Aluminium Metal Matrix Research Articles

Mechanical and Wear Properties of Graphite Reinforced Aluminum Metal Matrix Composites Processed by Ultrasonic-Stir-Squeeze Casting

Mechanical and Wear Properties of Graphite Reinforced Aluminum Metal Matrix Composites Processed by Ultrasonic-Stir-Squeeze Casting

Review of Technological Advances in High Temperature Overhead Line Composite Conductors

ACSR (Aluminium Conductor Steel Reinforced) conductors consisting of pure aluminum wires helically stranded around a core of high strength galvanized steel core wires are widely used in overhead transmission line applications. While the steel wires provides the required strength, the outer aluminium serves as electricity conducting member. The thermal rating or ampacity of conductors is the maximum current that a circuit can carry within the temperature limits as dictated by the allowable conductor sag or by the annealing onset temperature of the conductor, whichever is lower. On a continuous basis, ACSR may be operated at temperatures up to 100°C without any significant change in the conductor’s physical properties. Above 100°C, aluminum wires loses tensile strength over time and becomes "fully annealed" giving rise to increased thermal expansion of the conductor; this causes excessive sagging reducing the clearance between the ground and the energized conductors.
 While, the electric utilities are posed with increased challenges of production of additional capacities and building new transmission circuits to meet the ever growing demand and the high cost and environmental restrictions of constructing new lines, methods are being explored to increase their capacity with minimum changes in the existing towers. Replacement of the existing conductor with a advanced high temperature composite (HTC) conductors operating upto temperatures of 200°C with reduced sagging characteristics have been attempted and an increase in capacity of 30-80%, can be achieved through application of these composite conductors.
 The advanced HTC conductors with varied combinations of core material and outer conducting wires are being tried so as to achieve wide ranging properties. In general, HTC conductors features the combinations of either soft aluminum wires with ultra high strength steel or temperature resistant aluminium with or fiber reinforced metal/polymer matrix composites as the core. Both the alumina fiber reinforced temperature resistant aluminium metal matrix composite and the carbon fiber reinforced high temperature polymer resin composite wires as the core material appears to have favorable applications. The comparative performance of the HTC depends on the degree to which both outer aluminum strand and reinforcing core’s physical properties are stable at high temperature and on the elastic, plastic, and thermal elongation of the combined HTC.
 The summary of various developments realized in the area of composite conductors and their relative merits and demerits have been discussed in detail.

Preparation of hybrid reinforced aluminium (1350H19) metal matrix composite by using alumina and zinc

Lightweight and higher-strength materials are prevalent in many applications, such as aerospace, automobiles, and defence. The aim of this study is to develop and analyze the mechanical and microstructure properties of 1350-H19 (pure aluminium) reinforced with Zn-Al2O3 hybrid metal matrix composites (HMMCs). The fabrication of the HMMCs takes place via stir casting along with ultrasonic agitation. The hybrid composite material consists of various weight percentage of reinforcement like alumina (Al2O3) varies from 6 to 12 wt%, while the weight percentage of zinc is maintained at 5 percent. EDX and XRD result ensure the existence of reinforced particles in manufactured HMMCs. Taguchi's design parameter is used to optimize the number of experiments and find the ideal set of input parameters for the maximum micro hardness.The result shows that the mechanical properties such as UTS (Ultimate tensile strength) and hardness of the HMMC's improved considerably when compared to the base metal.

Analysis of disc brake with composite materials

While braking, frictional heat raise temperatures at the disc/pad interface. Due to which rotor's surface may experience early wear, thermally elastic instability, brake fluid vaporization, and thermally stimulated vibrations as a result of an excessive temperature increase brought on by frictional heat. In order to increase braking effectiveness and improve vehicle stability, an investigation on the use of various materials for the disc brake rotors of two different vehicle types, one of which is solid and the other of which is vented is carried out. The disc brake is modelled using modelling software CATIA and Finite element analysis (FEA) is carried out using ANSYS 14.5, the toolis able to analyse the temperature distribution, stress variation, and deformation over the rotor's profile of the disc brake rotor. After considering the impacts of temperature distribution, Vonmises stresses, and deformation. In this work analysis of disc brake is done with three materials (Aluminium Metal matrix composite, Mild steel and cast iron) used for vented with and without holes type disc brakes. Conferring to the results, Aluminium MMC is observed to be the optimum material for disc brakes where the deformation is minimum at mode shape 3 at frequency 597.1 Hz when compared to other mode shapes.

Investigation of mechanical properties of metal matrix composites

Aluminium is one of the lightest engineering materials. It offers a greater strength to weight ratio. Due to the numerous ways in which aluminium's advantageous properties—including strength, lightness, corrosion resistance, recyclability, and formability—can be combined; it is employed in an increasing number of structural applications. Several researchers have been evaluated in order to combine some of the components of the mechanical and wear behaviour of stir cast aluminium metal matrix composites. Aluminium 6061 alloy, in which aluminium serves as the basic element, is selected as the matrix alloy in this project. Medium-strength aluminium alloy 6061 exhibits high corrosion resistance. The 6000 series alloy with the maximum strength is 6061, it is known as a structural alloy. Two alternate weight ratios of Al2O3, SiC, and aluminium matrix have been offered for the work, which is processed using a stir casting set-up. The samples are tested, and the results are reviewed. Density, hardness, and toughness increases but the tensile strength decreases with an increase in the reinforcement percentage.

Optimization of stir casting process parameters in the fabrication of aluminium based metal matrix composites

As the need for lightweight constructions rises in everyday life, metal matrix composites (MMCs) made of aluminum are used in a range of fields, including sports equipment, automotive, aerospace, and defense. The stir casting technique is the most commonly used commercially in industries to fabricate aluminum-based metal matrix composites because that is the most straightforward and economical strategy. The responsiveness of the process parameters was optimized using the statistical and mathematical technique known as response surface methodology (RSM) in the production of aluminum metal matrix composites reinforced with TiB2. The process parameters like reinforcement (1.5%, 3.0% and 4.5%), melt temperature (750 °C, 775 °C and 800 °C) and stirring speed (500 rpm, 600 rpm and 700 rpm) were considered for optimization. The obtained data were analyzed using three level factorial designs in Minitab software version 19. The developed model was evaluated using analysis of variance (ANOVA). The mechanical properties and microstructure of the specimens were investigated. ASTM standards were used to test the mechanical characterization, which included Vickers micro hardness and tensile strength. The results showed that the composite had improved tensile strength and micro hardness (29% increase). Microstructure studies revealed the presence of black Mg2Si particles as well as Al-Mg-Si eutectic in an alpha aluminum matrix, as well as fine and small TiB2 particulates.

Analysis and investigation of efficacy of the nanoparticles on the mechanical properties of aluminium metal matrix composites: A review

This investigation presented a complete report of prior years’s literature research work in the field of nanoparticles reinforced aluminium matrix nanocomposites. Metal Matrix Composites has been played a dynamic role in the arenas of aero-space, defence sector and automobile industrial sector. In this survey work, focused on scientific research analysis and investigation of mechanical behavior and surface morphology of aluminium matrix composites reinforced by nanoparticles such as MgO, SiO2, Al2O3, SiC, TiC, BN, Si3N, TiB2 etc. This analysis has been done to understand the influence of nanoparticles on metal matrix composites and also on the fabrication techniques of MMC’s. Mostly authors showed interest on following grades of aluminium alloys are 356, 2024, 6061,7075 due to the excellent corrosion, wear resistance, thermal stability, annealable and its easy casting process. Nanoparticles have been used to improve the mechanical properties such as tensile strength, hardness, wear rate, yield strength etc. of metal matrix composite materials. This literature review was provided the complete overview about MMC’s.

Application of Non-destructive Testing in Quality Control of Manufactured Aluminium Metal Matrix Composite Components for the Automotive Industry

The manufacturing of automotive components using aluminium metal matrix composites (Al-MMCs) is progressively gaining a relevant place in the automotive industry. Due to the increasing competition in the automobile sector, there is a great need to supply efficient, stable, and high-quality products. Generally, following automotive standards is voluntary, which means that businesses and other organizations are not legally obliged to apply them. Nevertheless, in certain cases standards may facilitate compliance with legal requirements, such as those contained in European directives and regulations. IATF 16949:2016 is the current version of the IATF 16949 Standard and outlines the requirements an organization must maintain in their quality system for IATF 16949 certification. This new application of manufacturing Al-MMCs requires additional procedures to guarantee the quality of the components manufactured. Because the manufacturing process may generate various defects, such as cracks, voids, lack of fusion, inclusions, porosities, and other metallurgical aspects, non-destructive testing (NDT) techniques should be used for guaranteeing the quality of the components manufactured. The development of reliable NDT methods for aluminium metal matrix composite parts is thus a major challenge. This aspect is related to how NDT procedures need to be optimised or developed to address the singular structures of the processes, such as complex geometry, anisotropic material properties, special internal structures, and the presence of nanoparticles. The main objective of this work is to summarize and present the relevant potential of different NDT techniques used in quality control of manufactured Al-MMC components in the automotive industry, to be explorer in the European FLAMINGo project (Fabrication of Lightweight Aluminium Metal Matrix Composites and Validation in Green Vehicles). This study is very significant because the NDT techniques present different probabilities of detection of the defects, principally of the microdefects.

Corrosion, Fatigue, and Wear Performance of Friction Stir Welded Aluminum Metal Matrix Composites: A Review

Corrosion, Fatigue, and Wear Performance of Friction Stir Welded Aluminum Metal Matrix Composites: A Review

Wear properties of graphene-reinforced aluminium metal matrix composite: A review

Abstract The recent advancement in graphene-reinforced aluminium matrix composites improves wear behaviour in the production of lightweight and high-performance nanocomposites. Considerable works have been devoted to using graphene nanoparticles as solid self-lubricants to increase wear resistance, minimise friction coefficients, improve service efficiency, and extend the lifespan of related sliding components. In general, wear behaviour often depends on the homogeneous distribution of graphene in the aluminium matrix. The non-uniform distribution of reinforcement due to the tendency of graphene to agglomerate in aluminium matrix and its poor wettability becomes a challenge in developing optimum functional of composites. The wettability of graphene can be enhanced by proper processing methods and sufficient addition of magnesium that can improve the wear and frictional properties of the produced composites. Hence, this review article provides recent findings and the influence of graphene as reinforcement materials in composites, including the effects on wear behaviour and friction properties. This article also discusses new advancements in the effect of graphene in self-lubricating aluminium matrix composites and the impact of reinforcement on the wear mechanisms of the composites. The future direction of the wear properties of MMCs is also covered at the end of the review.

Mechanical characterization of aluminum-boron carbide composites

Aluminum metal matrix composite is widely used now days in aerospace, automobile and structural applications due to its low production cost and good mechanical properties. This paper deals about the preparation of metal matrix composites and evaluation of mechanical strength by introducing the micro size Boron Carbide (B4C) reinforced particles in 6351 aluminium alloy (AA6351). Stir casting method is used to produce composites. After the casting process, specimens are machined as per ASTM standards. Tensile, flexural, hardness and impact tests are conducted to find out the mechanical properties at room temperature. Those values have improved by increasing the weight particles B4C. Also, tensile strength and flexural strength of composite specimens are found using computer aided modeling and engineering software. Comparison has been done and has good agreement between these two methods.

Modeling and characterization studies of wear behavior of aluminium metal matrix composites reinforced with reduced graphene oxide, silicon carbide, and alumina

In the current study, we report on the modeling and characterization studies of wear behavior of aluminium metal matrix composites reinforced with reduced graphene oxide (rGO), silicon carbide (SiC), and alumina (Al2O3). A double stir casting process was utilized in the production of the metal matrix composites using a 10 wt% ratio of the reinforcements. The wear test was performed using a pin-on-disc at room temperature, by varying loads and sliding speed. The results show that the sliding speed, load, and interactions between the sliding speed and load as well as the load and the composition were significant model terms. The optimum predicted conditions were attained at a sliding speed of 750 rpm at a of load 750 g for composition C. The P-values was less than 0.0500, indicating that the model terms are significant. At lower load, a rubbing type of debris feature characterizes the debris morphology. However, at higher loads, a severe sliding feature with striations and straight edges was evident. The EDX peak suggests a mechanically mixed layer comprising Al2O3 on the surface.

Study on the mechanical characteristics of aluminum metal matrix composites with tungsten carbide

An effort has been made in this present work to prepare Aluminum Metal Matrix composite by stir casting method which uniformly distributes the reinforcement particles in the metal matrix. Aluminum is a light weight material and frequently used for the applications of automobiles and aerospace. Specimen of Al-7075 hybrid composites is manufactured with varying weight percentages of (0,2 and 4 wt%) Tungsten carbide and 2% Silicon carbide. The additional of the reinforcements are into the metal matrix improves the stiffness, strength, and wear compared to the engineering materials. This hybrid reinforcement approach was made to improve these properties.

Fabrication and characterization of aluminum metal matrix composites

This Paper hands out Fabrication and characterization of aluminium metal matrix composites. The aluminium composites have progressed mainly in the field of aeronautics, defence etc. In today’s time aluminium metal matrix composites (MMC) are taken into consideration as the maximum capability fabric for structural and purposeful applications. To attain favoured bodily and mechanical residences like excessive hardness, excessive strength, and excessive tensile strength. Al is reinforced with carbon fibre in metal matrix composites. It is fabricated with different matrix and with different thickness. The Specimens for the characterization of composites are prepared as per the ASTM standard and the test conducted on the specimen includes tensile test, flexural test and micro structure.

Synthesis of functionally graded aluminium metal matrix composites - a mini review

Functionally graded materials (FGMs) are materials with property gradients along a particular dimension. These are novel and advanced materials that are becoming excellent replacements for composites. Among the FGMs, functionally graded Aluminum metal matrix composites (FG AMMCs) are receiving tremendous attention as they possess versatile properties compared to their counterparts. Out of various synthesizing techniques, the Powder metallurgy (PM) route is the cheapest and easier method of fabricating functionally graded composites (FGCs). This review provides information about the Functionally graded Aluminium metal matrix composites and their synthesis through the PM route. The review analyses important properties including density, hardness, tensile and compressive strength. A study of the microstructure through Scanning Electron Microscopy (SEM) of the synthesized FGMs is presented. The PM route could be conveniently exploited for large-scale production of FG AMMCs. There is scope for the characterization of FG AMMCs reinforced with B4C, TiO2, TiB2, TiC, CNT, and Few layered Graphene (FLG) as only a few studies are reported in the literature. The variation in mechanical and tribological properties of the FGMs could be investigated by varying the processing parameters of the ball milling, compacting, and sintering conditions.

The experimental investigation of thermal conductivity of aluminum metal matrix composites

Aluminum and its alloys have grown in popularity as steel and other comparable material substitutes. These alloys have exceptional mechanical characteristics. Understanding the thermal behavior of hybrid metal matrix composites is critical in a variety of applications. Metal Matrix Composites' (MMCs') heat conductivity is one of its primary advantages. Because MMCs are utilized in a broad variety of temperatures, it is critical to examine their thermal characteristics at various temperatures in order to understand their behavior. Thermodynamic characterization of composite materials has received a lot of attention and has evolved into a crucial element of materials research and engineering. The thermal conductivity of aluminum alloys with Sic and Gr hybrid metal matrix composites is investigated in this work. Sic (0%, 1.26%, 2.6%, and 3.76%) and Gr (0%, 1.26%, 2.6%, and 3.76%) reinforcements are employed in various weight fractions. A variety of casting processes is used to create the composites, which have an Al-based matrix reinforced with Sic and Gr particles. Casting processes include advantages such as decreased material waste and lower porosity levels. The goal of this study is to examine the thermal conductivity behavior of hybrid composites reinforced with varied weight fractions, particularly at lower weight fractions.

Study on aluminium metal matrix composites reinforced with SiC and granite powder

The exceptional physical and mechanical properties of Aluminium matrix composites (AMCs) have garnered considerable attention, rendering them highly promising materials for a wide range of applications. The integration of reinforcements into the metallic matrix results in enhanced stiffness, specific strength, wear resistance, creep resistance, and fatigue resistance in AMCs as compared to conventional engineering materials. The present study is centred on the examination of the mechanical characteristics of Aluminium Matrix Composites (AMCs) that have been fortified with Silicon Carbide (SiC), Granite and Graphite powder. Composites featuring varying concentrations of SiC, Granite and powder were produced via a stir casting process. The composites were assessed through the implementation of ASTM standard procedures for conducting hardness, tensile, and shear strength tests. The findings underscore the potential of said composites for diverse applications that necessitate elevated levels of durability and resistance to abrasion.

Parametric optimization for sustainable WEDM of different profile cut on hybrid metal matrix composites

In this work, an experiment was performed on the WEDM to cut three different AMMC (Aluminium metal matrix composites), which were fabricated by a stir casting process. To fabricate AMMC, Al6061 was chosen as a matrix, and Alumina and Silicon carbide were selected as reinforcement materials. 1st AMMC was fabricated by using 10 % Al2O3, 2nd fabricated with 10 % SiC, and the third HMMC was fabricated by mixing 5 % alumina and 5 % SiC both. And BBD (box behnken design) approach of RSM (Response surface modelling) was used to develop an experimental design for input parameters such as pulse on time (30 µs-50 µs), pulse off time (6 µs-12 µs), and current(1Amp-5Amp) on cutting of three different shapes such as triangle, circle, and square for CV and SR responses. And experimental data was performed by using the BBD approach was optimized by MOPSO, and it was found that for AMMC/Al2O3 Ton = 30 µs, Toff = 12 µs, I = 1 Amp, and triangle profile were optimal input parameters. And for AMMC/SiC and AMMC/Al2O3/SiC, Ton = 30 µs, Toff = 6 µs, I = 1 Amp, and triangle profile was optimal input parameters. And from phase analysis by XRD, it show the proper mixing of reinforcement in matrix.

Study on mechanical and micro-structural properties of aluminium matrix composite reinforced with graphite and granite fillers

Composites are gaining increasing popularity nowadays due to their wide range of applications and flexible design options. Aluminium Matrix Composites (AMCs) have garnered increasing attention in contemporary times as a subject of research. The inclusion of reinforcements in the metallic matrix results in improved stiffness, specific strength, wear resistance, creep resistance, and fatigue characteristics when compared to conventional engineering materials. In our study, we are employing a 6061 grade Aluminium alloy as the fundamental material, and augmenting it with Synthetic Graphite and Granite fine particles as strengthening agents. The Aluminium matrix composite is produced through the incorporation of synthetic graphite particles and granite dust into the molten aluminium via a Stir Casting Furnace utilising a bottom pouring technique at temperatures within the range of 850 to 950 °C. The Aluminium Metal Matrix composite samples is fabricated with varying reinforcement percentages relative to the base material. The distribution of particles within the Aluminium Matrix is analysed. Furthermore, the fabricated composites have undergone Tensile, Impact, Shear, and Micro hardness tests to assess the effects of incorporating reinforcements. All examinations conform to the standards set by ASTM. A comparative analysis is conducted between the mechanical properties exhibited by the original Aluminium alloy and the Aluminium metal matrix composites that have been manufactured.

Influence of nanoparticles in reinforced aluminium metal matrix composites in aerospace applications – A review

The aerospace industry has seen a steady rise in the need for materials with a high strength-to-weight ratio and economic concerns. Although lightweight materials like Aluminium (Al) and its alloys are appealing, but their application is constrained by some characteristics including low thermal stability and high wear rate. To overcome these limitations and improve the performance of aluminium, many researchers have developed various composites made of metal matrix and reinforced with nanoparticles. The basic material's mechanical strength and wear resistance can all be enhanced by the nanoparticles. This paper is a review on inference of various nanoparticles in aluminium composite and the behavioural changes in properties. Aluminium has been used as base composite and its reinforcement is studied by focusing on the stir-casting method for fabrication. The characteristics of Metal Matrix Composites (MMCs) can be incorporated into the material and customised depending on the application, opening up countless opportunities for modern material research and development. Furthermore, the challenges of various nanomaterials reinforcement in Al MMCs also discussed.