Aluminum-based Composites Research Articles

Study on synergistic hydrogen generation from aluminum-based composites in different forms of water.

The environmental suitability of hydrogen storage materials is significantly influenced by the way aluminum reacts synchronously with water, ice, and water steam. The straightforward ball milling process was used to synthesize Al-based composite materials with carbon nanotubes (CNTs) or graphene oxide (GO). The reactivity of the composites in various types of water was investigated. The Al/Bi/CNT and Al/Bi/GO composites may react in liquid water, low-temperature ice, and high-temperature steam. The hydrolysis promotion of Al-based composites by CNTs is superior to that of GO, whether in liquid water at 20 °C or ice at -20 °C. The maximum hydrogen generation rate of Al/Bi/CNT composites can reach 34.6 mL g-1 s-1 at 20 °C. The hydrogen generation volume of Al/Bi/CNT can reach 700 mL g-1 in 15 min on ice at -20 °C. Moreover, the ignition temperature and ignition delay time of Al/Bi/CNT are shorter than those of Al/Bi/GO in high-temperature steam. The hydrogen generation volume from Al/Bi/CNT at 200 °C can reach 853 mL g-1. These may originate from the unique one-dimensional nanostructure of CNTs, which provides more surface area or reaction sites during the hydrolysis of the composite.

Advancing Aluminum-Based Composites with Fly Ash and SiC Reinforcement through Stir Casting

This study explores the advancement of aluminum-based composites through the integration of fly ash and silicon carbide (SiC) reinforcement via stir casting. The process involves melting the alloy in a crucible within a muffle furnace at 700°C, gradually introducing fly ash and SiC particles while stirring at 450 rpm for 12 minutes to ensure uniform dispersion. The addition of 5% SiC and 2.5% fly ash led to significant improvements in multiple mechanical properties.Tensile strength experienced a remarkable enhancement of approximately 19.56%, while hardness showcased a substantial increase of about 34.67%. Furthermore, fatigue strength demonstrated a notable improvement of approximately 26.87%, and wear resistance exhibited a significant enhancement of approximately 31.45%. These enhancements underscore the efficacy of integrating fly ash and SiC reinforcement, highlighting the potential for advanced aluminum composites with superior mechanical properties. This approach presents a promising avenue for enhancing material performance, with implications for diverse industrial applications requiring durability, strength, and wear resistance.

Green Reinforcement: Enhancing Aluminum-Based Composite Manufacturing with Waste Bagasse via Stir Casting Technique

This study explores the use of waste bagasse ash as reinforcement in aluminum-based composites manufactured via stir casting. Bagasse ash particles were methodically introduced into molten aluminum at 700°C while being stirred at 500 rpm for 12 minutes to achieve uniform dispersion. The addition of 7.5% waste bagasse ash resulted in significant improvements across multiple mechanical properties. Tensile strength increased by 12.45%, hardness showed a remarkable enhancement of 21.32%, fatigue strength exhibited a substantial improvement of 19.45%, and wear resistance demonstrated a notable enhancement of 18.76%, all compared to the base composite. These findings highlight the effectiveness of utilizing waste bagasse ash as reinforcement, offering a sustainable approach to enhance the mechanical properties of aluminum-based composites. This research contributes to advancing eco-friendly manufacturing practices and underscores the potential of waste materials in optimizing material performance.

Advancements in Aluminum-Based Composite Manufacturing: Leveraging ZrO2 Reinforcement through Friction Stir Process

This paper explores advancements in aluminum-based composite manufacturing by leveraging ZrO2 reinforcement through the Friction Stir Process (FSP). The FSP method, utilizing an electric field to enhance sintering, ensures a highly uniform dispersion of nanoparticles within the material matrix, crucial for optimizing mechanical strength, thermal conductivity, and electrical performance. Micrograph analysis reveals the homogeneous distribution of ZrO2 particles, indicating the effectiveness of FSP. Tensile strength improves by 19.26%, hardness by 34.56%, fatigue strength by 22.45%, and wear resistance by 28.45% after integrating ZrO2 nanoparticles via FSP. These enhancements underscore the significance of nanoparticle reinforcement in fortifying aluminum alloys against various mechanical stresses and wear mechanisms. The findings highlight the potential of FSP-based techniques in tailoring the properties of aluminum-based composites for applications in aerospace, automotive, and manufacturing industries, where superior performance and durability are essential.

Evaluation on the impact behavior of stir-casted Aluminum composites reinforced with SiC and Gr for lightweight applications

Increasing demands for lightweight materials in various industries, such as aerospace, automotive, and manufacturing, have led to a growing interest in the development of advanced materials with enhanced mechanical properties. One promising avenue for achieving lightweight and high-performance materials is the fabrication of aluminum-based composites reinforced with silicon carbide (SiC) and graphite (Gr) particles through stir casting. The current study examines the impact strength behavior of composites reinforced with AA6063 cast materials that contain different amounts of micron sized SiC particles and 5 weight percent graphite. By using liquid metallurgy, hybrid composites of AA6063, SiC, and Gr were created. The numerous created samples underwent the customary Charpy impact testing, and the impact strength was assessed. By reinforcing SiC and graphite to the aluminum matrix, a substantial increase in impact strength was observed. For the three test samples, the average impact strength of pure aluminum was found to be 7 Joule. Average Impact strength for aluminum with 10% silicon carbide was found to be 8 Joule, which is 14.28% greater than for pure aluminum. The average Impact strength for the composite of aluminum with 20% silicon carbide was 10 Joule, which represents a 42.85% increase in strength over pure aluminum.

An Effort for Identifying Suitable Machining Range During Drilling of a Novel Al-Based Composite Using Electric Discharge Machine

Various aluminium-based metal matrix composites (MMCs) have recently attracted significant interest and increased popularity. This is because of its’ outstanding mechanical properties, which makes it a very popular material since it has various applications in industries that need strong yet lightweight materials with high strength. Researchers have made great progress in the mechanical properties of Al-based composites. In any case, it becomes imperative to improve the mechanical characteristics of the given material on demand. The current work aims at producing these aluminium-based MMC and, subsequently, precise machined EDM. It is an uncommon machining process typically known to produce tough materials of any arbitrary geometry. EDM is a technique that involves the fine-tuning of the electrode material, pulse length, and pulse current to yield the best results without causing much damage to the workpiece and maintaining its mechanical strength. Lastly, the research comprises an elaborate discussion on the optimum process parameters and experimental results about the effective manufacture of superior strength aluminium-based composites as well as their accurate electro-discharge machining. These results provide valuable information on making and machine metals for various technical uses across construction, mechanical engineering and electronics manufacturing industries.

Microstructure and mechanical properties of Al/TiC and Al/(Ti,W)C nanocomposites fabricated via in situ casting method

A modified self-propagating high-temperature synthesis in bath (SHSB) via cast was successfully used to produce the aluminium-based composites reinforced by TiC and (Ti,W)C nanoparticles. The process was managed by the addition of a moderator affecting supercooling, which consequently influences the nucleation and growth of TiC crystals. Thus, by choosing the suitable amount of moderator, not only the size and amount but also the distribution of the strengthening particles can be controlled. In this work, the research was performed in a twin-track approach: fabrication of good quality TiC particles with a homogenous distribution inside of the aluminium matrix (1), and modification of TiC particles by the addition of W in order to improve the coherency degree between both particles and the matrix and ensure more uniform distribution of the reinforcement (2). Moreover, the homogenous microstructure of Al/TiC composites was obtained. TiC particles were uniformly distributed, and no cluster in the matrix in composite up to the highest moderator content (80 wt%) was found. The compressive strength and hardness of composites reinforced with TiC particles have been significantly improved (over 100 %) compared to the base alloy while the highest values were achieved for the composite containing 80 wt% of the moderator. Moreover, the addition of W causes a significant change in the lattice parameters of TiC at the interface without changing its face-centered cubic structure (fcc). This in turn leads to improved coherence at the particle/matrix interface.

Advancements in aluminum matrix composites reinforced with carbides and graphene: A comprehensive review

Abstract Automotive and aircraft industries are advancing swiftly, creating a constant need for innovative and trustworthy materials. Aluminum composites (aluminum matrix composites [AMCs]) exhibit enhanced mechanical and tribological behaviors when contrasted to their conventional equivalents and as a result have superior potential to be widely accepted for automotive and aircraft engineering and other component applications. This study aims to provide a thorough and critical analysis of the most recent research initiatives concerning the processing, characteristics, and applications of AMCs. It covers the recent advancements in the aluminum-based composites reinforced with SiC, TiC, and graphene, fabrication methods, and mechanical properties of AMCs. Graphene nanoplatelets are many times stronger and yet lighter than steel and other metals, and thus a good contender for reinforcing them. However, the homogeneous distribution of graphene into the metal or aluminum is a challenging aspect for material researchers. The fabrication techniques for AMCs for achieving homogeneous distribution of graphene are critically reviewed. The mechanical properties, specifically microhardness, wear behavior, and tensile strength of aluminum-based composites, are reviewed and analyzed. Finally, a way forward for fostering further development in this area has been discussed.

Effect of Sc on the microstructure and mechanical properties of direct laser-deposited/Al-Cu-Mg-Sc composite coatings

In order to improve the poor plasticity and uneven distribution of ceramic phases in ceramic-reinforced aluminum-based composites, 40 wt% TiC/Al-Cu-Mg-Sc composite depositional layers with different Sc additions were prepared by direct laser deposition (DLD) technology. The microstructure of the deposition layers was characterized by Optical Microscopy (OM), X-ray diffractometer (XRD), Scanning Electron Microscopy (SEM) with Energy Spectrometer (EDS), Electron Backscatter Diffractometer (EBSD), and its mechanical properties were characterized by Bush hardness and room temperature tensile test, respectively. The results showed that the deposition layer was well formed with few macroscopic defects, and an appropriate amount addition of Sc could not only effectively improve the fluidity of the molten pool and promote grain refinement, but also make the distribution of TiC particles more uniform, The composite deposition layer with 0.2 wt% Sc addition showed the best combination of plasticity and strength among all the samples. Meanwhile, the yield strength, tensile strength and elongation reached 126 MPa, 229 MPa and 3.1 %, respectively, which were 4.1 %, 5.5 % and 34.6 % higher than that of deposition layer without Sc addition.

Tribological Properties and Microstructures of Tungsten Carbide and Few-Layer Graphene-Reinforced Aluminum-Based Composites

Tribological Properties and Microstructures of Tungsten Carbide and Few-Layer Graphene-Reinforced Aluminum-Based Composites

MICRO-GROOVING OF ALUMINUM-BASED COMPOSITES USING Nd:YAG LASER MACHINING

This paper describes the pulsed Nd:YAG laser machining characteristics on 6351 aluminum reinforced with silicon carbide (SiC) and boron carbide (B4C) particles. The composites are prepared using stir casting route by varying the weight percentage of B4C (0, 5, and 10 wt.%). During experimentation, the traverse speed (5, 15, and 30 mm/s) and the laser pulse frequency (5, 9, and 15 kHz) are considered to evaluate the groove width. The results reveal that the lower pulse frequency produced poor groove surface quality. Higher thermal energy dissipation at lower traverse speed may also result in the formation of recast layer and heat-affected zone. This is evident from the microscopic image and the EDS analysis. Thus, the optimum condition (composite with 10 wt.% B4C machined at 30 mm/s and 15 kHz) to achieve minimum grove width with improved surface morphology is identified by desirability analysis. Additionally, the regression model is developed to predict future values ([Formula: see text] at 91.86% and [Formula: see text] (adj) at 87.55%). Finally, the probability plot confirms the effectiveness of the proposed model at 95% confidence level.

Effect of interlayer particles on the bonding improvement of aluminum laminated composites

Aluminum-based composites (AMMCs) have become a popular topic in industrial progress. The aluminum (Al) structure is such that, while it is very light, it also has significant strength. This capability has increased the use of Al in various industries, especially the aerospace and marine industries, even more. Other properties of Al include the favorable plasticity of these structures. It is worth mentioning that many methods can be used to produce Al metal matrix composite (AMMC). One of these methods is Accumulated Press Bonding (APB). APB is one of the most powerful processes as a solid welding method for making MMCs. This method can be called a complex technology that has many advantages. One of the main advantages of this method is that it has a high potential to refine the nanostructures that make up a composite, making it possible to design, produce and refine composites consisting of several layers. In addition to advantages, this process also has disadvantages. Actually, in this process, the bond strength (BS) is weak. This study uses Sn particles to improve the BS of Al laminates as filler metal. So, AA1060 bars with different wt% of Sn particles (interlayer filler material) were manufactured at various pressing temperatures (Temp’s) and APB steps. The peeling test was used to evaluate the bonding strength. It was found that the pressing Temp increased APB number of steps and Sn wt%, popular bonds with upper strength were shaped. Also, to illustrate the peeling surface of AA1060/Sn samples, scanning electron microscope (SEM) was used.

Investigation of corrosion resistance and impact performance properties of Al2O3/SiC-doped aluminium-based composites

Investigation of corrosion resistance and impact performance properties of Al2O3/SiC-doped aluminium-based composites

Effect of sintering temperature and time on corrosion characteristics of aluminum matrix composites

Aluminum matrix composites outperform traditional alloys in terms of mechanical properties and corrosion resistance. Silicon carbide is the main reinforcing material in aluminum-based composites that have developed rapidly in recent years. In this investigation, aluminum-silicon carbide composites were prepared through powder metallurgy with 10 and 20 wt.% of silicon carbide reinforcement. The influence of the SiC content, sintering temperature, and sintering time on the corrosion behavior of prepared Al-SiC composites in 0.5 M hydrochloride acid solution was assessed. The surface microstructure was characterized by scanning electron microscopy with energy dispersive analysis and X-rays. The experimental results demonstrated how the sintering parameters can affect the corrosion characteristics of sintered samples. The electrochemical analysis curves showed that when increasing the sintering temperature and sintering time, there is a possibility of self-repair of damaged passive film on the surface while further reinforcing of the composite with silicon carbide prevents penetration of chloride ions. The SEM images and EDS analysis of composite surfaces after being corroded in 0.5 M HCl revealed that increasing the sintering temperature and prolonging the sintering time reduce the pitting corrosion of composites.

The Effect of SiC and MgO Ceramic Reinforcements on the Mechanical Behavior and Electrical Properties of the Composite Structure in Al7075/SiC/MgO Hybrid Composites

In this study, certain technical properties of new generation aluminum-based composites, obtained by combining the Al7075 alloy widely used in the industrial field with two different ceramics, were investigated. For this purpose, SiC and MgO ceramics in particle form were reinforced into the Al7075 matrix material using powder metallurgy technique and composite structures were produced in three different reinforcement ratios. Measurements to determine electrical resistance and conductivity and bending and compression strength tests were performed on the obtained composite structures. The density and porosity amounts of the composite structures were also determined, and their microstructures were examined with a digital microscope. With the increase of SiC/MgO amount in the aluminum composite structure, the electrical resistance increased, and the conductivity value decreased. With the effect of SiC/MgO reinforcing materials, the density value of the composite structures decreased while the amount of porosity increased. The hardness values increased due to the effect of SiC and MgO ceramics in the structure. The bending and compression strength values initially increased and then started to decrease with the increase of reinforcement ratios. It has been determined that the formation of porosity in the composite structure negatively affects the mechanical behavior. The second important factor was evaluated to be the amount and shape of ceramic-based reinforcement particles in the structure. Due to the effect of SiC, which has very high electrical resistance, and MgO, which has dielectric properties, the electrical conductivity values of the composite structures decreased. The increase in electrical resistance and the decrease in electrical conductivity were directly proportional to the amount of ceramic-based reinforcement particles in the composite structure.

Development and characterization of grinding sludge-reinforced aluminum-based composite by friction stir process technique

PurposeThe quantum of metal particle waste generation in manufacturing industries is posing a great concern for the environment. The iron forging industries generate a huge amount of grinding sludge (GS) waste, which is disposed into the earth. The accumulation of this waste in dump yards causes an increase in soil and air pollution levels.Design/methodology/approachIn the current investigation, an effort was made to use this waste GS for the progress of aluminum-based composite. To maintain uniform distribution of reinforcing material, the friction stir processing technique was used.FindingsThe characterization based on the SEM image of the Al/GS composite revealed that uniform dispersal of reinforcement content can be attained in a single tool pass. Number of grains/inch was approximately 2,402. XRD of GS powder confirmed the presence of SiO2, Fe2O3, Al2O3 and CaO phases. These phases proved GS to be a better reinforcement with aluminum alloy. Tensile strength and hardness were significantly improved in comparison to the aluminum alloy. Thermal expansion and corrosion weight loss were evaluated to observe the influence of GS addition.Originality/valueThe studies proved that the use of GS as reinforcement material can help in curbing the menace of soil pollution to a large extent.

Enhanced mechanical and wear properties of aluminium-based composites reinforced with a unique blend of granite particles and boron carbide for sustainable material recycling

In this study, a two-step stir casting technique was employed to fabricate composites using scrap aluminium cans (SAC) as matrix and a unique blend of Granite Particles (GP) and boron carbide (B4C) as reinforcements. Mono and hybrid composites were developed to evaluate the effects of the GP-B4C on the microstructure, mechanical properties, wear characteristics, and fracture behaviour of the composites. The microstructural characterization of the composites revealed that the incorporation of reinforcement into the aluminium matrix led to a refined grain structure with distinct interfaces. Both mono and hybrid composites exhibited improved hardness, with the hybrid composite showing a significant increase of 15.74 % in macro hardness and 16.33 % in microhardness compared to the base material. The mono composite demonstrates the highest ultimate tensile strength of 218 MPa, followed by the hybrid composite with a strength of 192 MPa. The improved mechanical properties of the mono composite are attributed to the reduction in grain size and the enhanced interfacial bonding between the reinforcement and the matrix. Although the hybrid composite exhibited more porosities, it shows the maximum ultimate compressive strength of 1124 MPa. The tensile fractured surfaces displayed dimples, cleavage facets, transgranular cracks, and river line markings. The wear loss of the mono composite decreased by 11.2 %, while that of the hybrid composite decreased by an impressive 28 % compared to their parent base matrix. The worn surface exhibits a combination of abrasive, adhesive, and delamination wear mechanisms.

Particles’ distribution enhancing in aluminum-based composites produced by upward friction stir processing

A new variant of friction stir processing named upward friction stir processing (UFSP) is a promising approach to control particles’ distribution and promote a more uniform distribution over a larger processed area. This variant involves using two sheets with functional particles between them to produce metallic composites. A spacer is used to ensure the desired quantity and uniform distribution of the particles and prevent sputtering. This technique promotes an upward flow to introduce more particles with a uniform distribution in the processed volume, avoiding discrete holes or grooves. This study involved enhancing the particles’ distribution by varying process parameters. The resulting trial with the best particles’ distribution was characterized by means of light microscopy, eddy current testing, microhardness mapping, scanning electron microscopy, and energy-dispersive X-ray spectroscopy. The study revealed that UFSP can improve the particles’ distribution in the stir zone of metallic composites, especially when multi-passes are performed towards the retreating side of the plates. The process parameters that produced an improvement in particles’ distribution were six passes with an offset of 1 mm towards the retreating side, the tool rotation and processing speed of 900 rev/min, and 180 mm/min, respectively, and a spacer’s thickness of 0.5 mm. The resulting hardness and electrical conductivity profiles show that the UFSP technique can significantly affect material’s properties, including mechanical strength, particularly when processing with tool offset towards the retreating side. Furthermore, the hardness increased by about 22% in composites produced with the addition of reinforcement particles. However, for some aluminum alloys, the properties decreased under such conditions. These findings highlight the potential of UFSP for producing functionalized materials with tailored properties, while also underscoring the importance of careful parameters selection to optimize the material´s performance.Graphical

ENHANCEMENT IN MICROSTRUCTURAL CHARACTERISTICS AND MECHANICAL PROPERTIES OF A6082-BASED MMCS VIA YTTRIA STABILIZED ZIRCONIA INCORPORATION AND T6 HEAT TREATMENT

This study investigates the impact of Yttria Stabilized Zirconia (YSZ) and T6 heat treatment on the mechanical and microstructural properties of A6082-based Metal Matrix Composites (MMCs) prepared using the conventional stir casting route. A6082 is widely used in various industrial applications due to its excellent physical, structural and functional properties with good corrosion resistance. YSZ with superior mechanical and thermal properties that can enhance the strength and wear resistance of aluminium-based composites. T6 heat treatment is a widely adopted technique to improve the material properties of aluminium alloys. The results of this study indicate that the T6 heat treatment significantly refines the grain structure of the composites, resulting in improved hardness and tensile values compared to untreated samples. Mechanical properties are also enhanced by YSZ's integration into the composites, with a 9wt.% YSZ addition to the matrix alloy leading to a noticeable improvement in hardness for both the untreated and treated composites. The tensile parameters show a similar trend, with a gain in Ultimate Tensile Strength and Yield Strength up to 6wt.% YSZ addition, after which the findings follow a downtrend (at 9wt.%). The results of this research show that A6082/YSZ composites subjected to T6 heat treatment have great promise as a high-performance material.

An Investigation on the Enhanced Wear Behavior of Ultrasonically Stirred Cast A356/SiO2np Nano-composites

Metal matrix nanocomposites (MMNCs) are becoming the materials of choice in a variety of engineering and medical applications owing to their exhibiting a superior combination of targeted properties. Amongst different MMNCs, aluminum-based composites are of special importance. In many applications, a relatively inferior wear property limits the use of this valued metal in practice. However, reinforcing aluminum and its alloys by ceramics, carbon allotropes, etc., may circumvent these limitations to a great extent. In the present study, aluminum alloy A356/SiO2 nanocomposite is fabricated by a vibration-assisted casting process, wherein varied amount of nanosilica, namely, 0.125, 0.25, and 0.375 wt.%, have been added to the melt. The use of power ultrasonic treatment had a great influence on the microstructure, hardness, and wear properties. Microstructural and XRD analyses were performed on the fabricated monolithic and composite samples. To evaluate wear behavior, a hardness test and pin-on-disk experiment were conducted on the samples under 60, 80, and 100 N forces at a constant speed of 1 m/s and the sliding distance was varied from 1000 to 2000 m. The abraded surfaces, wear debris, and EDS analysis were used to identify wear mechanisms. The samples having 0.125 wt.% exhibited the highest increase in hardness and the highest reduction in both friction coefficient and wear rate by 52%, 50%, and 68%, respectively. The main governing wear mechanism was abrasion, with limited evidence of delamination.