Aluminium Hybrid Metal Matrix Composites Research Articles

A hybrid GRA-PCA-TOPSIS Technique Optimization of EDD Process Parameter on Drilling of AL8011/B4C/aloevera composites

A class of cutting-edge materials called hybrid aluminum metal matrix composites has been produced for applications such as the automobile, aerospace, and electronics industry and where weight and strengths are crucial factors. In the present research work, AA8011 composite reinforced with boron carbide particles and green aloevera has been fabricated using an economical stir casting process. In this 1% to 3% of boron carbide and 1% to 2% aloevera were used to fabricate the three different combinations of composites. The electrical discharge drilling process variables such as discharge current, pulse-on time, pulse-off time, and dielectric fluid pressure are investigated using the tubular copper electrode on drilling of hybrid composites. Performance aspects including drilling rate, roundness error, taper angle, and electrode wear rate have been analyzed, and the effect of process variables with the response surface methodology–central composite experimental design. The process parameters during the drilling of composites were optimized using a novel multi-criteria decision-making technique called the hybrid grey relational analysis–pulse component analysis–technique for order of preference by similarity to ideal solution method in order to maximize the drilling rate while concurrently minimizing other aspects. The optimum conditions were reached using the hybrid optimization method and a 1.5 mm tubular copper electrode with an input current of 9 Ampere , pulse on time 25 [Formula: see text]s, pulse off time 12 [Formula: see text]s, and pressure 60 kg/cm2. In comparison to the initial settings, the optimal condition shows a 25% faster drilling rate, with a 23% better roundness value, 14% lesser taper angle, and 7% lesser electrode wear rate.

Tribological Behavior of Hybrid Aluminum-TiB2 Metal Matrix Composites for Brake Rotor Applications

This research investigates the feasibility of hybrid aluminum metal matrix composites (MMC) incorporating TiB2 particles for brake rotor applications. The composites were produced by incorporating both in-situ, submicron-sized TiB2 particles and regular micron-sized TiB2 powders via stir and squeeze casting techniques into a A206 aluminum alloy matrix. Systematic adjustments in the fractions of in-situ and ex-situ TiB2 particles were conducted to evaluate their impact on wear behavior and mechanisms. Combination of both particle types allowed composites with up to 10 vol% of reinforcements. Composites with higher proportions of ex-situ particles demonstrated increased wear resistance compared to those solely composed of in-situ particles, control specimens without TiB2, and conventional cast iron counterparts. The lowest wear rate for the hybrid composites sliding against phenolic brake pads was 1.1 x 10-5 mm3/Nm, signifying a 3-fold reduction relative to cast iron sliding against the same pads. Wear analysis elucidated distinctive mechanisms within the hybrid composites, characterized by mild fragmented abrasive wear, adhesive wear, and plastic deformation, accompanied by the formation of an intermixed tribo-oxide layer.

An experimental analysis of sugarcane-based hybrid aluminium metal matrix composites through powder metallurgy

An experimental analysis of sugarcane-based hybrid aluminium metal matrix composites through powder metallurgy

An investigation of machinability in micro-EDM drilling of ZrB2/Fly ash/AA7075 hybrid aluminium metal matrix composite

This work investigates the importance of micro-drilling in Hybrid aluminum metal matrix composites (HAMMCs), particularly for the aerospace and automotive industries. The HAMMCs (AA7075/5% ZrB2/2% fly) ash was fabricated using the ultrasonic assisted stir casting method. Taguchi’s design of experiments is employed to optimize the material removal rate (MRR) and tool wear rate (TWR). Analysis of variance (ANOVA) is then used to determine the significance of the model. The study also utilizes a hybrid artificial neural network-genetic algorithm (ANN-GA) approach to optimize both MRR and TWR. By optimizing machining processes for HAMMCs, manufacturers can achieve high-precision micro holes. The optimal input parameters were found to be a feed rate of 10 μm sec−1, a capacitance of 1 nF, and a voltage of 85 V, achieving the minimum TWR and maximum MRR.

Optimization study of hybrid aluminium metal matrix composite using proposed Taguchi method

Optimization study of hybrid aluminium metal matrix composite using proposed Taguchi method

Synergistic approach to tribological characterization of hybrid aluminum metal matrix composites with ZrB2 and fly ash: Experimental and predictive insights

This research delves into the tribological performance of hybrid aluminum metal matrix composites (HAMMCs) incorporating zirconium diboride (ZrB2) particles and fly ash as reinforcing agents. The study employs a linear reciprocating wear test to investigate the impact of dry sliding wear on these HAMMCs under ambient and elevated temperatures. Wear mechanisms are discerned through field emission scanning electron microscopy. Optimization of wear test parameters, coefficient of friction (COF), and wear rate is achieved using the genetic algorithm. Additionally, artificial neural network (ANN) and multiple linear regression analysis are employed to formulate a predictive model for wear, estimating specific wear rate and COF under various testing conditions. The ANN predictions exhibit a deviation ranging from 0% to 1.39% from the experimental values, indicating the model's effectiveness in understanding and predicting wear behavior in the study of HAMMC.

Advances in hybrid aluminium metal matrix composite produced by stir casting route: A review on applications and fabrication characteristics

The sustained demand for lightweight parts, superior strength, and high-efficiency products has made material researchers interested to study and explore new materials with superior properties. One of the most promising materials for meeting this demand is aluminium metal matrix composite. Due to its tailored properties, the usage of composite is currently increasing in the automotive, aerospace, marine, electronic, defence, domestic, and sports sectors. Simplicity, affordability, and bulk production in the stir casting method have attracted the attention of many researchers across the globe. This paper reviews the need for hybrid aluminium metal matrix composites, various aluminium alloys, and reinforcement materials produced by the stir casting technique. In addition, the applications, morphological, mechanical, and tribological behavior of aluminium hybrid metal matrix composites are discussed. This review will assist materials researchers in selecting the matrix and reinforcements for a specific application of aluminium matrix composites using the stir casting route.

Fabrication and investigation of microstructural, mechanical and wear properties of in situ ZrB2/fly ash/AA7075 hybrid composite

This research explores the microstructural, mechanical and wear characteristics of hybrid aluminum metal matrix composites (HAMMCs). Initially ZrB2 is fabricated by melt reaction and then fly ash incorporated into the aluminum composite melt as secondary reinforcements to fabricate HAMMCs through the ultrasonic agitated stir casting method. Micrographic and phase analysis of the HAMMCs and base alloy is conducted x-ray Diffraction (XRD), and Energy-Dispersive x-ray Spectroscopy (EDS). A wear test was conducted to study the wear properties of alloy and hybrid composite material. The generated wear scar was analyzed using a profilometer to find the wear rate. The tensile strength and hardness of the hybrid aluminum metal matrix composites (HAMMCs) improved remarkably as compared to base alloy. The wear resistance of the fabricated composite also increases on increasing the in situ ZrB2 up to 3 weight fractions.

A critical review on the effect of various sustainable reinforcements on armor grade aluminum alloys

To deflect projectiles with kinetic energy by blunting them upon impact, armor with an exceptionally hard surface is required.In order to absorb and disperse the projectile's kinetic energy, the next material needs to be exceedingly tough and have a high work of fracture; hence, it needs to be metallic. To maximize the strength to weight ratio, it must also be composed of a versatile material, such as ceramic. Thus, the application requires a range of qualities, ranging from ceramic to metallic. Aluminum alloys (AAs) are sought-after materials for a variety of engineering and defense uses owing to their excellent low-temperature characteristics, good specific strength, and acceptable corrosion resistance. The main issues with AAs are poor heat tolerance and wear resistance, which makes them unsuitable for military applications owing to their heavy weight, which can exacerbate the deterioration of mechanical components and impair vehicle maneuverability and speed. This paper offers the possibility of modifying the properties of monolithic aluminum materials by adding reinforcement and replacing conventional particulates with low-cost wastes derived from agriculture and industry, which are rich in oxides and other debris, such as fly ash (FA) and rice husk ash (RHA). The result is the development of hybrid aluminum metal matrix composites, or HAMMCs, which combine the best features of both metals with a variety of sustainable inorganic and organic reinforcements that can enhance the mechanical and tribological performances by 40–62 % in comparison to the basic matrix. So, they can be tailored to meet the needs that make their performance superior compared to unreinforced AAs. Through a review of existing literature, this paper will provide an outline of the effect of various kinds of reinforcements on armor-grade aluminum alloys.

Synergistic effect of different high-performance fibers on the microstructural evolution and mechanical performance of novel hybrid metal matrix composites produced via friction stir processing for automotive applications

The present study aims to produce novel hybrid metal matrix composite (HMMC’s) material using a mixture of reinforcement (basalt, E-glass, and carbon fibers) in long, chopped, and flakes form via Friction Stir Processing (FSP) techniques. Subsequently, the effect of hybrid reinforcement on microstructural evolutions, mechanical performance, and the fracture mechanism of HMMC’s was investigated. The results demonstrated that hybrid reinforcement synergistically enhanced the tensile, flexural, and impact performance of FSPed HMMC’s compared to monolithic composites (non-hybrid) and received base metal (BM). The long fiber-reinforced hybrid aluminum metal matrix composites (HL) show a ~156% increment in tensile strength and ~196% increment in impact strength, while flakes-reinforced hybrid aluminum metal matrix composites (HF) show a ~101% increment in flexural strength compared to the BM. The field emission scanning electron microscopy (FESEM) analysis demonstrated a homogeneous dispersion of reinforcement and an excellent interfacial bonding of fibers with the aluminum matrix in the fabricated composites. The validation of element distribution and composition within the composites was confirmed using FESEM elemental mapping and energy-dispersive X-ray spectroscopy (EDS) spectrum.

Numerical and experimental investigation of the mechanical properties of MWCNT/RHA reinforced AlP0507-based hybrid aluminum metal matrix composites

Numerical and experimental investigation of the mechanical properties of MWCNT/RHA reinforced AlP0507-based hybrid aluminum metal matrix composites

Enhancing friction and wear performance in hybrid aluminum composites through grey relational analysis

Hybrid aluminum metal matrix composites (AMMCs) include qualities including being lightweight, very effective, and highly resistant to wear, and corrosion. The process used in this study to maximize friction and minimize wear of hybrid AMMCs involves applying grey relational analysis (GRA) to optimize the process features. Stir-casting was used to create hybrid AMMCs of the Al-6061 alloy reinforced with graphene (Gr) and silicon carbide (SiC). The experiment used Taguchi's L27 design, and three process parameters—normal load, sliding distance, and sliding speed—were combined with GRA to produce the maximum coefficient of friction and lowest wear rate. Al-6Gr-6SiC obtained the maximum hardness of 128 VHN and 253 MPa as tensile strength, further coefficient of friction, and wear were analyzed for the same composite., respectively. The ideal mixture of graphene (6 weight percent) and silicon carbide (6 weight percent) as reinforcement in Al-6061 alloy obtained the optimum value of frictional coefficient (0.29766) and wear (0.002588 mm3/m), respectively.

Experimental Studies on Microstructural, Physical, and Mechanical Characterizations of Hybrid Aluminium Metal Matrix Composites Incorporated with Cenosphere and Molybdenum Disulphide

This study addresses a research gap in composite material development by exploring the potential of innovative waste materials to enhance performance. An innovative and cost‐effective waste material serves as a reinforcing agent, with cenosphere and molybdenum disulphide used in proportions ranging from 0% to 4%. Employing a cost‐effective stirring cast technique, composites are fabricated, combining AA7075 alloy with cenosphere particles (AA7075/cenosphere) and molybdenum disulphide particles (AA7075/MoS2). The experimental design, utilizing a central composite design within the response surface methodology framework, examines the weight percentages of cenosphere and MoS2. Scanning electron microscopy reveals strengthening chemicals within the matrix, confirmed by electronic dispersive X‐ray spectroscopy for individual reinforcements in the aluminium alloy matrix. Density determination follows Archimedes’ principle and the OIML G14 standard, while mechanical properties (hardness and ultimate tensile strength) are assessed per ASTM standards. Results demonstrate a significant reduction in composite density with cenosphere reinforcement, while molybdenum disulphide marginally affects density. The incorporation of reinforcements notably enhances both hardness and ultimate tensile strength. In conclusion, this research bridges a composite material development gap, presenting a novel and sustainable approach. By showcasing the potential of unconventional waste materials, the study contributes valuable insights to material science and engineering, opening new avenues for future research.

Review On Development, Nanoparticle Reinforcement and Sustainable Materials For Enhancement Of Mechanical Properties In Aluminium Hybrid Metal Matrix Composites

Aluminium alloys are popular in many advanced applications and are considered to be an essential class of engineering materials mainly due to their desirable combination of low density, high strength, and cost-effectiveness compared to competing materials. Aluminium metal matrix composites and hybrid metal matrix composites will further enhance these properties by incorporating hardened particles as reinforcements. Hybrid metal matrix composites are second-generation composites that exhibit superior mechanical properties due to the synergistic combination of different reinforcement combinations. Various combinations of reinforcing particulates are being explored. The fabrication of the hybrid composites is done using a stir casting route, which will significantly influence the mechanical properties, microstructure and reinforcement distribution. Aluminium HMMCs offer lightweight, high strength, good wear resistance, and other properties that allow them to be extensively used in the structural, aerospace, marine, and automotive industries. Hybridization of metal alloys provides flexibility in designing components and quality control during manufacturing. Thus, this review paper is focused on the fabrication and characterization of hybrid Aluminium metal matrix composites, advancements in their mechanical properties, recent developments and applications.

Identification of tool wear and surface morphology measurements in sustainable milling of Al 6082 hybrid metal matrix composite

Aluminium hybrid metal matrix composites have significantly increased in many advanced applications owing to their unique properties. However, these hybrid composites are difficult to machine because of hard reinforcements in the matrix. After identifying the optimum cutting conditions, it's crucial to identify the tool wear mechanisms to keep surface roughness within the desired range, especially with hybrid composites. Hence, the present work mainly focuses on identifying the wear mechanism of PVD-coated TiAlN cutting tool inserts during the end milling of Al 6082 hybrid metal matrix composites. MQL, CO2, and a combination of MQL + CO2 cooling conditions were employed over the cutting zone to decrease tool wear. In the context of 300 mm of cutting length, employing CO2, MQL, and MQL + CO2 conditions led to a significant reduction in tool wear by 34.5 %, 50.1 %, and 74.7 %, respectively, compared to dry cutting. The results showed that the MQL + CO2 condition produced better results than the other cooling conditions, improving tool life and surface quality.

Numerical simulation of linear reciprocating wear mechanism of hybrid aluminum metal matrix composite using finite element method

This work aims to analyze the wear properties of the hybrid aluminum metal matrix composites (HAMMCs) using finite element analysis (FEA). A dry sliding linear reciprocating wear mechanism is analyzed using ANSYS 19.1. Aluminum 7075 alloy and HAMMC reinforced with ZrB2 (1, 3, and 5 wt.%) and fly ash (2 wt.%) is taken as sample material. A steel ball (EN 52100) is utilized as a counterpart in the dry sliding wear properties study. The deformation of the steel ball during the wear process is assumed to be negligible. Under various circumstances, a 3D point-to-surface connection is built to analyze the dry sliding wear process. The wear depth, contact pressure, and wear volume are analyzed using FEA. The analytical results are compared with the experimental results with the help of ANSYS to analyze the process parameters. The ANOVA analysis is employed for optimization, which exhibits that the load had the most significant impact on the material’s wear rate, followed by the material’s composition and temperature. The wear depth, wear rate, and contact pressure at optimum input parameters for the HAMMCs are 0.47 μm, 11.31 × 10−6 mm3 Nm−1, and 0.33 MPa, respectively. The Simulated results support the experimental results, and the average error is 9.82%.

A comparative study on multi-objective optimization of drilling of hybrid aluminium metal matrix composite

A comparative study on multi-objective optimization of drilling of hybrid aluminium metal matrix composite

Fabrication of Aluminium Hybrid Metal Matrix Composite Reinforced with Silicon Carbide and Graphite by Stir Casting Method

The AA2014/SiC/Gr hybrid metal matrix composites are developed with addition of 0.5% to 1.5% SiC particles (weight fraction) in 0.5% weight fraction interval and the graphite (Gr) is 1% weight fraction constant for all composites were prepared by stir casting method. The effects of SiC and Gr on the microstructural and mechanical properties of the base cast and hybrid composites were studied by SEM, hardness, and impact tests. The results indicate that mechanical properties of the aluminium hybrid metal matrix composites (AHMMCs) change according to their increment of SiC and Gr particle. The hardness and impact strength of base cast and hybrid composites increased during the addition of SiC and Gr particle. The hardness and impact strength of base cast and hybrid composites increased during the addition of SiC and Gr particle. The maximum hardness is observed in the fourth sample with 1% Gr and 1.5% SiC with 7% increment which is 102.4 VHN. The high impact strength was observed for base alloy of 24% than hybrid composite. The composite of 1% SiC and 1% Gr is given less wear loss and coefficient of friction. The Corrosion resistance is better in the composite of 0.5% SiC and 1% Gr and the optical micrographs shows that the composite with 0.5% SiC and 1% Gr shows good texture.

Influence of Control Parameters during Drilling of Aluminum Reinforced with HNT Hybrid Matrix Composites

The current paper aims to find the optimum control parameters such as weight percentage of HNT, weight percentage of boron nitride, drilling speed, and feed rate in drilling of aluminum hybrid metal matrix composites. The aluminum matrix material are reinforced with different weight percentage of HNT (3%, 5%, and 7%) and BN (2%, 3%, and 4%). The hybrid matrix are fabricated through the sir casting technique. The prediction of process parameter are optimized using Taguchi assisted grey relation analysis. Also the ANN model is developed to predict the output parameter. Through Taguchi S/N ratio method the effect of each control parameters are optimized. The results show that the weight percentage of HNT and feed rate are the most influencing parameters which affect the drilling of developed aluminum composites. The GRA results show that the optimum parameters are 3% of HNT, 4% of BN, 500 rpm drilling speed, and 20 mm/min in combination, which has minimum surface roughness, lower temperature, highest cutting force, and highest material removal rate.

MECHANICAL AND WEAR EVOLUTION OF HYBRID Al COMPOSITES REINFORCED WITH GRAPHITE AND BLAST FURNACE PARTICLES

In this study, we tried to make hybrid aluminum metal matrix composites (AMMCs) reinforced by adding steel slag and Gr particles in it by combined powder metallurgy and press bonding process with 15% of blast-furnace slag and variable values of Gr contents. By examining the composite microstructure, the excellent distribution of particles in matrix aluminum as well as accuracy in the results, no reaction is observed between Al and particles. The obtained results showed that the wear rate and density of hybrid composite samples decreased to 2.3% and 24% by increasing the Gr volume contents, respectively. Also, the wear rate of samples which is related to the hardness value, increased by 181% by increasing the Gr content up to 10[Formula: see text]vol.%.