. This study provides new insights and guidance for the ongoing study of pH and CaO2 enhanced algal dehydration.

The effect of Al and Zr content on corrosion of AlNiCoCuZr high-entropy alloys in a 5 wt% NaCl solution

High-entropy alloys are attractive structural materials for the design of apparatus for various chemical technologies due to their relative ease of production, corrosion resistance and high values of mechanical properties (hardness, strength). In the present work, the influence of aluminum and zirconium content on the corrosion resistance of Al(20−35)-Ni(5−15)-Co(15−30)-Cu(20−35)-Zr(5−40) high-entropy alloys was studied experimentally for the first time. Corrosion tests were performed in a 5 wt% NaCl aqueous solution during 1500 h at 298 K. It is established that the electronegative metals included in the alloy - Al and Zr are passivation components and with increasing their content in AlNiCoCuZr composition the corrosion rate in the studied conditions is decreased. It is shown that degradation of alloys occurs mainly as a result of nickel and cobalt hydroxide formation, the solubility of which is several orders of magnitude higher than that of aluminum hydroxide and zirconium hydroxide.

Effects of adding metals to Beta zeolite on ethanol conversion to hydrocarbons

This study investigated the effects of Beta zeolite ion exchange with Fe, Zn, and Co on ethanol conversion to hydrocarbons. Various characterization techniques such as X-ray fluorescence (XRF), inductively coupled plasma optical emission spectrometry (ICP-OES), X-ray diffraction (XRD), magic angle rotation nuclear magnetic resonance spectrometry (MAS NMR) of 29Si and 27Al, scanning electron microscopy (SEM), nitrogen physisorption, ammonia temperature-programmed desorption (NH3-TPD) and Fourier transform infrared spectroscopy (FTIR) were employed. Catalytic tests were performed at temperatures from 475 to 550 °C under ambient pressure. The metal addition to Beta zeolite reduced micropore area and volume, decreased the concentration of the extra-framework aluminum, and increased total acid site density and Lewis acid sites, except for Fe. For all catalysts, ethylene was identified as the primary product. However, catalysts containing Zn and Co displayed the formation of propylene and C1 to C3 paraffins. The catalyst with Fe exhibited the highest deactivation and a significant decrease in acidity, attributed to the formation of extra-framework aluminum, resulting in exclusive ethylene production.

Chemical and Physical Characterization of Three Oxidic Lithological Materials for Water Treatment

Water treatment necessitates the sustainable use of natural resources. This paper focuses on the characterization of three oxidic lithological materials (OLMs) with the aim of utilizing them to prepare calcined adsorbent substrates for ionic adsorption. The three materials have pH levels of 7.66, 4.63, and 6.57, respectively, and organic matter contents less than 0.5%. All of the materials are sandy loam or loamy sand. Their electric conductivities (0.18, 0.07, and 0.23 dS/m) show low levels of salinity and solubility. Their CEC (13.40, 13.77, and 6.76 cmol(+)kg) values are low, similar to those of amphoteric oxides and kaolin clays. Their aluminum contents range from 7% up to 12%, their iron contents range from 3% up to 7%, their titanium contents range from 0.3% to 0.63%, and their manganese contents range from 0.007% up to 0.033%. The amphoteric oxides of these metals are responsible for their ionic adsorption reactions due to their variable charge surfaces. Their zirconium concentrations range from 100 to 600 mg/g, giving these materials the refractory properties necessary for the preparation of calcined adsorbent substrates. Our XRD analysis shows they share a common mineralogical composition, with quartz as the principal component, as well as albite, which leads to their thermal properties and mechanical resistance against abrasion. The TDA and IR spectra show the presence of kaolinite, which is lost during thermal treatments. The results show that the OLMs might have potential as raw materials to prepare calcined adsorbent substrates for further applications and as granular media in the sustainable treatment of both natural water and wastewater.

Dietary burden of phosphorus and aluminum in ready-to-eat wheat flour tortillas exceed that of corn tortillas: Implications for patients with renal or cardiovascular disease.

Ready-to-eat, shelf-stable tortillas contain several phosphorus- and aluminum-containing additives that may increase the risk of adverse events in patients with chronic kidney disease (CKD). The present study analyzes and compares the elemental content of wheat flour and corn tortillas with special reference to dietary aluminum and phosphorus burden. Twenty-one elements were quantified by ICP-MS and ICP-OES in 14 corn and 13 wheat flour tortilla brands purchased from local supermarkets in Southern California. The aluminum and phosphorus concentrations of many ready-to-eat tortilla brands can present a daily dietary load of up to approximately 100 mg aluminum and 700 mg phosphorus based on an average daily tortilla intake of 330 grams. Ready-to-eat wheat flour tortillas generally had more phosphorus than corn tortillas. Tortillas with aluminum listed as a food additive contained a higher aluminum content than those without such listing, exceeding the tolerable weekly intake. Despite conventional wisdom that CKD patients should avoid phosphorus-rich corn tortillas, ready-to-eat wheat flour tortillas consistently had a higher aluminum and phosphorus content due to additives. CKD patients and healthcare providers should pay attention to food labels, and regulatory authorities should monitor the use of approved food additives and mandate food label warnings for patients at risk.

COMPARATIVE ANALYSIS OF EFFECTIVENESS OF POLVAK 15/72 AS A COAGULANT FOR DRINKING WATER PRODUCTION

New coagulant Polvak 15/72 consisting of aluminum hydroxychloride with a pure Al2O3 content of at least 15.3 wt % was investigated as a possible highly effective agent for discoloration, clarification, and cleaning the natural freshwater to produce high-quality drinking water. Water was taken from the river of Dnipro during the winter-summer period of 2022. A 20 mg dm-3 coagulant concentration showed sufficient water cleaning effectiveness, and brought its chromaticity, turbidity, permanganate oxidizability, aluminum and iron contents within the sanitary limits. This result has been achieved using a coagulant that does not consist of Fe (for which the toxicity is higher than that of Al) and less Al than in the widely used Polvak-68. The effectiveness of removing trihalomethanes (THM, mostly chloroform) by Polvak 15/72 is insufficient, and additional non-polar adsorbent or the use of a chlorine-free water disinfection technology is required to keep the content of THM within the sanitary limits.

LLDPE/TiO2 composites with high UV aging resistance and mechanical properties by controlling the alumina coating on TiO2

AbstractFor preparing high performance LLDPE film, the photocatalytic activity and the UV absorption capacity of TiO2 were regulated by the alumina coating content on the surface of TiO2. Alumina‐coated TiO2 was prepared by the chemical liquid deposition method, and characterized by element analysis, TGA, FTIR, and morphology observation. The alumina coating layer had been proven to covalently bind to the surface of TiO2 through AlOTi bonds, which formed a continuous and dense coating layer, followed by forming a loose flocculent coating layer with the increase of alumina content. The alumina coating layer could significantly reduce the formation of carbonyl group on the LLDPE chains, and enhance UV aging resistance of LLDPE by inhibiting the photocatalytic activity of TiO2. Moreover, the dispersion of alumina‐coated TiO2 in the LLDPE matrix was improved. Thus, the transmittance of LLDPE/alumina‐coated TiO2 composites was reduced and the whiteness was improved. Importantly, the continuous and dense alumina coating layer was enough to inhibit the photocatalysis effect of TiO2 on LLDPE. The further increase of alumina coating content reduced the UV absorption capacity of alumina‐coated TiO2 and its compatibility with the LLDPE matrix. Therefore, the best alumina coating content on the surface of TiO2 was 1.46 wt% for preparing high performance LLDPE/TiO2 composites.Highlights Alumina‐coated TiO2 with controllable coating thickness was successfully synthesized. LLDPE/alumina‐coated TiO2 has excellent UV aging resistance and mechanical properties. The photocatalytic activity and UV absorption capacity of TiO2 could be regulated. 1.46 wt% of alumina coating is the best content for high performance LLDPE/TiO2 composites.

Characterization of Jurassic mudstones of the Northwest Caucasus as a raw material for clinker tile production

The article characterizes Jurassic mudstones of the North-West Caucasus as a potential raw material for the production of clinker tiles with water absorption of less than 3%. It is noted that traditional for the south of Russia raw materials for the production of ceramic bricks and tiles in the last centuries were various types of loams, which are widely distributed almost throughout the territory. However, for a number of reasons, they cannot be considered as raw materials for the production of clinker tiles, for which there has been a steady demand in recent years, especially on the Black Sea coast. Geographically, the Jurassic sediments in the Krasnodar region are traced in a wide strip (50–100 km) at a distance of 20 to 60 km from the coast. These are the oldest rocks in the region. The thickness of numerous mudstones varies from a few to many tens of meters. The chemical composition of mudstones is characterized by the content of aluminum oxide from 17 to 22 %, increased content of potassium oxide and iron oxides. The mineral composition is represented by hydrous mica, kaolinite and chlorite with admixture of quartz and feldspars. Pre-firing properties of argillites can be regulated by the degree of grinding. In terms of sinterability, argillites are qualified as a strong-medium sintering raw material of low-temperature sintering with high strength of ceramic stone. The results and analysis of the obtained data allow us to assert that the Jurassic mudstones of the North-West Caucasus are potentially suitable raw materials for production of clinker tiles with a wide range of physical and technical properties using a simplified technology.

Facile Determination of Aluminum Content in Industrial Brine by Investigating the Effects of Buffer Systems.

The aluminum content of concentrated (27 wt%) sodium chloride solutions could be crucial for large-scale chlor-alkali-based industries applying membrane cell electrolysis. Thus, a facile method which enables a fast and reliable protocol to determine the Al content of these solutions on ppb scale in industrial environments is fundamentally important. It was demonstrated that the increased sensitivity of colorful Al-ECR (eriochrome cyanine R) complex by the use of a cationic surfactant and specific biological buffers could effectively indicate the Al content in an extended pH interval of a concentrated saline medium under industrial conditions. The dependence of the analytical protocol on pH, temperature, time, wavelength, and the salinity of the medium was investigated. It was shown that the absorbance-based measurements of the solution should be performed at least 2-4 h after its preparation. By applying the selected two Good's buffers (HEPES: 4-(2-hydroxyethyl)-1-piperazineethanesulfonic acid, MOPS: 3-(N-morpholino)-propanesulfonic acid) and Tris (tris(hydroxymethyl)aminomethane), 32.8-38.1 % increase in the sensitivity was achieved for saturated NaCl solutions. Moreover, the limits of detection and quantification (LOD, LOQ) were also lowered by 19.0-29.8 %, and the salinity dependence of the calibration was also reduced.

An advanced ceramifiable organic-inorganic hybrid polysiloxane coating with superior moisture-resistant property

A ceramifiable organic-inorganic hybrid polysiloxane, prepared via a straightforward solution blending method, was successfully coated on the surface of silicon dioxide ceramic via a scrapping method. A uniform and dense lithium aluminum borosilicon (LABS) vitrified layer in situ formed on the surface of silicon dioxide ceramics was successfully prepared through liquid phase filling method to fulfill the moisture resistance requirements under high temperature cycle conditions. Effects of aluminum content on the microstructure change process and moisture resistance properties of the ceramifiable organic-inorganic hybrid polysiloxane have been systematically researched. With the increase of aluminum content, the ceramic yield of the hybrid polysiloxane and the heat loss capacity of LABS glass-ceramics increase. The crack-free and high temperature fluid vitrified layer endows the LABS glass-ceramic with excellent thermal shock resistance cycle ability, self-healing ability and moisture resistance. Results showed that the LABS vitrified coating with an aluminum-boron ratio of 1:2 presents the most appealing thermal shock cycle resistance and crack self-healing ability after 20 thermal cycles, as well as a water absorption rate of 0.3814 %. By refining the application of modified polysiloxane moisture-resistant coatings in high-temperature circulation environments, this work shed lights on the importance of in situ growth LABS vitrified coating in accelerating surface reconstruction and improving moisture resistance, incenting additional innovative breakthroughs in the LAS-based glass-ceramic materials design and fabrication within the aviation field.

Structural, optical and dielectric properties of (AZT) aluminum doped zinc titanate nano-composites

Aluminum-doped Zinc Titanate (AZT) AlxZn1-xTiO3 ( for x= 0.20,0.40,0.60,0.80) nanoparticles are synthesized through low temperature hydrothermal method and their physical properties such as structure, surface, energy gap and dielectric characteristics were investigated using X-ray diffraction (XRD), Field Emission Scanning Electron Microscopy (FESEM), Transmission Electron Microscopy (TEM), UV-visible spectroscopy and impedance analysis. XRD analysis indicated structural transformation of tetragonal phase for samples of x = 0.20 to 0.60 and some secondary phases for x=0.80. It was found that lattice constants of the sample decrease with increasing aluminium content. The morphology of nano-composites, as evidenced by FESEM and TEM imaging, displayed the formation of nano-spheres and nano-rods. The impedance and dielectric modulus analysis for the current samples revealed their dielectric behaviour, microstructure and conduction procedure. However negative dielectric property was seen in nano-composite with x=0.60. All samples with x ranging between 0.2 to 0.8 displayed high ac-electrical conductivity at 1 MHz frequency. These samples are well suitable for charge storage capacitors and as perfect absorbers.

Preparation of high-strength and low-shrinkage composite salt cores by binder jetting and vacuum impregnation

ABSTRACT Binder jetting (BJ) technology was employed combined with vacuum impregnation to fabricate alumina-reinforced Na2SO4-NaCl water soluble composite salt cores (WSCSC), intended for manufacturing aluminum alloy castings featuring intricate cavity structures. The bending strength and sintering shrinkage rate of WSCSC were investigated to discern the influences of alumina content, vacuum impregnation pressure and time, accompanied by a detailed analysis of the microstructure and reinforcement mechanism. The findings reveal that WSCSC containing 40 wt.% alumina exhibits exceptional mechanical properties, demonstrating a bending strength of 29.13 MPa, which is 197% higher than that of WSCSC without alumina. Furthermore, when the vacuum impregnation of saturated brine is conducted at a pressure of 30 KPa for 90 s, the resulting WSCSC possesses a sintering shrinkage rate of 4.94%, reflecting a significant reduction of 73.5% compared to that of WSCSC without vacuum impregnation treatment. Microstructural analyses show that alumina, as a stable secondary phase, can refine the NaCl grains within WSCSC, deflecting cracks and elongating their propagation paths, thereby remarkably enhancing the bending strength. Moreover, the fine inorganic salt particles crystallized and precipitated from saturated brine during the drying process are filled in the internal pores of WSCSC through vacuum impregnation, dramatically reducing the sintering shrinkage rate. Ultimately, the high-strength and low-shrinkage WSCSC parts were successfully manufactured.

Damage and Recovery Behavior of Low-Replacement-Rate Fly Ash Concrete after Different High-Temperature Exposures.

This study focuses on investigating the strength recovery of fire-damaged fly ash concrete (FAC) with a low substitution rate of 10% through post-fire curing. The chemical and microstructural changes were analyzed using X-ray diffraction (XRD), derivative thermogravimetry (DTG), scanning electron microscopy (SEM), energy dispersive X-ray spectrometry (EDS), and nitrogen adsorption. The findings indicate that the incorporation of fly ash slightly enhanced the strength after exposure to 400 °C; this was attributed to improved pozzolanic reactions, which were not observed at higher temperatures of 600 °C and 800 °C. Moreover, a positive effect on the recovery of compressive strength was observed due to the pozzolanic reaction. However, due to the relatively low fly ash content, depletion occurred at a later age, resulting in the inability to inhibit microstructural damage caused by the production of portlandite, thereby weakening the compressive strength. Interestingly, fly ash influenced the morphology of calcium carbonate and calcium silicate hydrate crystals, which is potentially ascribed to the role of high aluminum content acting as a crystallization-guiding agent.

LncRNA 51A: A promising diagnostic biomarker for assessing cognitive decline in occupationally exposed aluminum workers

ObjectiveTo assess the diagnostic utility of lncRNA 51 A in detecting cognitive decline among aluminum-exposed workers occupationally. Methods921 male workers from an aluminum manufacturing facility underwent cognitive assessments, measurement of plasma aluminum levels and quantification of lncRNA 51 A levels. Receiver Operating Characteristic (ROC) curves were constructed to assess the diagnostic potential of lncRNA 51 A. Bayesian network model was utilized to predict the likelihood of cognitive decline among the study population. ResultsSignificant differences in lncRNA 51 A levels, plasma aluminum concentration and MMSE scores were observed between cognitive normal and decline groups. The lncRNA 51 A expression was negatively correlated with MMSE scores. The area under the curve (AUC) was 0.894, with 89.3 % sensitivity and 73.9 % specificity. The Bayesian network model indicated varying probabilities of cognitive decline based on lncRNA 51 A expression levels. ConclusionPlasma lncRNA 51 A shows potential as an excellent biomarker for cognitive decline diagnosis in aluminum-exposed workers.

The oxide films formed under the low oxygen pressure in a particular system containing competing chromium and aluminium

AbstractIn this paper, pre‐oxidation treatment was carried out at 950 °C under oxygen pressure of 10−16 atm for nickel‐10 % chromium‐x % aluminium‐1 % silicon‐0.5 % yttrium(x=0 wt.–%, 1 wt.–%, 3 wt.–%, 5 wt.–%) alloys. Morphology and structure of oxide layers on the alloys after pre‐oxidation were analyzed by scanning electron microscopy and electron discharge spectroscopy. The results showed that a chromium oxide film was formed on the surface of the alloy without aluminium addition, while the oxide layer on the surface of the alloy with aluminium addition gradually transformed into M2O3 (M=aluminium and chromium) oxide film. The oxidation behavior was analyzed by means of chemical thermodynamics, and it was seen that because the interaction coefficient,εijof aluminium and chromium is a positive value, the increase of aluminium addition will strengthen the interaction and increase the diffusion coefficient,Diof aluminium and chromium. The diffusion of chromium and aluminium in each other therefore promotes their interaction, which is beneficial to the formation of the outer oxide film. Thus, with the increase of aluminium addition, the thickness of the outer oxide film gradually increased, and the aluminium content in M2O3 (M=aluminium and chromium) increased significantly, and with 5 % aluminium added, the aluminium oxide of the outer oxide film became the main body.

Zn-Al Ferrite/Polypyrrole Nanocomposites: Structure and Dielectric and Magnetic Properties for Microwave Applications.

In this study, Zn-Al ferrite/polypyrrole (PPy) nanocomposites were synthesized and thoroughly characterized to explore their potential for microwave applications. X-ray diffraction analysis confirmed the presence of ZnO, AlFeO3, and Fe2O3 phases, with the crystal size decreasing from 31 nm to 19.6 nm as aluminum content increased. High-resolution transmission electron microscopy (HR-TEM) revealed a distinctive core-shell morphology, where the polypyrrole encapsulates the ZnAlxFe2-xO4 particles. Magnetic measurements showed that decreasing aluminum concentration led to a reduction in both saturation magnetization (Ms) from 75 emu/g to 36 emu/g and remanent magnetization (Mr) from 2.26 emu/g to 2.00 emu/g. Dielectric analysis indicated that both the real (ε') and imaginary (ε″) components of dielectric permittivity decreased with increasing frequency, particularly between 10 and 14 GHz. Furthermore, electrical modulus analysis highlighted the significant impact of aluminum doping on relaxation time (τIP), indicating the presence of interface polarization. Impedance spectroscopy results underscored the dominance of interface polarization at lower frequencies and the presence of strong conduction paths at higher frequencies. These combined magnetic and dielectric loss mechanisms suggest that the Zn-Al ferrite/polypyrrole nanocomposite is a promising candidate for advanced microwave absorption applications.

Assessment of the environmental impacts of utilizing coal ashes and OPC for soil stabilization applications: Leachate analysis in response to rainfall interaction

The construction industry is a leading sector for coal ashes utilization, including in cement manufacturing and soil stabilization applications. In soil stabilization, coal ashes, alongside Ordinary Portland Cement (OPC), are the most commonly used materials. However, the environmental impact of coal ashes, particularly the leaching of heavy metals from stabilized soil when exposed to rainfall, remains underexplored. There is a notable gap in assessing the environmental impacts of this utilization, particularly when the stabilized soil interacts with rainfall in real-world scenarios. Therefore, this study aimed to contribute to filling this gap. Accordingly, in this study, peat soil was stabilized by using fly ash, bottom ash, and OPC. The characterization of soil mixture materials, including physicochemical and engineering properties, was established and studied first. Following the environmental impact, simulations were conducted using a column to study soil leachate under different conditions and seasons (dry and wet) in response to its interaction with rainfall. The leachate was analyzed using Inductively Coupled Plasma Mass Spectrometry (ICP-MS) to measure the concentrations of heavy metals, including copper (Cu), aluminum (Al), manganese (Mn), iron (Fe), and zinc (Zn). Additionally, Ion Chromatography (IC) was employed to determine the concentrations of major anions, including fluoride (F⁻), chloride (Cl⁻), nitrate (NO₃⁻), phosphate (PO₄³⁻), and sulfate (SO₄²⁻). The findings revealed the complex interaction of the chemical stabilization processes and environmental factors with the leaching behavior of heavy metals and anions, highlighting the significant impact of stabilization on leaching patterns. To conclude, this study provides a valuable contribution to understanding the environmental and engineering implications of utilizing coal ashes in soil stabilization.

Preparation of polymeric aluminum chloride from secondary aluminum dross and its water purification effect

ABSTRACT Aluminum dross is solid waste generated by the aluminum industry. Currently, a large amount of aluminum dross is produced annually year. Aluminum dross, a hazardous waste, contains harmful substances such as aluminum metal, aluminum nitride, fluoride and chlorine salts, which pose a serious threat to human health and also cause damage to the ecological environment. Thus, it is important to recycle secondary aluminum dross and realise its high-value utilisation. Polymeric aluminum chloride (PAC) is a polymer flocculant, at present, China's annual use of PAC in the field of water treatment is about 5 × 105 t, and with the continuous improvement of water purification requirements, the annual use of PAC increased year by year. Here secondary aluminum dross was used as a raw material to prepare PAC by hydrochloric acid (HCl) leaching, followed by the addition of sodium carbonate. The optimal conditions for the acid leaching of secondary aluminum dross for the preparation of PAC were as follows: HCl concentration, 18%; liquid-to-solid ratio, 4.5:1; stirring rate, 200 r/min; reaction temperature, 90 °C; and 60 min. An aluminum leaching rate of 85.5% was obtained under these conditions. The results showed that the acid leachate after adding sodium carbonate, under the conditions of polymerisation temperature of 70 °C, polymerisation time of 6 h, and polymerisation pH value of 3.0, the PAC prepared had an alumina content of 10.19%, salinity of 32.37%, density of 1.32 g/cm3, 1% aqueous solution pH 4.3. The water purification effect of the prepared PAC surpassed that of the commercially available PAC. The utilisation of secondary aluminum dross can reduce the environmental pollution caused by aluminum slag.

Ultrasonic powder consolidation of metallic glass/Al-6061 composites

Traditional powder consolidation methods for fabricating metallic matrix composites often require high temperatures, high pressures, and substantial energy consumption. Therefore, developing new processing technologies that can manufacture composites rapidly, efficiently, and economically is crucial. This study introduces ultrasonic powder consolidation process as a novel strategy for fabricating and tuning metallic glass (MG) and aluminum alloy composites. By optimizing the mass ratios of Zr55Cu30Ni5Al10 (at.%) MG to Al-6061 powders, a diverse range of composites with tailored compressive strength and plasticity was achieved. Mechanical testing showed that increasing the aluminum content improved plasticity while maintaining significant strength. Notably, the composite with a 5:5 mass ratio exhibited the best balance of mechanical properties. Morphological characterizations demonstrated excellent densification and uniformity in the composites, with no visible defects and relative densities ranging from approximately 92 %–99 %. Detailed microstructural analysis revealed the formation of a well-bonded interface with a diffusion layer, confirming the metallurgical bonding was facilitated by ultrasonic vibration. Furthermore, the ultrasonic consolidation process enabled the successful fabrication of complex shapes, such as star and gear components, demonstrating the method's potential for advanced manufacturing. These results show that the ultrasonic powder consolidation process is a viable and efficient approach for producing high-quality MG/Al-6061 composites with enhanced mechanical performance and application versatility.