Aluminum Alloy Composites Research Articles

Processing of silicon carbide particulate reinforced aluminum alloy composites using rotary electrochemical discharge machining

ABSTRACT As a kind of metal matrix composites, silicon carbide particulate reinforced aluminum alloy composites (SiCp/Al) have been widely applied in numerous fields. However, it is still difficult to process this composite material with electrical discharge machining (EDM) at present. To address this problem, this study introduces a novel rotary electrochemical discharge – chemical composite machining (RECDM-CM) method. This method uses rotating electrodes and workpieces to improve the flushing effect of working medium and utilizes the electrolysis to reduce the recast layer thickness. The chemical reaction between sodium carbonate (Na2CO3) and aluminum oxide (Al2O3) at high temperatures is used to remove the non-conductive Al2O3 in this composite machining. Rotary electrochemical discharge – chemical composite machining is used to process silicon carbide particulate reinforced AA2009 aluminum alloy composites with the silicon carbide volume fraction of 55%. The experimental results reveal that the material removal rate (MRR) of rotary electrochemical discharge – chemical composite machining is 5.2 times that of rotary electrical discharge machining, and its relative tool wear rate (RTWR) is 37.42% of rotary electrical discharge machining. The recast layer thickness is reduced to less than 13 μm via rotary electrochemical discharge – chemical composite machining.

Effect of Nano Particle Size on Mechanical and Fatigue Behavior of TiO2 Particular—Reinforced Aluminum Alloy Composites

Aluminum alloys are among the most widely used materials in the parts and vehicle sectors due to their high strength-to-weight ratio and qualities such as higher corrosion and wear resistance, as well as minimal thermal growth when compared to other metals. This research involved matrix alloy AA7075 aluminum reinforced with constant 7 wt. % TiO2 (with different particle sizes 30, 70, and 100 nm). The goal of this study is to improve the mechanical (impact strength and young modulus) and fatigue properties of AA7075 alloy-based metal matrix composites, and fatigue. AA7075 composites with a constant weight percentage of 7wt.% of TiO2 and variable particle size have been successfully synthesized by the stir casting route. Microstructural examinations revealed that nanocomposites with (30nm) particle size have better distribution and less porosity compared to the other particles size. The nanocomposite having 30 nm particle size was found to have maximum improvement UTS and YS in comparison with the other nanocomposites, 20.45%, and 12.87% respectively, and minimum elongation. An increase in particle size and fatigue results indicates the decreasing trend of fatigue life and strength. The higher endurance fatigue limit was recorded to be (23.875 MPa) for (30 nm) nanocomposite.

Development of sustainable aluminum alloy‑tungsten carbide hybrid composites using industrial waste - An experimental analysis

The research article focuses on the development of aluminum alloy 6061 sustainable composites with the utilization of industrial waste through the use of the stir casting process. Recycling industrial waste is essential for reducing environmental impact. Thus, the red mud waste came from the aluminum production process, which was considered for producing sustainable metal matrix composites (MMCs). Also, tungsten carbide (WC) microparticles have been used to develop hybrid aluminum composite materials. The concentrations of red mud and tungsten carbide were 2 wt%, 4 wt%, and 6 wt%, respectively, and were used to achieve the desired strength performance of aluminum metal matrix composites. The elemental and bonding analyses of hybrid composites were analyzed using X-ray Diffraction (XRD) and Fourier Transform Infrared Spectroscopy (FTIR) analysis. Mechanical characterizations of aluminum hybrid sustainable composites were also investigated, including tensile, compression, and microhardness testing. The results show that increasing reinforcement by up to 4 wt% increases the mechanical strength of aluminum alloy composites. The tensile, compression, and microhardness of metal matrix composites are increased by 25.24 %, 40.2 %, and 20.6 %, respectively, as compared to the aluminum alloy 6061 alloy. The surface morphology of metal matrix composites was analyzed by utilizing Field emission scanning electron microscopy. The proposed sustainable aluminum composites have the potential to develop structural and automotive components due to their higher strength-to-weight ratio.

Flat silk cocoons: A candidate material for fabricating lightweight and impact-resistant composites

The utilization of silk cocoons in the production of lightweight and tough composites has been gaining increasing attention. However, the limited applications of normal silk cocoons (NSC) are attributed to their small size and irregular shape. To overcome this deficiency, flat silk cocoons (FSC) with a similar structure and controllable size were prepared. Next, we systematically characterized and compared the microstructures, morphologies, compositions, thermal properties, and mechanical properties of FSC with NSC. Subsequently, FSC was successfully utilized to fabricate a novel silk fibroin fiber reinforced sericin matrix composite (HPFSC) using a hot pressing method, followed by the analysis of its microstructure evolution, mechanical properties, failure modes, and theoretical modeling. This composite has outstanding mechanical properties including hardness, modulus, and strength. HPFSC has a relatively low density of ~1.3 g/cm3, whose absorbed impact energy can reach a maximum value of 11.1 J/mm, exceeding that of most engineering materials, such as aluminum alloy, ceramics, glass, and carbon fiber composites. The exceptional performance of HPFSC can be attributed to the reduced porosity, enhanced bonding between silk fibroin fibers facilitated by sericin, and their structural transformation. This study offers valuable guidance for the fabrication of lightweight and impact-resistant composites using flat silk cocoons.

E-glass fiber featured hybrid aluminium alloy composite: Metallographic, mechanical and fracture failure study

E-glass fiber featured hybrid aluminium alloy composite: Metallographic, mechanical and fracture failure study

Comparative Study on the Tribological Performance of Conventional and Metal Matrix Composite Brake Pads in Automotive Applications

Abstract: This study investigates the wear and mechanical properties of aluminum alloy composites reinforced with titanium dioxide (TiO2) nanoparticles. Aluminum-based composites are increasingly favored in engineering due to their excellent properties, and incorporating TiO2 nanoparticles presents a promising method for further enhancement. The composites were produced using a powder metallurgy technique, and their mechanical performance—including tensile strength, hardness, and impact resistance—was thoroughly assessed. Additionally, wear tests under various conditions were conducted to evaluate the composites' wear resistance. The findings indicate that incorporating TiO2 nanoparticles significantly enhances both the mechanical properties and wear resistance of the aluminum alloy.

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.

The interpretable descriptors for fatigue performance of wrought aluminum alloys

Aluminum alloys are extensively utilized in the transportation and aerospace industries due to their excellent processability and corrosion resistance. A key aspect affecting the application of aluminum alloys is fatigue failure, with fatigue strength constituting an essential indicator for assessing the failure mode. In this study, 859 data sets were collected to evaluate the effects of aluminum alloy composition and mechanical properties on fatigue strength. To comprehensively evaluate the features that exert a great influence on the fatigue strength of wrought aluminum alloys, atomic physical quantities of aluminum alloys were added to the original data set. To improve the computational efficiency and physical interpretability of the model, Spearman correlation analysis, optimal subset method, and other methods were used to perform feature selection on the atomic feature quantities and mechanical properties in the data set. Finally, a mathematical relationship between material descriptors and fatigue strength was established based on the alloy composition and the three most relevant features in the feature screening, which helps to better understand and predict the fatigue behavior of wrought aluminum alloys.

Erosion wear of the multilayered high velocity oxy‐fuel ceramic coatings on aluminum alloy composite substrate

AbstractHigh velocity oxyfuel coatings have been sprayed on aluminium (Al) alloy composites substrate with varying coating thickness and tested for their wear behavior. The density and micro‐ hardness of the coatings found to increase with increase in coating thickness. The air erosion wear test has been conducted using quartz sand of size up to 75 μm as erodent. The steady state experiments indicate that the greatest specific erosion rate is at 60° and minimum at 30°. Due to the presence of interlayer, specific erosion rate decreases with the increase in the thickness of the coatings. Surface topography of the eroded samples indicate a decrease in surface roughness with increase in impact velocity. Thereafter, Taguchi (L16) orthogonal array has been utilized in order to optimize the input parameters. Analysis of variance has been applied to determine the contribution of individual control factors. The results from Taguchi experiments and analysis of variance find the order of dominance of control factors and their individual contribution as: velocity (47.31 %) > coating thickness (29.94 %) > angle (13.26 %) > erodent feed rate (7.65 %). Coatings have exhibited a semiductile wear behavior.

Role of scandium addition to microstructure, corrosion resistance, and mechanical properties of AA7085/ZrB2+Al2O3 composites

The effect of varying amounts of scandium (Sc) on the mechanical performance and corrosion resistance of aluminum alloy (AA7085) composites reinforced with Zirconium diboride (ZrB2) and Aluminum oxide (Al2O3) nanoparticles was investigated. The specimens were made using an in-situ process with varying amounts of Sc up to 0.5 wt%, and their microstructural behavior, corrosion, and mechanical properties were explored in detail. Phase structural analysis revealed the successful incorporation of ZrB2 and Al2O3 into the matrix through in-situ synthesis, ranging from 30 to 61.7 nm. In addition, HRTEM and XRD analysis displays the Al3Zr prominence observed with 0.1 wt% Sc content, transforming to Al3(Sc, Zr) in the 0.3 wt% Sc composite, and finally becoming Al3Sc with 0.5 wt% Sc. Corrosion analysis revealed that the 0.3 wt% Sc composite exhibited fine Al3(Sc, Zr) precipitate phases that enhanced corrosion properties. The Sc addition leads to a significant improvement in the mechanical properties of AA7085/ZrB2+Al2O3 composites. The ultimate tensile strength of 678 ± 5 MPa for 0.5 wt% Sc under the hot rolled and T6 aged condition was achieved. The optimum content of Sc in AA7085/ZrB2+Al2O3 composites has identified both corrosion and mechanical properties enhancement at 0.3 wt% and 0.5 wt%, respectively.

Optimization of Dry Sliding Wear in Hot-Pressed Al/B4C Metal Matrix Composites Using Taguchi Method and ANN.

The presented study investigates the effects of weight percentages of boron carbide reinforcement on the wear properties of aluminum alloy composites. Composites were fabricated via ball milling and the hot extrusion process. During the fabrication of composites, B4C content was varied (0, 5, and 10 wt.%), as well as milling time (0, 10, and 20 h). Microstructural observations with SEM microscopy showed that with an increase in milling time, the distribution of B4C particles is more homogeneous without agglomerates, and that an increase in wt.% of B4C results in a more uniform distribution with distinct grain boundaries. Taguchi and ANOVA analyses are applied in order to investigate how parameters like particle content of B4C, normal load, and milling time affect the wear properties of AA2024-based composites. The ANOVA results showed that the most influential parameters on wear loss and coefficient of friction were the content of B4C with 51.35% and the normal load with 45.54%, respectively. An artificial neural network was applied for the prediction of wear loss and the coefficient of friction. Two separate networks were developed, both having an architecture of 3-10-1 and a tansig activation function. By comparing the predicted values with the experimental data, it was demonstrated that the well-trained feed-forward-back propagation ANN model is a powerful tool for predicting the wear behavior of Al2024-B4C composites. The developed models can be used for predicting the properties of Al2024-B4C composite powders produced with different reinforcement ratios and milling times.

Parametric study to investigate mechanical properties of welded dissimilar Al6063 and Al 7073 alloys through FSW process

Aluminium alloys have been the most prominent materials that have applications in every industry due to their high strength-to-weight ratio. The low melting point and easy recyclability also attract the scientific community to apply such material in modern manufacturing. The revolution in aluminium alloys came after the invention of friction stir welding, which provided high-end welding results and catastrophically increased its application in aerospace industries. Still, many inconclusive studies need to be explored for its high-end application, especially for newly invented aluminium alloy composites. Hence, this study investigates the application of friction stir welding process for welding dissimilar Aluminium alloy compositions. The investigation starts by analysing the effect of rotational speed, feed rate, and force on temperature generation, hardness, and welding strength. Three levels of process parameters, i.e. rotational speed in the range of 1000–1200 rpm, force of 12–18 N and feed rate of 40–60 mm min−1, are selected to analyse the effect on hardness and strength of the weld. After analysis, the optimum conditions obtained were a rotational speed of 1200 rpm, a feed rate of 50 mm min−1, and an average load of 15 N for a maximum hardness of 93.16 BHN and welding strength of 228 MPa. The investigation’s findings indicated that several phenomena, including the effects of high blending activity, plastic disfigurement, the repercussions of grain structure, and frictional intensity, may influence the hardness and strength of the weld. The growth of uniform structure at the stirred area is caused by pin movement during welding, specifically from the retreating side to the advancing side.

Characterization and Mechanical Testing of Hybrid Metal Composites of Aluminium Alloy (A356/LM25) Reinforced by Micro-Sized Ceramic Particles

Characterization and Mechanical Testing of Hybrid Metal Composites of Aluminium Alloy (A356/LM25) Reinforced by Micro-Sized Ceramic Particles

Ultra‐high bonding strength of carbon fiber–doped polyamide–aluminum alloy composite structure achieved by changing crystallinity

AbstractLightweight and high‐strength polymer–metal hybrid structures are favored for reducing material and energy consumption. In this study, carbon fiber‐reinforced polyamide 6 (CFPA) composite materials were prepared through melt blending, and 30 wt% CFPA exhibited the highest shear strength and lowest shrinkage rate among other carbon fiber contents. With pretreatments of anodizing and etching treatment, injection molded direct joining was employed to create polyamide 6 (PA)/CFPA–Aluminum alloy (Al) composites. The impacts of the injection temperature and speed on the bonding strength of the PA/CFPA–Al composite materials were investigated. The characterization results confirmed that carbon fiber doping reduces the coefficient of linear thermal expansion (CLTE) and enhances crystallization ability of PA. The higher injection temperatures and lower injection speed significantly increase the crystallinity of PA and the infiltration of the molten polymer into the nanoporous anodic aluminum oxide films. When the injection temperature was 270°C and the speed was 6 mm/s, the bonding strength of the PA–Al hybrid structure reached a maximum of 36.6 MPa. When the injection temperature was 300°C, the bonding strength of the CFPA–Al hybrid structure reached a maximum of 40.8 MPa. Adhesive parts with high shear bonding strength are critical to satisfying engineering requirements and have significant potential, particularly in polymer–metal composite structures. The polymer‐metal hybrid structure can meet the high interfacial bonding strength required in most engineering applications.Highlights Injection temperature and speed in IMDJ affect PA crystallinity. Carbon fiber doping reduces the CLTE of PA and increases the shear strength. High temperatures and low injection speeds are beneficial to adhesives. The bonding strength of PA–Al reached a maximum of 36.6 MPa. The bonding strength of CFPA–Al reached a maximum of 40.8 MPa.

Optimization of physico-mechanical and erosive wear properties of single/multilayer – coated granite filled aluminum alloy composites

Abstract In the present research, uncoated and coated (CrN/SiN–CrN) granite dust reinforced aluminum alloy (AA 1050, AA 5083) composites samples were fabricated using stir casting and their physical, mechanical and slurry erosion behavior were assessed. The study reveal a persistent increase in void content, hardness, impact strength and stress intensity factor for both uncoated and coated alloy with the inclusion of reinforcement. In contrast, flexural strength and corrosion rate decrease continuously with increased granite content and also with the corresponding coating. Multilayer coated 5083 aluminum alloy composite with 6 wt.% granite particle shows maximum hardness, impact strength and stress intensity factor and minimum slurry erosion rate. The entropy method was applied to the operating parameter to rank the fabricated composites. The performance of each operating parameter is determined using the VIKOR (Vise Kriterijumska Optimizacija Kompromisno Resenje) optimization method. The optimal formulation based on Performance-Defining Attributes (PDAs) is observed for multilayer-coated 6 wt.% granite particulate reinforced 5083 aluminum alloy composites.

Multi-response optimization of reinforcement parameters of aluminum alloy composites by Taguchi method and grey relational analysis

The present work describes the optimization of reinforcement parameters for hardness, thermal conductivity, and coefficient of thermal expansion while developing LM6 alloy/soda-lime glass particulate composite through Taguchi-based Grey Relational Analysis (GRA). Soda-lime glass particle weight % (1.5, 3.0 and 4.5 %), particle size (100, 150 and 300 μm) and pre-heat temperature (260, 380 and 500oC) are varied accordingly to explore the effect of reinforcement parameters on LM6 alloy/soda-lime glass composite properties. Composites are developed through stir casting based on the L9 Taguchi orthogonal array approach. The properties such as hardness, thermal conductivity and coefficient of thermal expansion of developed composites are assessed. Signal to Noise Ratios (S/N ratios) are calculated and used for the optimization of parameters. GRA is employed for multi-response optimization to find the levels of parameters that affect the desirable properties of the composite. Thus, the reinforcement parameters are optimized for attaining the combined objectives of higher hardness, higher thermal conductivity and lower coefficient of thermal expansion values considered in this investigation. The analysis shows that 4.5 wt %, particle size of 200 μm and pre-heat temperature of 380oC are optimal parameter levels. A confirmation test is carried out with the optimal parameter levels and the GRG value of 0.7778 is obtained. The GRG with the initial parameter settings is 0.4711, and the improvement of GRG is found to be 65.1 %. ANOVA is performed on GRG to find out significant parameters and the contribution of each parameter is identified. The wt.% of soda-lime glass is the most significant parameter and its contribution is 92.6 %.

Anti-penetration response and response mechanism of laminated structures made of different composite materials under impact load

Composite laminated structures are often subjected to high-speed impact from external objects in high impact environments, resulting in unpredictable forms of damage and even uncontrollable damage modes. To ensure the safety and reliability of these structures, research was conducted on the anti-penetration response and response mechanism of laminated structures made of different composite materials. Using carbon fiber reinforced plastic (CFRP) laminated structures and glass fiber/epoxy resin composite aluminum alloy (GLARE) laminated structures as research objects, a high-impact experimental setup was constructed based on a first-stage light gas gun to explore the relationship between the energy absorption characteristics and impact energy of composite laminates. Combined with the ballistic limit equations, the ballistic limit values of the composite laminated structures were determined, and the ballistic limits of the 2 mm thick CFRP laminated structure and the 2 mm thick GLARE laminated structure were 138.3 m/s and 215.6 m/s, respectively. The damage modes of CFRP laminated structure are mainly fiber fracture on the impact surface and fiber delamination, fiber tensile fracture and fiber bundle splitting on the back surface, while the damage modes of GLARE laminated structure are mainly plastic deformation, internal fiber fracture and crack extension at the penetration. At the same time, the cohesion unit is introduced to carry out numerical simulation research, which shows that the damage pore morphology of the cohesion unit between layers of composite laminated structures are closely related to their fiber layups, and the damage mode of cohesion unit between layers of composite laminated structures have been investigated, which reveals the damage mechanism in high-impact environments. The research results provide theoretical basis and common technical support for reverse design of composite laminated structures suitable for high impact environments.

Influence of graphene nanoplates and titanium diboride particulate on wear and interfacial bonding properties of sintered aluminium alloy composites

Graphene has been considered an appropriate reinforcing filler for aluminium/titanium metal matrix composites due to its outstanding strength and stiffness and its exceptional thermal and electrical properties. The variable concentrations of graphene nanoplates (GNPs) was considered in this research, such as 2 %, 4 %, 6 % and 8 %, for determining wear properties and interface bonding aluminium alloy composites. The graphene-reinforced Al 7075/10 % TiB2 hybrid nanocomposite samples were produced using ball milling and pressure-less vacuum sintering process. The wear loss was investigated for all the variable graphene concentration samples with respect to wear load and sliding distance by pin-on-disk method and optimum concentatrion of GNPs was obtained by design of experimental (DOE) analysis. Further, Field Emission Scanning Electron Microscopy (FESEM), Elemental mapping, Energy Dispersive X-ray (EDX), and microhardness tests were utilized to analyze the graphene-reinforced Al 7075/10 % TiB2 hybrid nanocomposites, It was concluded that the wear resistance and microhardness of Al/10 % TiB2/4 % GNPs increased by 71.3 % and 17.6 %, respectively, compared with non-hybrid aluminium alloy materials. Moreover, a Transmission Electron Microscope (TEM) has been used to investigate the interfacial strength of aluminium alloy composites. The wear loss characteristics was also optimized using and central composite design (CCD) of response surface methodology (RSM).

Role of ilmenite particles on high temperature wear behavior and coefficient of friction of LM30 aluminium alloy composites

In this study, experimental approach involves material preparation via stir casting, extensive testing, and characterization. Optical microscopy, Scanning Electron Microscopy (SEM), and X-ray Diffraction (XRD) analysis reveal the uniform distribution of ilmenite particles within the alloy matrix and the formation of intermetallic phases. The thermal characteristics analysis demonstrates reduced 29 % coefficient of thermal expansion (CTE) in the composites, in the case of 15 wt% fine ilmenite particles reinforced composite. Hardness tests improvements in hardness, with the 15 wt% (32–50 μm) ilmenite Aluminium Metal Matrix Composite (AMC) exhibiting a 69% increase over the base alloy. Wear testing at various temperatures and loads showed the superior wear resistance of the composites compared to the base alloy, with the C3-15 composite outperforming cast iron typically used in brake drums. The wear rate of LM30 and LM30 + 15 wt% ilmenite (32–50 μm) (C3-15) sample is 38.8671 x 10−4 mm3/m and 10.50768 x 10−4 mm3/m at 200 °C and 68.67 N applied load, respectively. The coefficient of friction analysis further supports the enhanced performance of the composites. The coefficient of friction (COF) of LM30 + 15 wt% ilmenite (32–50 μm) (C3-15) is 0.29898, 0.47645 at 9.81 N and 68.67 N load, respectively measured at a temperature of 200 °C. Examining worn surfaces and debris provides insights into the wear mechanisms, including adhesion and abrasive wear. Overall, this research suggests the potential suitability of ilmenite-reinforced LM30 alloys as alternatives to traditional brake drum materials, offering improved thermal stability and wear resistance.

Explainable machine learning accelerated density functional theory prediction for diffusive transport behaviour of elements in aluminium matrix and graphene/aluminium interface

In this paper, the diffusive migration behaviour of alloy atoms in aluminium matrix and different types of graphene/aluminium interfaces is systematically investigated by using a machine learning accelerated density functional theory. A small sample dataset is established by first principles calculation, the types of input and output eigenvalues are determined by feature engineering, and the number of input features for perfect interfaces, defective interfaces, and aluminium matrix are finally determined to be 6, 5, and 4 by taking into account the effects of model complexity and prediction accuracy. With a five-fold crossover and by comparing more than a dozen machine learning models, the CatBoost algorithm possesses the lowest error as well as a better coefficient of determination. We further optimized the CatBoost algorithm with further parameters and adjusted the regularization term coefficients to avoid the risk of overfitting. The impact of each feature on the model prediction results was quantitatively described by constructing a matrix of SHAP values. The best performing Catboost model was used to predict the full periodic table data, which in turn was used to screen out the elemental species that are easy to move towards the graphene/aluminium composite interface. Those alloying elements are beneficial for modifying the defective graphene in the composite by comparing the results of elemental diffusive migration in the aluminium matrix as well as at different graphene/aluminium interfaces. The results of machine learning accelerated first principles calculations can provide a theoretical basis for further development of new aluminium alloy composite.