Aluminium Hybrid Research Articles

Enhancing machining efficiency in hybrid metal matrix composites through EDM parameter optimization via grey relational analysis

In summary, this study utilized stir casting to develop three distinct aluminium hybrid composites incorporating boron carbide and alumina. These composites were identified as Al7075 + 12%B4C + 6%Al2O3, Al7075 + 6%B4C + 6%Al2O3, and Al7075 + 6%B4C + 12%Al2O3. The novelty of this research lies in the unique combination of materials and their proportions, offering enhanced properties yet unexplored in this specific configuration. The research focused on machining these composite materials using EDM and employed a Taguchi L27 orthogonal array design to plan the machining tests. Key process parameters considered were gap voltage (V), duty cycle (%), current (A), and different percentages of reinforcement content. This aspect adds a significant novel dimension to the study, as the impact of EDM machining parameters on hybrid composites with this particular composition has not been extensively explored previously. The study applied Grey Relational Analysis to evaluate the impact of EDM machining process parameters on critical output responses, specifically material removal rate (MRR) and tool wear rate (TWR). SEM images revealed redeposited molten material, craters, and surface cracks, emphasizing the importance of controlling discharge energy and current levels for desired surface quality. An optimal configuration was identified peak current 2 A, pulse duration 100 μs, duty factor 20%, Composition 2 for improved surface attributes. These qualitative and quantitative insights inform process optimization strategies for EDM machining of aluminium hybrid composites.

Process parameters optimization of EDM for hybrid aluminum MMC using hybrid optimization technique

This study explores how machining parameters affect Surface Roughness (SR), Tool Wear Rate (TWR), and Material Removal Rate (MRR) during Electrical Discharge Machining (EDM) of a hybrid aluminum metal matrix composite (AMMC). The composite includes 6 % Silicon carbide (SiC) and 6 % Boron carbide (B4C) in an Aluminum 7075 (Al7075) matrix. A combined optimization approach was used to balance these factors, evaluating Pulse ON time, Current, Voltage, and Pulse OFF time. Response Surface Methodology (RSM) optimized single responses, while multi-response optimization employed a hybrid method combining the Entropy Weight Method (EWM), Taguchi approach, TOPSIS, and GRA. Analysis of Variance (ANOVA) assessed parameter significance, revealing substantial impacts on SR, MRR, and EWR. Based on TOPSIS and GRA, optimized parameters achieved a desirable balance: high MRR (0.4172, 0.5240 mm³/min), minimal EWR (0.0068, 0.0103 mm³/min), and acceptable SR (10.3877, 9.1924 μm) based on EWM-weighted priorities. Confirmation experiments validated a 15 % improvement in the closeness coefficient, and a 16 % improvement in the Grey relational grade, which considers combined SR, MRR, and EWR performance. Scanning Electron Microscope (SEM) analysis of surfaces machined with optimal parameters showed minimal debris, cracks, and no recast layer, indicating high surface integrity. This research enhances EDM optimization for AMMC, achieving efficiency in machining, minimizing tool wear, and meeting surface quality requirements.

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

Research of Hybrid Aluminium Castings with the Use of Porous Cores

Research of Hybrid Aluminium Castings with the Use of Porous Cores

Effect of Electrical Discharge Machining Parameters and Cryogenic Treatment on Surface Roughness of Aluminum Metal Matrix Composite (Al6061/SiC/Graphite)

This study examines how process parameters -Current (Amp), Pulse on time (Ton), Duty cycle, and voltage ( v) affects the surface finish of the hybrid aluminum composite (Al6061/SiC/Graphite), comparing the effectiveness of cryogenic treatment on the EDM tool with a non-treated tool. One factor at a time (OFAT) approach shows that increasing current from 4 A to 12 A raises surface roughness from 0.2 µm to 2.5 µm. However, using silicon carbide, cryogenically treated electrodes, and longer pulse-on times can reduce roughness, though debris removal may be needed. Higher voltages above 120 V also increase roughness, which can be lessened by better flushing and cryogenic treatment. Lower duty cycles (0.36 to 0.48) yield smoother surfaces, while medium duty cycles (0.6 to 0.72) increase roughness, which can also be mitigated by cryogenic treatment.

Development and characterization of hybrid aluminium matrix composites through stir-squeeze casting using distinct reinforcements for structural applications

Development and characterization of hybrid aluminium matrix composites through stir-squeeze casting using distinct reinforcements for structural applications

Evaluation of the role of process parameters of CMT welding and their statistical behaviour on the tensile properties of weld joint of novel aluminium hybrid composite

Evaluation of the role of process parameters of CMT welding and their statistical behaviour on the tensile properties of weld joint of novel aluminium hybrid composite

Development and characterization of powder metallurgy processed Al/Fe/SiC/MoS2 hybrid composites

This study explores hybrid aluminum matrix composites through powder metallurgy, incorporating silicon carbide, iron, and molybdenum disulfide at varying weight percentages (5%, 10%, and 15%). Defect-free hybrid composites with a uniform distribution of reinforcing particles were fabricated and characterized for microstructure, hardness, density, and wear. The EDX spectra show peaks consistent with Al, Fe, SiC, and MoS2, confirming their presence in developed hybrid composites. The pure aluminum sample presents a relative density higher than that of hybrid composites, while its hardness is lower (25%–41%) than that of hybrid composites. The wear rate decreased with the amount of reinforcing particles. The presence of hard silicon carbide, iron, particles, and lubrication by molybdenum disulfide effectively enhanced the wear behavior of hybrid composites.

Effect of Kevlar and Carbon Fiber Face Sheet on the Deformation Behavior of Aluminum Hybrid Composite Foam Core Sandwich Panel under Flexural Loading

Effect of Kevlar and Carbon Fiber Face Sheet on the Deformation Behavior of Aluminum Hybrid Composite Foam Core Sandwich Panel under Flexural Loading

Investigation on mechanical properties of aluminum hybrid matrix composites reinforced with fly ash and titanium diboride using stir casting technique

Aluminium hybrid matrix composites (AHMCs) is employed in the automotive and aerospace industries because to their high strength-to-weight ratio, corrosion resistance, and tribological properties. The objective of this research is to examine the metallurgical, mechanical, and corrosion characteristics of Aluminum hybrid matrix composites (AHMCs) produced by reinforcing LM25 alloy with 5% fly ash and varying percentages (4%, 8%, 12%) of TiB2 using the stir casting technique. The uniform distribution of reinforcing particles was verified by capturing images via SEM and EDAX. Density, Tensile strength, microhardness was conducted for the prepared AHMCs. The outcome reported there was an enhancement by adding reinforcement particles of fly ash and TiB2 comparing to the pure LM25 alloy. This improvement was attributed to the presence of fly ash and TiB2 particles, resulting in a higher dislocation density, with increasing TiB2 content demonstrating improved strength and ductility compared to conventional LM25 alloy.

Enhancing high-speed EDM performance of hybrid aluminium matrix composite by genetic algorithm integrated neural network optimization

Hybrid aluminium matrix composites (HAMCs) are highly valued in manufacturing sectors but are difficult to machine conventionally due to reinforcements' inherent hardness and abrasiveness. This research finds high-speed wire electric discharge machining (WEDM) to be a potent solution for machining stir-squeeze-casted HAMC (AA2024 with ceramic nanoparticles: Al2O3, SiC, Si3N4, BN) and creating complex profiles with superior erosion characteristics. The erosion performance has been assessed in terms of material removal rate (MRR) for different profiles (plane, angular, and curve), and wire wear ratio (WWR) by employing machining variables, i.e., pulse voltage (PV), pulse current (PI), wire feed rate (WFR), pulse (P), and drum speed (DS). Results revealed that MRR_curve has highest MRR (37.84 mm3/min), followed by MRR_angular (36.07 mm3/min) and MRR_plane (34.40 mm3/min). The lowest WWR (0.0094%) was achieved at lower magnitudes of machining variables. The microscopic observations unveil shallow craters, minute-sized melt redeposits, and micro-pores on machined surface under the conditions of PV = 90 V, PI = 2 A, WFR = 13 m/min, P = 20 mu, and DS = 40 Hz. Optimization using non-dominated-sorting-genetic algorithm (NSGA-II) resulted in significant enhancements of 75.37, 73.90, and 76.01% in MRR_plane, MRR_angular, and MRR_curve, respectively, and a depreciation of 16.50% in WWR.

A Comparative and Experimental Study of Parametric Influence on Drilling Process of Hybrid AMMC

Abstract: To aim for the highest quality product quality and a high metal removal rate, metal cutting is crucial. The primary obstacle to attaining optimal quality and high production is the short tool life. The hybrid aluminum metal matrix AA 6082, with reinforcement consisting of titanium dioxide (7.5%) and cenosphere (2.5%), was optimized using the Modified Taguchi optimization method for simultaneous minimization and maximization of surface roughness (Ra), machining time, and material removal rate. The surface finish was affected by different types of geometrical precision values of the CNC drilling process parameters in order to both minimize and maximize the responses. The experiments, including call for the machining of hybrid AMMC and the use of an HSS drill bit, will be performed using a CNC with different process parameters. The L16 orthogonal array will be used for the examinations, and each experiment will be run under a distinct set of circumstances, including feed, speed, and pecking. Using the TAGUCHI design, the optimal geometrical and machining parameters were determined from the experimental output responses, and significant influences were discovered for the corresponding specific output responses.

Synergistic Effects of Graphene and Ceria Nanoparticulates on Microstructure and Mechanical Behavior of Stir-Cast Hybrid Aluminum Composite

Synergistic Effects of Graphene and Ceria Nanoparticulates on Microstructure and Mechanical Behavior of Stir-Cast Hybrid Aluminum Composite

"Evaluating the mechanical and tribological characteristics of aluminium hybrid composites incorporating ZrO2 and graphite micro-particles "

"Evaluating the mechanical and tribological characteristics of aluminium hybrid composites incorporating ZrO2 and graphite micro-particles "

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.

Effect of hybrid ratio and sintering temperature on hardness properties of hybrid AMCs

The present research work is aimed toward fabrication of hybrid Aluminium matrix composites (AMCs) of different hybrid ratios of Alumina (Al2O3) and Silicon Carbide (SiC) followed by investigation of their microstructure and hardness properties. Hybrid AMCs were fabricated through powder metallurgy process by adding 5 wt% and 10 wt% mixture of Al2O3 and SiC reinforcements of various hybrid ratios (0:1, 1:3, 1:2, 1:1, 3:1, 2:1 and 1:0) with the pure Aluminium powder. The mixture powder were properly mixed by ball milling arrangements for 6 h. The mixture powder were preheated at 500 °C for 2 h in a high temperature programmable tube furnace followed by immediate compaction under a closed die at 1500 psi pressure through automatic hydraulic press. The compacted specimens were then sintered at 350 °C, 500 °C and 650 °C for 2 h in the same furnace. Hardness test of the fabricated hybrid AMCs were carried out by Vickers Micro-hardness testers and hardness values were measured by the integrated software. The hardness properties of hybrid AMCs also were compared with the hardness properties of pure Aluminium specimens fabricated through the same process route and process parameters. It is interestingly observed that hardness of hybrid AMC is more when pure Aluminium powder is reinforced with only SiC of same wt.% for both the cases (5 wt% and 10 wt% reinforce AMCs) and it decreases with decrease of weight fraction of SiC and simultaneously increase of weight fraction of Al2O3 keeping total weight fraction of mixture as constant.

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.

Effect of TiO2-SiC and heat treatment on tribological characteristics of bimodal hybrid aluminium composites under dry sliding condition

Abstract The dry sliding wear behavior of bimodal TiO2np/SiCp/Al6082 composites was studied using a pin-on-disk tribometer. The investigation included both as-cast alloy and T6 heat-treated composites, with variations in applied load (40 N, 60 N, and 80 N) and sliding distance (600, 900, 1200, 1500, 1800, and 2100 m) at a constant sliding speed of 2 m/s. The microstructure of the composites and the worn surface were examined using a scanning electron microscope. A linear increase in wear rate was observed with sliding distance up to the transition limit. It was found that at 40 N, a shield began to develop between the disc and pin surface, reducing the coefficient of friction (COF), and friction and oxide were the primary processes of wear mechanisms. A larger load caused the protective layer to be destroyed; increasing COF, and adhesion and delamination were the two types of wear that were noticed. The wear resistance of alloys and bimodal composites were increased by heat treatment because it strengthened the matrix.

Experimental Analysis of Polishing of Hybrid Aluminium Metal Matrix Composite Reinforced with SiC, ZrO2, and NiTi Particles Using a Developed Rotary Abrasive Float Polishing System

Experimental Analysis of Polishing of Hybrid Aluminium Metal Matrix Composite Reinforced with SiC, ZrO2, and NiTi Particles Using a Developed Rotary Abrasive Float Polishing System