Aluminium Hybrid Metal Matrix Composites Research Articles

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.

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.%.

Entropy-guided VIKOR technique for optimal selection of aluminium hybrid metal matrix composites

The objective of this study is to assess the most suitable aluminum hybrid metal matrix composite through mechanical and physical characterizations utilizing the Entropy-VIKOR optimization method. To appraise the optimal composite, aluminum hybrid metal matrix composites were manufactured following the L18 Taguchi orthogonal array, which was designed by considering three levels of matrix materials, two levels of hybrid reinforcements, and three levels of weight percent of reinforcements. The production of Aluminum Hybrid Metal Matrix Composites (AHMMCs) was conducted using the stir casting process under optimal conditions and subjected to testing for mechanical and physical characterization, including hardness, tensile strength, porosity, and density. These characterizations were examined using the Entropy-VIKOR method to determine the optimum AHMMC. Ultimately, the Entropy-VIKOR optimization outcomes revealed that a 9% silicon carbide with flyash-reinforced AA5083 composite emerged as the optimal AHMMC material concerning its mechanical and physical characteristics. Finally, microstructural studies were carried out on the optimal AHMMC using a Scanning Electron Microscope (SEM) to assess the uniformity of particle distribution in the matrix. The SEM results demonstrated the uniform dispersion of reinforcement particles with no voids.

Identifying the most significant parameter in stir casting process for optimizing the effect of nano reinforcement MWCNT on AA 7075-T651

The purpose of this research is to determine the most important factors affecting the mechanical properties of hybrid aluminum metal matrix composites (MMCs). The literature review and the pilot experiments both helped to determine which variables were most and least important. The fishbone diagram visually represented the identified elements, but it ignored the meaning of the responses provided. FMEA, which stands for Failure Mode and Effect Analysis, was used to identify critical parameters from among all of the elements shown in the fishbone diagram. After that, we used a Plackett–Burman layout to narrow down the list of relevant elements and identify the most influential ones. It was found that stirring time, speed, and reinforcement were among the most crucial factors in achieving ultimate tensile strength (UTS) is high, and Hardness.

Investigation of sustainable production opportunity in fabrication of hybrid Aluminum metal matrix composites by Powder Metallurgy technique

Investigation of sustainable production opportunity in fabrication of hybrid Aluminum metal matrix composites by Powder Metallurgy technique

Machinability studies on hybrid nano-SiC and nano-ZrO2 reinforced aluminium hybrid composite by wire-cut electrical discharge machining

This paper deals about the optimization and modelling of Wire cut Electric Discharge Machining factors such as pulse OFF-Time (Toff), gap voltage (Vg) and pulse ON-Time (Ton) during machining nano- silicon carbide (nSiC) and nano-zirconium oxide/zirconia (nZrO2) reinforced in Al6061 aluminium alloy matrix. Nanomaterial is synthesis in the planetary high energy ball milling and the hybrid aluminium metal matrix composite (HAMMC) was fabricated by using the stir casting technique. For performing machinability studies on the cast composite. To design the experiments, Response Surface Methodology (RSM) based central composite design (CCD) with face-centred approach is implemented. To optimize input conditions, kerf width and surface roughness were analysed. To determine the suitability of the developed model, Analysis of Variance (ANOVA) is applied and to model the process factors regression analysis is carried out. It is observed from the results that, kerf width decreases when Toff increases and increases with increase in Ton and Vg. A decreasing trend of surface roughness is observed with increasing trend of Vg and surface roughness increase with increase in Ton increases.

Experimental Analysis on Machining Properties of Aluminum Hybrid Composite Materials

<div class="section abstract"><div class="htmlview paragraph">Hybrid Composite materials meet a major demand in current industrial market through mixture of various percentages of metal compositions at different levels. One such material, which is most widely employed, is aluminum. Aluminum hybrid metal matrix composites is substituted with conventional alloys in order to meet the rigid, high-end requirements at major industries. In this work, it is reinforced with Aluminum-Tungsten Carbide-Graphite composite and fabricated using the stir casting process. Die sinking electric discharge machining (EDM) process is preferred over conventional process for the purpose of machining complex shaped materials with accuracy. The optimization of minimizing surface roughness and maximize material removal rate is essential to increase the effective and efficient usage of hybrid composites. In this experimental work, the sensitivity of various parameters of EDM on the output responses is found using Taguchi experimental design, Multi response optimization and Analysis of variance (ANOVA) to generate the mathematical model. From the experiment, it is found that %WC = 6 %, %Gr = 3 %, I= 5A, V=50V, T<sub>OFF</sub>=50μs, is the most optimal value among others due to its meta stable bonding in improving the machining parameters to achieve optimization of minimizing surface roughness and maximizing material removal rate</div></div>

Processing of nanoreinforced aluminium hybrid metal matrix composites and the effect of post-heat treatment: a review

Processing of nanoreinforced aluminium hybrid metal matrix composites and the effect of post-heat treatment: a review

Wear Optimization of Aluminium and Hybrid Reinforcement Metal Matrix Composites Using Response Surface Methodology

Aluminum 6061 alloy-based alloys were used to make various motor vehicle parts such as connecting wire, O-ring, circular blocks, disc brakes and aircraft primary components, but the use of alloys was restricted in some of their applications due to their low strength, poor stiffness and high friction wear resistance. Hybrid Aluminium Metal Matrix Composites are achieved the potential mechanical properties compared to single reinforced composite materials. Tribological behaviour of hybrid composites were optimized by Response Surface Methodology (RSM) using Design of experiment statistical analysis. The contribution of various parameters rotational speed, sliding distance and axial load on hybrid composite materials were evaluated by Analyses of Variance (ANOVA). For each output response, a multilayer linear equation was used to examine the relationship between the parameters. According to the results, hybrid compounds provide greater adaptability and reliability in the development of a component of the product depending on the reinforcement composition and structure.

Machinability Studies on Hybrid Aluminum Metal Matrix Composites

Hybrid metal matrix composites are new invention in material science and Engineering. The hybrid metal matrix composites (Hybrid MMC’s) generally consist of two or more reinforcements in it. These hybrid MMC’s have several benefits over the single reinforcement. The presence of reinforcements in it exhibits improved mechanical, tribological and machinability properties. Aluminium-based MMC’s have made attention in recent years as engineering materials. But in some Aluminium-based MMC’s the use of single reinforcement may sometimes lead to weakening in its physical properties. Conversely, to overcome the problem of single reinforced composites, the idea of the use of two different types of reinforcements is being explored in the Aluminium matrix. In the hybrid MMC’s, generally one of the reinforcements will be a hard phase and the other reinforcement being a soft lubricating phase. Hard reinforcements such as TiO2, Al2O3, SiC, etc. will improve the hardness and abrasive wear resistance of Aluminium but it has a negative effect on the machinability of Aluminium. To balance these effects, reinforcements like graphite which is a solid lubricant can be dispersed in Aluminium along with hard reinforcements. In the present study, the paper reviews on the effect of processing techniques, effect of reinforcement and effect of machining parameters on the machinability of hybrid aluminium metal matrix composites.