Aluminum-based Composite Materials Research Articles

Preparation of biomimetic reinforced modified carbon fiber composites and study of their friction properties

Because aluminum-based parts cannot be used for long-term applications in large load-wear environments, nickel–tungsten (molybdenum disulfide)/carbon fiber/aluminum composites were successfully prepared in this study for that purpose. By adjusting the plating solution ratio, nickel–tungsten was used as a carrier to introduce molybdenum disulfide nanoparticles, forming a nickel–tungsten/molybdenum disulfide composite coating on the surface of carbon fibers. To enhance the interfacial bonding strength between the carbon fiber and aluminum matrix, a laser was employed to induce the formation of a honeycomb-like structure on the surface of the aluminum base. This increased the contact area between the carbon fiber, aluminum matrix, and epoxy resin adhesives, forming a nickel–tungsten (molybdenum disulfide)/carbon fiber/aluminum composite material. The performance of this composite material was tested and analyzed. The results demonstrated that compared with the carbon fiber/aluminum composite material, the shear strength of the nickel–tungsten (molybdenum disulfide)/carbon fiber/aluminum composite material was increased by 129.7 %, and the friction coefficient and wear rate were reduced by 54.8 % and 83 %, respectively. Next, investigation of the mechanism underlying the honeycomb structure's contribution to the adhesive strength of the composites and their resistance to shear load revealed that the wear-resistant mechanism of molybdenum disulfide nanoparticles reinforced the nickel–tungsten composite coatings. The preparation and study of nickel–tungsten (molybdenum disulfide)/carbon fiber/aluminum composites provide a reference for expanding the applications of aluminum-based composite materials to meet the service requirements of complex environments.

Tribological, corrosion, mechanical, and metallurgical behavior of clay and Al2O3-reinforced aluminum-based composite material

Aluminum-based composite materials have garnered considerable attention in recent years owing to their outstanding mechanical and tribological properties. The integration of clay and Al2O3 into the aluminum matrix has notably elevated its tribological, corrosion, mechanical, and metallurgical characteristics. An examination of the metallurgical properties involved a thorough analysis of the material's microstructure and wettability. Notably, the composite material demonstrated enhanced wettability and a more uniformly distributed reinforcement, leading to improved mechanical attributes when incorporating 5% alumina and 5% clay particles. This composition resulted in heightened strength, improved hardness, and increased fatigue strength. Specifically, the addition of a mixture of ball-milled 5% alumina and 5% clay particles led to substantial improvements, with tensile strength, hardness, and fatigue strength increasing by approximately 40.49%, 44.11%, and 62.15%, respectively. However, this enhancement came at the cost of reduced toughness in aluminum, decreasing by about 46.66% following the addition of the ball-milled mixture. Tribological assessments, involving wear tests under varying loads and speeds, demonstrated that the inclusion of 5% clay and 5% Al2O3 substantially improved wear resistance. Furthermore, corrosion resistance was evaluated, revealing that the composite material exhibited enhanced corrosion resistance attributed to the passivation of the surface. Altogether, these findings underscore the promising potential of aluminum-based composite materials for various applications, particularly when tailored with specific ratios of alumina and clay particles.

Heat treatment behavior of Cr in the form of collagen powder and Al2O3 reinforced aluminum-based composite material

In the present study, collagen powder in the form of Cr has been extracted from chrome-containing leather waste. Extracted collagen powder along with alumina has been used as reinforcement with AA6061 matrix material. The composite material was fabricated by the stir casting technique. Comparative behavior of composite material with and without heat treatment was observed. The microstructure image of the Al/5% Al2O3/5% collagen composite has shown the uniform distribution of reinforcement particles. Proper wettability between the collagen powder, alumina, and matrix material was observed after the solidification for Al/5% Al2O3/5% collagen composite material. Tensile strength, hardness, ductility, and impact strength of composite material were significantly improved after the heat treatment process. However, results showed that ball-milled reinforced composite has a higher Young's modulus as compared to heat-treated composite. The percent porosity of aluminum alloy was found to be 0.18%. However, the porosity of Al/5% Al2O3/5% collagen powder ball milled composite material was found to be 1%. The XRD of the heat-treated Al/5% Al2O3/5% collagen powder composite showed the presence of Al, Al2O3, Cr, and Cr2O3 phases. Thermal expansion and corrosion behavior of the composite were also observed to identify the heat treatment effect on Al/Al2O3/collagen powder composite material.

Optimisation of EDMed fly ash and rice husk ash reinforced hybrid Al-based composite using improved COPRAS and entropy method

Rice husk ash (RHA) and fly ash (FA) pose a hazard to human health environment and are available abundantly across the globe. Attempts are being made to use such waste materials to create aluminum-based composite materials that can be used in a spectrum of uses. The Al6061/RHA/FA hybrid composite was prepared with 2.5 wt. % of each RHA and FA particle using a stair casting technique. This paper discusses mechanical characteristics like tensile strength, hardness, percentage elongation, and surface morphology, which were investigated using SEM. In addition, machinability investigations have been carried out using electric discharge machining, targeting the productivity of the component, quality, and accuracy. Taguchi's L9 array was used to investigate the impact of parameters like pulse current, duty-cycle, pulse ontime, and gap voltage on output parameters MRR, tool eroded, and radial overcut. Enhancements in tensile strength and harshness have been observed by the reinforcement of FA and RHA particles. [Submitted 15 July 2021; Accepted 17 September 2021]

Development of Aluminum-Based Composite Material by using Bagasse Ash and Eggshell as Reinforcement Along with Nano-CuO Particles

Development of Aluminum-Based Composite Material by using Bagasse Ash and Eggshell as Reinforcement Along with Nano-CuO Particles

Recovery of Cr from chrome-containing leather wastes to develop aluminum-based composite material along with Al2O3 ceramic particles: An ingenious approach

Abstract Leather industries cause soil pollution in terms of leather wastes. Chrome-containing leather wastes (CCLW) also cause various types of pollutions such as air and soil pollution. The utilization of CCLW in the development of aluminum-based composite is the emerging area in the synthesis of materials. In this study, chromium(Cr) in the form of collagen powder was extracted from CCLW. Extracted collagen powder was ball milled with alumina particles for 12.5, 25, 50, 75, and 100 h. The average density of the mixture of ball-milled collagen and alumina particles was reduced by about 1.20% after ball milling for about 100 h. The stir casting technique was employed to develop the aluminum-based composite material. The ball-milled reinforced aluminum-based composite material showed a fair distribution of reinforcement particles as compared without ball-milled reinforced composite material. Tensile strength and hardness of composite material improved by about 35.53 and 46.61%, respectively, after using the mixture of ball-milled 5% collagen powder and 5% alumina particles in the aluminum alloy. However, ductility and toughness were reduced. Corrosion weight loss and thermal expansion of the Al/5% collagen/5% alumina particles with ball-milled composite were found to be 0.022 mg and 5.44 mm3, respectively. X-Ray diffraction of the Al/5% collagen/5% alumina particles with ball-milled composite showed the presence of Al, Al2O3, Cr2O3, and Cr phases. The presence of hard phases such as Al2O3, Cr2O3, and Cr was responsible for enhancing the hardness and tensile strength of the composite. The developed composite material can be utilized in the fabrication of engine blocks, connecting rods, and piston rings.

INVESTIGATIONS ON THE MECHANICAL ALLOYING PROPERTIES OF AL 2024 ALLOY BY THREE-DIMENSIONAL BALL MILL

Aluminum-based composite materials are frequently preferred in many new-generation engineering applications due to their high strength, wear and corrosion resistance, improvement of mechanical properties, machinability, and low density. Mechanical alloying has an important place in the production of composites with high properties in powder metallurgy, which is one of the composite material production methods. In this paper, the deformation of Al 2024 alloy powder, which is frequently used in the industry, is investigated by the three-dimensional ball mill. Three different rotation speeds (150, 200 and 250[Formula: see text]rev/min), three different ball-to-powder ratio (5:1, 10:1 and 20:1) and three different milling times (30, 60 and 90[Formula: see text]min) were used in the milling processes. Deformations in the powders were evaluated by particle size analysis and powder structure examination. The obtained results were analyzed with analysis of variance and regression method, three-dimensional graphics, and scanning electron microscope images. When the results are examined, the maximum percent areas covered by the deformed particles and maximum particle size among the selected experimental parameters were obtained at 250[Formula: see text]rev/min, 20:1 ball-to-powder ratio and 60[Formula: see text]min as 6.849% and 54[Formula: see text][Formula: see text]m.

Fabrication and Characterization of Aluminum (Al-6061) Matrix Composite Reinforced with Waste Glass for Engineering Applications

Aluminum composites with various reinforcement materials are widely applicable in advanced engineering due to their better strength to weight ratio, better stiffness, and high thermal conductivity as well as excellent wear and corrosion properties. This stimulates curiosity to study aluminum metal matrix composite reinforced with waste glass to improve its mechanical and physical properties. The composite specimens were prepared using stir-casting rout by varying weight percentage of reinforcing waste glass powder from 0% to 30%. The fabricated composite samples were characterized using universal testing machine, FTIR, DSC, TGA, and optical microscope. The results revealed that as the waste glass particle content increased in the metal matrix, there was a significant enhancement of the mechanical properties like hardness and tensile strength as compared to the pristine sample. The microstructural properties analyzed using optical microscope show good bonding between the reinforcements and the pristine materials in the composite that indicates the glass particulates are uniformly distributed in the Al-6061 matrix. All in all, the effect of waste glass powder in aluminum metal matrix composite was clearly observed and it enhances the mechanical, physical, and thermal properties of the newly fabricated aluminum-based composite materials.

Research on Preparation and Mechanical Properties of Multilayer Graphene Reinforced Aluminum Matrix Composite

In order to solve the problem of the dispersion of graphene in aluminum-based composite materials, a high-energy ball milling method was used to prepare graphene/aluminum-based composite powder, and then the graphene/aluminum composite material was obtained by vacuum hot pressing. XRD, SEM, TEM were used to analyze and study the morphology and microstructure of graphene/aluminum-based composite powders, and the tensile mechanical properties, hardness and fracture morphology characteristics of graphene/aluminum-based composites. The research results show that the addition of graphene can reduce the cold welding of aluminum powder during the high-energy ball milling process, and obtain better dispersed graphene/aluminum composite powder; when the content of graphene is 1 wt.%, the composite material The tensile strength can reach 295.62 MPa, the hardness is 113.6HV, which is 24% higher than the pure aluminum tensile strength, and the hardness is increased by 20%; graphene exists in the dimples of the tensile fracture, under the action of tensile force, Graphene can carry load transfer and improve the tensile strength of composite materials, which is the enhancement mechanism of graphene in aluminum-based composite materials.

Alumina catalyst waste utilization for aluminum-based composites using the friction stir process

Abstract A significant amount of environmental pollution is caused by oil refinery industries in the form of spent alumina catalyst (SAC) waste generated during the process. This waste causes various detrimental effects on human health. In this study, an effort has been made to consume the SAC in the fabrication of aluminum-based composite materials via the friction stir process (FSP). An X-ray diffraction image of the SAC powder used in this work confirms the occurrence of Al2O3, Fe2O3, SiO2, and CaO phases. These hard-phase materials form the basis for SAC to be used as reinforcement content with the aluminum alloy. The FSP is used to create the composite material. It is evident from the scanning electron microscopy image of the Al/SAC composite developed by the FSP technique that fair distribution of constituent ingredients is attained during the process. The incorporation of SAC contents in the aluminum alloy results in remarkable enlargement in tensile strength and hardness of the composite material. The Al2O3, Fe2O3, SiO2, and CaO phases of SAC showed a considerable effect on thermal expansion and corrosion weight loss of the composite.

Effects of graphene size and arrangement on crack propagation of graphene/aluminum composites

Aluminum-based composite material is one of the most important candidate materials in the mechanical industry and aerospace engineering due to its light weight and high strength. Graphene is an ideal reinforcement for composite materials for its excellent mechanical properties. Till-now, the contribution of graphene sheets in the process of crack propagation in composites is not clear. In present work, the effects of graphene size and distribution in graphene/aluminum composites are explored using molecular dynamics simulation methods. It is found that when the length of graphene flake is less than 3.35 nm, the generated sub-cracks in the composite is benefit to the crack propagation. This effect reduces the mechanical properties of composite. When the length of graphene flake is greater than 3.35 nm, graphene sheet impedes the crack propagation and dislocates slip at sub-cracks. In addition, the distribution of graphene flakes angle changes the crack propagation path. Our findings also provide insights into ways to optimize mechanical properties of graphene/aluminum composites.

Study of CCLW, Alumina and the Mixture of Alumina- and CCLW-Reinforced Aluminum-Based Composite Material with and Without Mechanical Alloying

Study of CCLW, Alumina and the Mixture of Alumina- and CCLW-Reinforced Aluminum-Based Composite Material with and Without Mechanical Alloying

Tribological Properties of Al-Based Composites Reinforced with Fullerene Soot.

Aluminum-based composite materials reinforced with fullerene soot, which is a mixture of fullerene and amorphous carbon, are promising materials for friction and wear applications. Composite materials: aluminum with 2% fullerene soot (f.s) and Al with 2% f.s and 2% Cu were obtained via mechanical milling followed by hot pressing. The tribological properties (friction and wear) of the listed composites were investigated and compared with the results for pure aluminum obtained under similar conditions. It has been shown that the addition of fullerene soot reduces the friction coefficient by 25%. At additional alloying with copper, the friction coefficient decreased by 35% in comparison with pure aluminum and also lad to a decrease in friction fluctuations. The wear rate of composite Al with 2% f.s decreased twice in comparison with that of pure aluminum, and with additional alloying it decreased 2.5 times. The morphology of the wear surfaces was investigated by scanning electron microscopy (SEM). The influence of fullerene soot and additional alloying on the wear mechanism was shown.

Production of Aluminum Matrix Composite Material by Active Carbon Additive

The effectiveness of composite materials with the addition of activated carbon produced from biomaterial with a new application on aluminum-based composite materials was investigated in this study. Activated carbon was produced from the peanut shells via the chemical activation method and the obtained activated carbon was mixed with aluminum and composite material. For the characterization of the composite material obtained, XRD and SEM–EDS optical photographs were assessed in the experimental process. According to Vickers Hardness and Dynamic Micro Hardness results, the sample with the hardness value of 2% AC added had the highest hardness value. The value of the elastic modulus was found to be 9.59GPa with an increase of 3.4 times compared to aluminum with 2% activated carbon addition. This increases with activated carbon quantity, and weakens the composite structure due to weak van der waals interaction with aluminum, which reduces hardness; therefore, the best ratio of the activated carbon reinforcement to the aluminum matrix was obtained at 2% activated carbon addition.

Influence of Nano-CuO on Synthesis and Mechanical Behavior of Spent Alumina Catalyst and Grinding Sludge Reinforced Aluminum Based Composite

In the present study, an attempt has been made to utilize spent alumina catalyst (SAC) waste as well as grinding sludge (GS) waste in the development of aluminum-based composite material. Nano-CuO particles have been added to the Al/SAC/GS composite to further enhance the mechanical properties of composite material. The microstructure of the developed composite by the stir casting technique showed the uniform distribution of the reinforcement particles. Results showed that tensile strength, hardness, and compressive strength of composite material improved by about 21.39%, 34.20%, and 20.73%, respectively, after adding the 4.5% SAC, 4.5% GS, and 1.5% nano-CuO in the aluminum alloy. However, the toughness of the composite material is decreased with respect to the aluminum alloy after adding the reinforcement particles. XRD of the composite material shows the presence of Al, Al2O3, Fe2O3, SiO2, and CuO phases. The presence of these hard phases may be responsible for enhancing the tensile strength, hardness, and compressive strength of composite material. Corrosion weight loss and thermal expansion of the developed composite have been also investigated to identify the SAC, GS, and nano-CuO addition to the aluminum alloy.

Synthesis and Mechanical Behavior of Ball-Milled Agro-Waste RHA and Eggshell Reinforced Composite Material

Abstract Nowadays, there are various industrial wastes from industries that produce lots of environmental pollution. Rice husk ash (RHA) is agricultural waste and eggshell waste is industrial waste. These wastes also produce lots of soil pollution. However, by utilizing these wastes, some environmental problems can be reduced. In the present investigation, an attempt was made to utilize RHA and eggshells as reinforcement material in the development of aluminum-based composite material. Carbonized eggshell ash (CESA) particles and RHA were ball-milled for 75 hours to obtain a single entity. The mixture of CESA and RHA particles has been varied from 2.5 % to 12.5 % in the development of the composite. Ball-milled reinforcement particles in the single entity showed uniform distribution in the aluminum-based matrix material. Results showed that after the heat treatment process, the tensile strength and hardness of the aluminum/5 % CESA/5 % RHA composite was found to be 189.95 MPa and 56 brinell hardness number (kgf/mm2) respectively. The tensile strength and hardness of the composite after heat treatment were enhanced by 31 % and 60 %, respectively. However, the toughness and ductility were reduced after adding the mixture of carbonized eggshell particles and alumina in the aluminum alloy. Corrosion loss and thermal expansion behavior were also observed to identify the carbonized eggshell and RHA addition in the aluminum alloy. Corrosion loss and thermal expansion of the AA3105/5 % eggshell powder/5 % RHA composite after heat treatment were found to be 0.011 gm and 4.35 mm3, respectively.

A critical review on different casting technique to develop the composite material and its tribo-mechanical behaviour

Nowadays, there are various types of techniques have been used to develop the composite material by using various types of reinforcement particles. In the present review article, different techniques have been discussed for the development of aluminum-based composite material. Furthermore, the percent utilization of different reinforcement particles has been also discussed. Mechanical properties of the developed composite were also discussed. It was identified from the literature that normal load, sliding velocity, sliding distance, and reinforcement weight percent also affect significantly the tribological behavior of composite material.

WEAR PROPERTIES OF ALUMINUM MATRIX COMPOSITES REINFORCED BY GRAPHENE ENCAPSULATED SiC NANOPARTICLES

Graphene encapsulated SiC nanoparticles reinforced aluminum matrix composites were prepared by high energy ball-milling and hot-press sintering methods. The effect of graphene content on microstructure and wear properties of composites was investigated. The results show that the graphene sheets successfully encapsulates SiC nanoparticles to form a composite reinforcement phase under the condition of the graphene content of 1 wt.%. SiC nanoparticles encapsulated with graphene predominantly are homogeneously distributed on the grain boundaries of Al matrix. The interface between graphene and Al matrix is sharpand no Al-C compound is formed on the interface. The increase of the reinforcement phase reduces the wear performance of the composite material. The main wear mechanisms of aluminum-based composite materials are the combination of delamination wear and abrasive wear. As the graphene content increases, the wear mechanism changes from abrasive wear to delamination wear.

STUDY OF THE PECULIARITIES OF THE LASER WELDING OF ALUMINIUM BASED COMPOSITE MATERIALS

The paper considers the problem dealing with the development of the methods of the laser welding of new light composite materials of the increased strength on the base of the aluminum allows, having fiber, dispersive and layered strengthening. Obtaining of their permanent joints requires the application of such innovation solutions, which can be efficiently implemented in industry. One of the solutions may be laser welding process. The paper studies the characteristic features of the laser welding of the aluminum- based composite materials, necessary experiments for the development of the technological methods for the obtaining qualitative joints were carried out. It is established that among the parameters of the aluminum-based composite materials structure the volume part of the fiber material in the matrix greatly influences the welding process. Analysis of the results of studies shows that when the content of fibers is higher than 30% the welding process becomes more complicated. Main obstacles for the formation of the qualitative joint are high heat input and difference of melting temperatures of the composite materials. As a result of the intensive heating there exists the probability of the fibers destruction and formation of the intermetallidic compounds. The quality of the permanent joints, obtained by fusion welding can be improved by means of strict dosing of the heat input. The studies, carried out allowed to determine the characteristic features of the laser welding of the aluminum-based composite materials, which have matrix filler of different types .It was established that the presence of boron fibers on one hand improves welding properties of the aluminum composite and allows to obtain sound welds but on the other hand-worsens the mechanical properties of the obtained joint. Dispersed alloying of the aluminum composite with the particles of Al2O3 leads to the formation of the pores in welded joint, obtained by laser welding. Presence of the steel fibers improves the welding properties but leads to the formation of the intermetallidic compounds. For joining the composites with the binders in the form of the fibers or separate particles it is necessary to use additional technological methods, for instance, welding-soldering. This type of welding is recommended to perform with maximum possible speed (to reduce specific energy intensity). Another special method for welding aluminum composites of all the considered types is the application of the repetitively pulsed radiation with the frequency within the range of 200 – 330 Hz, and relative pulse duration of 1.5 and welding with the aluminum adaptor or welding on the back-up plate with the gap between the ends ~0,6 mm and its filling by means of the filler wire fusion.

Tensile, compressive and heat transfer analysis of ZrO2 reinforced aluminum LM6 alloy metal matrix composites

In the present investigation, aluminum LM6 alloy is used as a matrix and it was reinforced with various weight fractions of ZrO2 Such as 0, 3, 6, 9 and 12 wt%. The composite materials were cast using the stir casting method. The various stir cast samples were subjected to Energy Dispersive Spectrometry (EDS) analysis, mechanical and thermal analysis. The mechanical analysis of tensile and compressive strength was carried out for the five various weight proportions of ZrO2. The EDS analysis confirmed that the presence of aluminum and, ZrO2 particles in developed composites. Tensile and compressive strength was increased by the addition of ZrO2. In this work, mainly deals with the analysis of heat transfer for the newly developed aluminum-based composite materials when it is used as a pin fin for varying the weight percentages of ZrO2 with the aluminum particles. The Heat transfer analysis was carried out for the Aluminum LM6 matrix in addition to that varying the weight proportions of ZrO2. The efficiency and effectiveness of each fin were measured during this test. From the analysis, it was revealed that heat transfer rate was increased for the increased weight fraction of ZrO2. Similarly, the efficiency of the pin and effectiveness was increased for the increasing weight percentages of zirconium dioxide. A similar test was carried out for the same materials for varying the input voltage and current. From that test, it was identified that heat transfer is gradually increased for the increasing supply of voltage and current.