Aluminum-based Composites Research Articles

Machine Learning Modeling of the Mechanical Properties of Al2024-B4C Composites

Aluminum-based composites are in high demand in industrial fields due to their light weight, high electrical conductivity, and corrosion resistance. Due to its unique advantages for composite fabrication, powder metallurgy is a crucial player in meeting this demand. However, the size and weight fraction of the reinforcement significantly influence the components' quality and performance. Understanding the correlation of these variables is crucial for building high-quality components. This study, therefore, investigated the correlations among various parameters—namely, milling time, reinforcement ratio, and size—that affect the composite’s physical and mechanical properties. An artificial neural network model was developed and showed the ability to correlate the processing parameters with the density, hardness, and tensile strength of Al2024-B4C composites. The predicted index of relative importance suggests that the milling time has the most substantial effect on fabricated components. This practical insight can be directly applied in the fabrication of high-quality Al2024-B4C composites.

Synthesis and Purification of Nano-sized Titanium Carbide Particles through Vacuum Carbothermal Reduction for enhanced Mechanical, Microstructural Morphology, and Tribological Properties in Friction Stir Processed A356-based Aluminum Composites

This study focused on the synthesis and purification of nano-sized titanium carbide (TiC) particles through vacuum carbothermal reduction under a hydrogen/argon atmosphere. The process involved the production of carbon-coated titanium precursors, followed by heating under vacuum conditions at 1500°C for 2.5 hours. The resulting products underwent additional treatment in either a hydrogen/argon (1:1) mixed gas or pure hydrogen gas. Experimental findings revealed that TiC powders exhibiting a single phase are obtained within a molar ratio of Ti to C ranging from 1:2 to 1:4. Adjusting the molar ratio of Ti/C in the precursors allowed for controlled variation in the particle size of the synthesized TiC powders, ranging from 50 to 80 nm. Treatment in hydrogen/argon mixed gas at 850°C for 3 hours resulted in TiC products with an impressive purity of 99.40%. The subsequent incorporation of 5% Nano-TiC-3 (Ti to C ranging from 1:3) as reinforcement into an aluminum alloy by Friction stir process technique demonstrated a remarkable 19.41% improvement in tensile strength, highlighting the efficacy of this specific reinforcement. The nano-TiC-3 reinforced composite exhibited uniform distribution without porosity. Additionally, a notable 50.81% improvement in hardness and the best wear resistance were observed for the 5% Nano-TiC-3 reinforced aluminum composite. This comprehensive study contributes valuable insights into the synthesis, purification, and application of nano-sized TiC particles, paving the way for the development of high-performance aluminum-based composites with enhanced mechanical and tribological properties.

Corrosion and mechanical properties of Al/Al2O3 composites fabricated via accumulative roll bonding process: Experimental and numerical simulation

With the advancement of science and technology and the construction of metal-based composites (MMC), it became possible to achieve improved properties that were not easily available in an alloy. In fact, with the emergence of such technology, manufacturers were able to adjust the resulting materials according to their needs in such a way as to provide mechanical strength, hardness, corrosion resistance, or other desired properties. These composites were used in various aerospace, automotive, construction, and production industries. Aluminum-based composites are among the structures that have taken an important place in the industry due to their lightweight and high strength. The present study produced bi-alloy aluminum-based 1060/5083 composites fabricated with alumina particles with a Hot ARBp at T = 380 °C. Also, the effect of rolling steps on the roll bonding mechanism is investigated using numerical simulation. As the novelty of this study and for the first time, a bi-alloy 1050/5083 composites reinforced Al2O3 particles via ARB process have been produced and then, potential dynamic polarization in 3.5 Wt% NaCl solution was used to study the corrosion properties of these composites. The corrosion behavior of these samples was compared and studied with that of the annealed aluminum. The study aimed to investigate the bonding behavior between the bi-alloy layers. So, as a result of enhancing influence on the number of ARBp, this experimental investigation revealed a significant enhancement in the main electrochemical parameters and the inert character of the Alumina particles. Reducing the active zones of the material surfaces could delay the corrosion process. Results showed that the corrosion resistance of the sample fabricated after six steps improved more than 100 % in comparison with the initial annealed Al alloy. Also, the average peeling force improved from 45 N to 94 N for the sample fabricated with six steps. Moreover, at a higher number of steps, the corrosion of MMC improved. Moreover, increasing the number of ARBsteps illustrated an improvement in the wear resistance of samples. Finally, the samples' bonding interface, corrosion surface, and peeled surface were investigated using scanning electron microscopy (SEM).

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.

Enhanced nucleation at Al(111)/Ti3AlC2(0001) interfaces: The role of doping in adhesion and interfacial stability

This study investigates the structure of the Al(111)/Ti3AlC2(0001) interface and elucidates the mechanism of heterogeneous nucleation of Ti3AlC2 particles within aluminum-based composite materials. A comprehensive examination of adhesion work, interfacial energy, and electronic structure is conducted for pristine and doped Al(111)/Ti3AlC2(0001) interfaces. The findings reveal that the C(TiC)-terminated hexagonal close-packed (HCP) stacking configuration at the Al(111)/Ti3AlC2(0001) interface exhibits the highest adhesion work and the lowest interfacial energy. This is attributed to the prominent covalent bonding between Al-3p and C-2p orbitals, indicating robust interfacial bonding strength and stability. Consequently, the results substantiate the potential of Ti3AlC2 particles as suitable substrates for heterogeneous nucleation of α-Al grains, effectively enhancing the strength and ductility of aluminum-based composites. Notably, doping the interface layer with specific elements significantly influences the adhesion work and interfacial energy. Introducing Ti and Mn at the interface substantially enhances adhesion work and concurrently reduces the interfacial energy of the C(TiC)-terminated HCP stacking Al(111)/Ti3AlC2(0001) interface, actively promoting nucleation of the aluminum matrix. However, incorporating Mg, Cu, and Zn at the interface decreases the adhesion work, unfavorable for the nucleation of Ti3AlC2 on the aluminum matrix. The binding energy at the doped Al(111)/Ti3AlC2(0001) interface follows the hierarchy: Mn > Ti > Mg > Cu > Zn. These findings provide valuable insights into the distinctive characteristics of Al(111)/Ti3AlC2(0001) interfaces and the underlying nucleation processes, holding substantial promise for the development of advanced aluminum-based composites.

TRIBOLOGICAL AND MECHANICAL CHARACTERIZATION OF AL6060/SI3N4/BN HYBRID ALUMINIUM METAL MATRIX COMPOSITES

In recent years, aluminium-based composites have emerged as preferable substitutes for conventional aluminium alloys in various contemporary applications, like the aerospace and automotive industries. This shift can be attributed to their enhanced characteristics and superior properties. Improved strength-to-weight ratio, reduced thermal expansion, and superior wear resistance are just a few of the benefits. Several researchers have created aluminium metal matrix composites (AMMCs) by combining various ceramic reinforcing elements with aluminium alloys. Ceramic reinforcing materials increase the strength, hardness, and wear resistance. The aim was to enhance the mechanical and wear characteristics of a composite material, i.e., to find the mechanical characteristics of an Al6060/BN hybrid alloy, such as tensile strength, impact, hardness, etc. The composites were developed by incorporating silicon nitride (Si3N4), a hard ceramic material, as the main reinforcing component, along with boron nitride (BN), a solid lubricant, as the secondary reinforcement. The stir-casting technique was employed to fabricate aluminium metal matrix composites with varying weight fractions (0, 5, and 10) w/% of Si3N4 and BN. Tensile and hardness tests were conducted to analyse the basic mechanical properties of the resulting composites.

Mechanical properties of aluminum /SiC bulk composites fabricated by aggregate accumulative press bonding and stir-casting process

Today, the emergence of composite structures can be considered a huge transformation on an industrial scale, especially in the transportation industry. Among all the structures made by the composite process, aluminum-based composites (AMMCs) are particularly popular both in the scientific and industrial fields. These structures are very light in weight and, at the same time, have significant strength. The ability to work with the machine in these structures is very high, and their plastic deformation is so high that they can be used in different industry sectors. Today, various methods are used to induce plastic deformation in aluminum-based composites (AMMCs). One of these methods is called aggregate accumulative press bonding (APB). The advantage of this method compared to other methods is that this method can create a homogeneous nanocomposite with ultra-fine grains. In the present study, the investigation of mechanical properties (MP's) of AA5083/5%SiC bulk composites fabricated via APB vs. pressing temperature (Temp) was conducted. All primary composite samples were fabricated via the stir-casting process (SCP). APB process was done on composite samples as a supplementary process. Finally, the effect of pressing Temp on the MP and microstructural properties (MSP) was investigated. The pressing Temp was varied between the ambient Temp's up to T = 300 °C. The MP were measured in this study by the Vickers micro-hardness (VMH) test, tensile test, and scanning electron microscopy (SEM). It was realized that the pressing Temp has a prominent effect on the MS and MP of fabricated 400°C. Samples fabricated at the ambient Temp have low ductility and high strength while for samples fabricated at T = 300 °C, the elongation and toughness values were higher than others. The TS of samples after 2 steps of APB at T = 200°C is 1.31 times more than that of fabricated at T = 300°C. Elongation was reduced sharply to 1.8% after the two steps at the ambient Temp, while it was 21% for the annealed AA5083.

Microstructure, mechanical, and wear properties evaluation of Al-Cu based composite using RHA as reinforcement

ABSTRACT This study utilised a two-step stir-cast technique to fabricate Aluminium-based composites reinforced with 5% wt Copper (Cu) and varying weight percentages (1–4% wt) of Rice husk ash (RHA). Our work investigated the role of RHA reinforcement on the microstructure, mechanical properties, and wear characteristics of AlCuRHA composite. Characterisation of the composites and fracture surfaces was performed utilising SEM. The hardness and tensile properties were evaluated. Wear was conducted on the composites in dry and wet conditions using H2SO4 as the medium. The microstructure revealed the homogeneous distribution of the RHA within the AlCu matrix. The hardness of reinforced AlCu is enhanced from 54.24 Hv to 122.74 Hv with an increment of RHA reinforcement from 0 to 4%. The Ultimate tensile (UTS) and specific strengths were noted to increase with increased RHA content from 1 to 4% wt. The ductility levels were reduced with the increase in RHA content. The RHA-reinforced AlCu composite exhibits mixed ductile and brittle fracture modes. The composites with RHA exhibited greater wear resistance. Compared to the dry condition, the composites exhibited improved wear resistance in the acidic environment. The composite with 4 wt% RHA exhibited the lowest wear rates regardless of the environment.

Fabrication and characterization of alumina-based composites by in-situ combustion synthesis in Al-FeTiO3-B2O3-C alumino-thermic system

Fabrication and characterization of alumina-based composites by in-situ combustion synthesis in Al-FeTiO3-B2O3-C alumino-thermic system

Structure, Phase Composition, Mechanical and Corrosion Properties of Aluminum-Based Composites

Structure, Phase Composition, Mechanical and Corrosion Properties of Aluminum-Based Composites

On the Possibility of Using Secondary Alloys in the Production of Aluminum-Based Metal Matrix Composite

Aluminum-based composites provide tribological performance and thermophysical properties that, combined with being lightweight, are suitable for their application in automotive brake discs. Aluminum alloys allow the use of secondary materials to produce composites, with the drawback of several elements, impurities, and oxides that can harm the mechanical and thermophysical properties. This preliminary study explored the mechanical and thermophysical performance of a composite material produced with a secondary matrix alloy. Overall, the results are promising, with a minimal decrease in mechanical and thermophysical properties despite clustered silicon carbide particles in the composite with the secondary matrix. The challenges in effectively dispersing carbides in the melt seem linked to aluminum oxides, and future microstructural investigations will aim to clarify this aspect.

Ultrasonic elliptical vibration micro-cutting mechanism of CoCrFeNiAlX short fiber reinforced aluminum-based composite

This study explores the precision micro-machining of CoCrFeNiAlX short fiber-reinforced 7A09 aluminum matrix composites, focusing on the interplay between machining parameters and composite properties. The investigation scrutinizes the influence of vibrational amplitude, oscillation frequency, penetration depth, fiber orientation, and aluminum concentration on machining dynamics. Findings reveal that enhancing the X-axis vibrational amplitude to 80 μm is associated with a decrease in machining force, which then rises after reaching a threshold. In contrast, maintaining the Y-axis amplitude below 90 μm significantly increases the machining force. Higher amplitudes and frequencies were observed to reduce machining forces by up to 57% at an ultrasonic frequency of 15 kHz. Employing ultrasonically assisted vibration cutting (UEVC) culminated in a substantial 72% decrease in machining forces when fibers were optimally oriented at 45°. The study also identifies a direct correlation between the cutting temperature and both the vibrational amplitude and penetration depth, with the Y-axis amplitude having a more significant impact, causing a 55% variation in temperature. An increase in frequency initially lowers the cutting temperature, with the lowest temperature of 92 °C achieved at 5 kHz, while the peak temperature occurs at a machining depth of 60 μm. Temperature profiles indicate an initial rise with increased fiber orientation, followed by a decline. A slight increase in aluminum concentration marginally raises the cutting temperature. Furthermore, UEVC is found to produce a parabolic residual stress distribution, where amplitude and penetration depth determine the peak stress levels, and higher frequencies contribute to stress reduction. Fiber orientation also affects residual stress, with proper alignment reducing compressive stress and misalignment increasing it. The lowest point of residual compressive stress is detected in the Al0.6 fiber composite, while the peak is observed in the Al1 composites.

Semisolid stir processing of AZ91/TiO2 nanocomposite analysis with SiC exposure: behaviour measures

ABSTRACT This research affair to synthesize the magnesium alloy (AZ91) hybrid nanocomposites with 0.5wt% titanium dioxide (TiO2) and 2.5, 5, and 7.5wt% of silicon carbide (SiC) nanoparticles through a semisolid stir cast route under argon (inert) nature and its particle distribution enhanced with uniform stir speed of 400rpm as well as the casting defects reduced by using nature of inert. The excellence of semisolid stir processing with SiC exposure on AZ91/TiO2 composite is analyzed with physical, surface morphological and mechanical exploits. Compared to aluminium-based composites, this composite weight is less, with an acceptable level of voids (less than 1.5%). An effort of processing, the microstructure proved their SiC and TiO2 appearance as uniform. The AZ91/0.5wt%TiO2/7.5wt% SiC exploited maximum hardness of (84±0.8HV), impact toughness of (16.3±0.3J/mm2), and excellent strength (251±5MPa) with reduced elongation percentages of (4.5%). This optimum property sample will be planned for automotive roof frame applications.

Wettability and Mechanical Properties of Red Mud-Al2O3 Composites.

In 2023, the global production of new red mud is expected to reach nearly 200 million tons, but less than 10% of it is currently being utilized in an environmentally friendly manner. To reduce the sintering temperature of alumina ceramics, a sintering aid method is used, as high-purity alumina ceramics require a solid-phase sintering temperature of over 1700 °C. The metal oxides present in red mud are necessary components for high-performance composite alumina ceramics. Composites were obtained by mixing and sintering red mud and Al2O3. This study focused on the mechanical properties and wettability of these composites. The results indicated that the 10% red mud-Al2O3 composite exhibited the highest hardness (20.12 GPa) and flexural strength (346 MPa). This is attributed to the formation of a mineral phase dominated by CaAl12O19, generated by the red mud during the sintering process, which filled the pores and reduced porosity. The surface energy of the red mud-Al2O3 composite was the highest at room temperature and high temperature, reaching 49.60 mJ·m-2 and 1164.7 mJ·m-2, respectively, indicating that it has better stability at both room and high temperatures. This study provides an important fundamental basis for the application of red mud-alumina composites to replace alumina-based composites in the field of construction materials, molten metal filters, ceramic cleavers, etc.

Advance processing of cluster-free CNT reinforced 6082 Al matrix nanocomposites: influence of mechanical milling and cryomilling

ABSTRACT In the present study, lightweight high-strength carbon nanotubes (CNTs) reinforced aluminium-based composite was fabricated through powder metallurgical processing. The effect of planetary milling and cryogenic assisted milling on the structure, morphology, mechanical properties, phase composition, and thermal stability of CNTs reinforced Al6082 Al nanocomposites powders was investigated using X-ray diffraction (XRD), scanning electron microscope (SEM)- Energy dispersive spectroscopy (EDS), transmission electron microscope (TEM), and indentation techniques. The CNTs in the Aluminium (AL) matrix were distributed uniformly after 50 h of milling. Further, the cryomilling of 50 h milled Aluminium matrix composites (AMC) decreases agglomeration even more and was successful in cleaving the nanotubes as well as minimising entanglements. The broadening of diffraction peaks suggests a reduction in the crystallite size (from ~36 to ~20 nm) and an increase in induced strain. Milled powders were consolidated through the hot-press and spark plasma sintering technique. The mechanical properties of these AMCs were evaluated through indentation for hardness (>250 HV) and compressive testing techniques. SPSed samples reported better properties in comparison to hot-pressed samples. It is discovered that post-CM of Mechanical Milling (MM) powder aids in overcoming issues related to the agglomeration of Al/CNT composites, and the goal to fabricate tangle-free CNT reinforced composite was achieved. Moreover, it showed enhanced mechanical properties with a maximum yield strength of 210 MPa and good synergy between strength and ductility.

Advancing Aluminum-Based Composite *Manufacturing: Leveraging TiO2 Reinforcement through Stir Casting Technique

This study explores the advancement of aluminum-based composite manufacturing through the integration of titanium dioxide (TiO2) reinforcement using the stir casting technique. Aluminum alloy served as the matrix material, combined with ceramic reinforcement particles, melted at approximately 700°C within a muffle furnace. Through continuous stirring at 400 rpm for 10 minutes, ceramic particles were uniformly dispersed into the molten alloy, crucial for enhancing composite properties. The incorporation of 6.5% TiO2 via stir casting resulted in significant enhancements across multiple mechanical properties. Tensile strength improved by 23.67%, while hardness saw a remarkable increase of 38.9%. Additionally, fatigue strength exhibited a notable improvement of 26.67%, and wear resistance showed a substantial enhancement of 24.34%. The uniform dispersion of TiO2 particles throughout the composite material underscores the efficacy of the stir casting technique in achieving consistent improvements across various performance metrics. These findings hold promise for the development of high-performance aluminum-based composites tailored for diverse engineering applications.

Steel Chips Reinforcement in Aluminum-Based Composites: Revolutionizing Manufacturing via Stir Casting Technique

This study investigates the utilization of waste steel chips as reinforcement in aluminum-based composites through the stir casting technique. Steel chip particles were introduced gradually into the molten aluminum alloy while stirring at 400 rpm for 10 minutes to ensure uniform dispersion. Precise temperature control prevented premature solidification, facilitating effective incorporation of steel chips. The resulting composite exhibited a predominantly uniform distribution of reinforcement, indicating successful processing.The addition of 7.5% waste steel chips led to remarkable improvements in mechanical properties. Tensile strength increased by 15.67%, while hardness showed a substantial enhancement of 25.56% compared to the base composite. Moreover, wear resistance exhibited a notable improvement of 19.45%. These enhancements underscore the efficacy of waste steel chips as reinforcement, revolutionizing manufacturing practices in aluminum composites. The findings highlight the potential for sustainable and cost-effective approaches to enhance mechanical performance, contributing to advancements in materials engineering and promoting eco-friendly manufacturing practices.

Evaluation of microstructure evolution and mechanical properties of Al-10Zn-1.63Si/Irvingia gabonensis particulates alloy composites.

This study demonstrates the feasibility of using Irvingia gabonensis shell particulates (IGSp) as alternative reinforcing materials in the development of aluminium-based composites. In this experimental study, the microstructure, phase composition, and mechanical behaviour of Al-10Zn-1.63Si/xIGSp (wt%, x = 1, 3, 5 and 7) composites were investigated. The Al-10Zn-1.63Si based composites were fabricated using the stir-casting technique. Different weight percentages (1, 3, 5 and 7) of IGSp were added to the Al-10Zn-1.63Si matrix. The chemical constituents of the IGSp were determined using X-ray fluorescence (XRF). The grain characteristics and phase(s) compositions were determined using Scanning Electron Microscopy (SEM) and X-ray diffractometer (XRD). The ultimate tensile strength, hardness, and impact strength of the developed composites were also determined. The SEM and XRD results revealed the presence of different phases: aluminium phosphate (Al16P16O64), gahnite (ZnAl2O4), andalusite (Al2SiO5), Quartz (SiO2) and aluminium silicate (Al2O3.5.SiO2). Results show that addition of IGSp led to an increase in ultimate tensile strength, with the highest value (128 MPa) obtained at 3 wt% IGSp. The hardness of the composites increased with increasing concentrations of IGSp, reaching a maximum value of 285 HV after adding 7 wt% IGSp. The impact strength improved with the addition of IGSp, with the highest value (30 J) obtained at 1 wt% IGSp. The improvements in mechanical properties were attributed to the dispersion of three major phases: aluminium silicate (Al2O3.54.SiO2), Al16P16O64 and Al2O3.54.SiO2. These phases contributed to the enhanced strength and hardness of the composites. The study noted a sudden decrease in ultimate tensile strength with higher concentrations of IGSp due to the increase in the intensities of Al16P16O64 and precipitation of hard but brittle new phase; Al2Si60.6O126.33. The study concludes that IGSp has the potential to serve as an alternative reinforcing material for aluminium-based composites.

Enhancing Aluminum-Based Composite Manufacturing: Leveraging ZrB2 Reinforcement via Friction Stir Process

This study investigates the enhancement of aluminum-based composite manufacturing through the utilization of ZrB2 reinforcement via Friction Stir Process (FSP). Achieving a uniform distribution of ZrB2 particles is crucial for optimizing material properties. The addition of ZrB2 nanoparticles using FSP has led to notable improvements in various mechanical properties of aluminum. Tensile strength increased by 20.25%, hardness by 35.67%, fatigue strength by 23.67%, and wear resistance by 29.45%. These enhancements underscore the effectiveness of nanoparticle reinforcement in fortifying aluminum matrices against mechanical stresses and wear mechanisms. The results demonstrate the potential of FSP-based techniques in tailoring the mechanical properties of aluminum-based composites for diverse applications. This research contributes valuable insights into advanced manufacturing methods for developing high-performance materials with enhanced mechanical characteristics, facilitating the advancement of aluminum composite technologies for industries requiring superior strength, durability, and wear resistance.

Revolutionizing Aluminum-Based Composites: Enhancing Strength with Eggshell and Bagasse Ash Reinforcement via Stir Casting

The study explores a novel approach to enhance the strength of aluminum-based composites by incorporating eggshell and bagasse ash reinforcement through stir casting. The alloy melting process occurred within a muffle furnace, reaching a temperature of 690°C to ensure complete liquefaction. Eggshell and bagasse ash particles were gradually introduced into the molten alloy, while stirring at 480 rpm, ensuring uniform dispersion over 14 minutes. The addition of 4% eggshell and 2.5% bagasse ash led to significant improvements across various mechanical properties. Tensile strength experienced a notable enhancement of approximately 17.89%, while hardness showcased a remarkable increase of approximately 24.66%. Furthermore, fatigue strength demonstrated a significant improvement of approximately 19.56%, and wear resistance exhibited a significant enhancement of approximately 23.8%.These findings underscore the efficacy of eggshell and bagasse ash reinforcement in bolstering the mechanical performance of aluminum-based composites. Such advancements hold promise for diverse applications, from structural components to wear-resistant coatings, offering sustainable and cost-effective solutions in materials engineering.