Aluminium Based Metal Matrix Composites Research Articles

A review on processing and properties of aluminum based metal matrix composites

This journal paper presents an in-depth exploration of Metal Matrix Composites (MMCs), a vital class of composite materials extensively employed in diverse sectors such as aerospace, automotive, defense, and marine due to their exceptional combination of high strength and reduced weight. The review focuses on various processing methods for MMCs, emphasizing the range of fabrication techniques available. The experimental evaluation of these composites is discussed, encompassing essential assessments like hardness, tensile strength, compression resistance, fatigue behavior, and tribological performance, all conducted in accordance with ASTM standards. The objective of the paper is to provide a thorough understanding of MMCs, from their fabrication processes to the systematic evaluation of their properties, contributing valuable insights to the field.

Comparison of Machinability of Al-4.5%Cu/TiB2/3p MMC for Multi-Layer Coated Insert: Validated FEM and Statistical Approaches

Aluminum-based Metal Matrix Composites (MMC) are commonly used in metal-cutting applications due to their better mechanical and physical properties, such as high strength, hardness, and low weight. Also, modern coating applications, especially multi-layer coated tools, have the cutting-edge potential for relieving the difficulties of machining MMCs to improve insert performances. Therefore, this study aimed to reveal the turning Al-4.5%Cu/TiB2/3p performance of the multi-layer coated cemented carbide insert with verified FEM and statistical approaches. Different coating materials, two and three of which were soft and hard, were appointed at different thicknesses and sequences in the design of experimentally calibrated simulations. The Grey Relation Analysis (GRA) was set to investigate the multi-layer coated insert performance for turning the MMC concerning the resultant cutting forces (FR) and maximum insert temperature (Tmax). The optimal multi-layered coating was found at levels 4-2-4-3-2 for the factors of coating materials: tungsten disulfide (WS2), molybdenum disulfide (MoS2), titanium nitride (TiN), aluminum oxide (Al2O3), and titanium carbo-nitride (TiCN), respectively. The contribution rates of each factor were significant concerning General Linear Model (GLM) at 47.13% and 24.43% for WS2 and Al2O3 coatings materials, respectively. In the future, multi-layered coatings can be a valuable solution for the difficulties of machining the MMCs.

A Critical Review on Recent Advancements in Aluminium-Based Metal Matrix Composites

Aluminum matrix composites (AMCs) have garnered significant attention across various industrial sectors owing to their remarkable properties compared to conventional engineering materials. These include low density, high strength-to-weight ratio, excellent corrosion resistance, enhanced wear resistance, and favorable high-temperature properties. These materials find extensive applications in the military, automotive, and aerospace industries. AMCs are manufactured using diverse processing techniques, tailored to their specific classifications. Over three decades of intensive research have yielded numerous scientific revelations regarding the internal and extrinsic influences of ceramic reinforcement on the mechanical, thermomechanical, tribological, and physical characteristics of AMCs. In recent times, AMCs have witnessed a surge in usage across high-tech structural and functional domains, encompassing sports and recreation, automotive, aerospace, defense, and thermal management applications. Notably, studies on particle-reinforced cast AMCs originated in India during the 1970s, attained industrial maturity in developed nations, and are now progressively penetrating the mainstream materials arena. This study provides a comprehensive understanding of AMC material systems, encompassing processing, microstructure, characteristics, and applications, with the latest advancements in the field.

Effects of hot extrusion on compressive strength and densification of aluminium-based metal matrix composites

ABSTRACT Metal matrix composites (MMC) made from powder metallurgy (PM) require post-processing to improve the mechanical properties or achieve the final shape. In this experimental study, Aluminium metal matrix composite (Al-MMC) was first fabricated through PM, followed by a hot extrusion process to study the effects of extrusion on compressive strength and density. Hot extrusion of Al-MMC results in microstructure refinement, enhanced dispersion of reinforcement particles and improved mechanical properties. The experimental findings revealed that hot extrusion of Al-MMC resulted in densification, reflected as an average improvement of 5% in the density. An average improvement of up to 22% was observed in the compressive strength of the Al-MMC. Therefore, hot extrusion can be considered an effective post-processing method for enhancing the Al-MMC fabricated through PM. It was also found experimentally that the extrusion ratio also affects the mechanical properties and performance of Al-MMC. It was revealed that the compressive strength is enhanced with an increase in extrusion ratio. It is also important to note that the PM process is one of the processes which offers reasonable control over the utilisation of starting material. Hence, reinforcement retention is higher than other methods like stir casting.

Influence of Tool Pin Profiles on Aluminium Alloy A356 and Ceramic-Based Nanocomposites for Light Weight Structures by Friction Stir Processing

In this research, the main aim is to focus the enhancement of aluminium-based metal matrix composites for improving the attributes of light weight metals, aerospace structures and other tailor blank material properties. By this way, the friction stir processing (FSP) was the suited alternate technique to enhancing the mechanical attributes and superior microstructural amendment in the processed MMCs. Therefore, this study investigates the dispersion of ceramic-based strengthening particles of chromium oxide (Cr2O3) in the aluminium base matrix of A356 alloy. During the processing, the different tool pin sizes having the conical threaded tool pin profiles. Similarly, the tool spinning speed and tool travel speed also varied while in FSP. Before the processing, the A356 alloy was prepared by the grooved surfaces for packing the chromium oxide particles to compose the aluminium metal matrix composites. The tensile strength and hardness was employed to carry out from the friction stir processed A356 alloy with influencing of Cr2O3. The maximum occurred tensile processing parameters are 1500 rpm of spinning speed, 6 mm of tool pin sizes and 90 mm/min of tool travel speed. Similarly, the maximum obtained hardness processing parameter are 2000 rpm of spinning speed, 5 mm of tool pin sizes and 90 mm/min of tool travel speed. A scanning electron microscope was utilized to investigate the dispersed Cr2O3 in the A356 alloy for confirming the refinement grains in the nugget zones of FSPed A356 alloy. The increased grain boundary by the influence of different tool pin sizes was the major reason to produces the better mechanical properties in the processed A356/Cr2O3.

Experimental Study on Mechanical Characteristics of Aluminium Metal Matrix Composite Reinforced with Titanium Oxide (TiO2) and Graphite (Gr) Particles Processed by Stir Casting Method

Abstract: In recent trend Aluminium based metal matrix composites are most used in mechanical and automobile component design applications because of their excellent mechanical, Tribological and its physical properties. Also, Aluminium metal matrix composites are used for a variety of applications such as military, aerospace, electrical industries, and automotive purposes. The present work concentrates on the experimental study on the effects of TiO2 and Gr on aluminium alloy. During this investigation, Titanium oxide (TiO2) and Graphite (Gr) particles was reinforced with aluminium and it was prepared using stir casting technique with various weight percentage combinations of TiO2 particles 2% by wt., 4% by wt., and 6% by wt. and 3% of Gr constant for all trials. Mechanical parameters were estimated by selecting the standard test methods.

AN EXTENSIVE REVIEW ON THE ROLE OF METAL MATRIX NANOCOMPOSITES IN THE RECENT RESEARCH AREAS

Metal matrix nanocomposites have received more focus in the last two decades because of their desirable alternative features. Many researchers have made several attempts to identify the suitable nanoreinforcement particles for getting improved results in various applications. Many of them tried to improve the properties of several metal matrix nanocomposite materials including mechanical properties, electrical properties, barrier properties, structural properties, moisture permeability, etc., with the help of a variety of techniques. Research study results revealed that the addition of nanosized reinforcement particles improved the mechanical and wear characteristics of aluminum-based metal matrix composites. Metal matrix nanocomposites are being employed in many application areas such as in biomedical field, self-cleaning marble coating application, antimicrobial application and wear-resistant coating application. This review workhas gone through a bulk of research works related to metal matrix nanocomposites. The entire study has been grouped under a few major categories such as synthesis of nanocomposites, characterization study on various nanocomposites, application areas of various nanocomposites, optimization works carried out on nanocomposites, and risk management of nanocomposites.

Bond formation between aluminum-based metal matrix composites and aluminum alloys in compound castings

Bond formation between aluminum-based metal matrix composites and aluminum alloys in compound castings

A Hybrid Design of Experiment Approach in Analyzing the Electrical Discharge Machining Influence on Stir Cast Al7075/B4C Metal Matrix Composites

The present work centers on aluminum-based metal matrix composites (AMCs), synthesized via stir casting and then processed by electrical discharge machining (EDM) in the case of Al7075 as a matrix and 6 wt.% boron carbide (B4C) as reinforcement. A design of experiment (DoE) approach, powered by hybrid optimization techniques (such as the entropy weight method (EWM), grey relational analysis (GRA) incorporated Taguchi method) was used to investigate the relationship between current (I), pulse ON time (Ton), pulse OFF time (Toff), and electrode gap (Gap) as input parameters and the material removal rate (MRR), tool wear rate (TWR), and surface roughness (SR) as response parameters. The results showed that an I = 140 A, Ton = 120 ms, Toff = 50 ms, and Gap = 0.4 mm combination gives the best response parameters of MRR = 0.5628 mm3/min, TWR = 0.0048 mm3/min, and SR = 4.4034 μs.

An enhanced technique for friction stir welding of ceramic particle reinforced aluminium based metal matrix composites

AbstractThis manuscript proposes an enhanced technique for the friction stir welding (FSW) of ceramic particle‐reinforced aluminium‐related metal matrix composites. The proposed technique is the joint implementation of both the Aquila Optimizer and Pelican Optimization Algorithm. This proposed method aims is to enhance the welding efficiency, quality, and overall performance of the weld joints. The test is conducted in an all‐purpose machine at cutting speeds that permit temperatures that are comparable to the FSW of stainless‐steel, aluminium alloys and copper. Reaction–diffusion studies are conducted to better understand the diffusion‐control process under tool wear, and the tool wear rate is determined by the length of the cutting tool's nose tip. Rotational speed at 10 mm/min is examined. SiC exhibits the highest performance of aluminium and stainless steel. As the fraction of SiC increases to 18%, the axial force and rotational speed of FSW also increase.

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.

In-situ synthesized polymer-derived SiC reinforced aluminum matrix composites

In the current work, in-situ formed polymer-derived SiC reinforced aluminum-based metal matrix composites were synthesized to uniformly distribute ceramic particles in metal matrix with good matrix-reinforcement interface. Polymeric precursor (allyl hydrido polycarbosilane) was cross-linked at 300 °C and the cross-linked precursor was mixed with molten aluminum at 800 °C under nitrogen using stir casting route to obtained composites reinforced with 2 wt%, 4 wt% and 7 wt% of SiC (particle size < 10 µm) distributed uniformly in the synthesized composites. Structural characterization of samples were performed using FTIR, XRD, optical microscopy, FESEM and Raman spectroscopy. The composites demonstrated significant improvements in hardness (∼58%), ultimate tensile strength (∼45%) and compressive strength (∼58%) for 7 wt% in-situ formed SiC in aluminum matrix compared to pure aluminum.

Empirical Analysis of Multiwalled Carbon Nanotube Deposition for Enhancing Mechanical and Tribological Characteristics in Aluminium-Based Metal Matrix Composites

Empirical Analysis of Multiwalled Carbon Nanotube Deposition for Enhancing Mechanical and Tribological Characteristics in Aluminium-Based Metal Matrix Composites

An Extensive Study and Evaluation of Tribological Properties of Fsw Plates Using Linear Reciprocating Tribometer (LRT)

This study extensively focuses on analyzing the fretting wear characteristics of Aluminum-based hybrid Metal Matrix Composites (MMCs) under dry conditions, essential in understanding materials' tribological properties in mining environments. Aluminum-based MMCs offer improved wear resistance and durability, potentially enhancing mining equipment performance. The investigation targeted Aluminum 7075 alloy-based MMCs, comprising 7% fine greenish Silicon Carbide and 3% chopped E-glass fibers (2-3mm length, 10-14 micrometer diameters). Using traditional stir casting and Friction Stir Welding (FSW) techniques, composite plates meeting ASTM standards were fabricated. FSW parameters like rotation speed and tool feed rate were varied.Analyzing fretting wear on the welded zone, employing different loads through Linear Reciprocating Tribometer (LRT), provided insights into the tribological performance of these Aluminum-based hybrid MMCs. The lightweight and exceptional thermal properties of Aluminum have significantly expanded its use across various industries, enabling partial replacement of ferrous materials, especially in MMCs where Aluminum alloys offer distinct advantages over other materials.This research aids in determining the suitability of these MMCs for demanding mining conditions, where materials endure extreme stress. Understanding their tribological behavior is crucial for potential applications in mining equipment, contributing to longevity and improved performance.

Finite element analysis of deformation mechanism of SiC reinforced 6061 aluminium-based metal matrix composites under compression

Finite element analysis of deformation mechanism of SiC reinforced 6061 aluminium-based metal matrix composites under compression

Optimizing turning parameters for improved surface quality and productivity of Al-MMC under dry, wet, and MQL conditions

The machining of Aluminum-based Metal Matrix Composites (Al-MMCs) is challenging due to their inhomogeneity, anisotropic nature, and dynamic cutting forces. In this paper, the effect of machining parameters, including cutting speed, feed rate, and depth of cut, on surface quality (Ra) and main (Normal) cutting forces (Fc) during turning of Al-MMCs under different cutting conditions (DRY, WET, and MQL) was investigated. Statistical analysis tools were used to analyze the experimental results, and ANOVA and RSM techniques were used to model the relationships between machining parameters and responses. The results showed that feed rate significantly affected both Ra and Fc for all machining conditions. The DRY machining mode was optimal for surface finish, and the MQL mode was effective in reducing cutting forces due to its cooling and lubrication properties. A feed rate of 0.03 mm rev−1 was found to be the most favourable for all cutting environments as it resulted in lower Ra and Fc values. Turning in the WET condition also produced lower Ra due to the effective flushing of chips and cleaning of the cutting zone. In contrast, turning in the MQL condition reduced cutting forces by 17% and 50% as compared with dry and Wet conditions respectively under optimal conditions. Similarly, surface roughness improves under dry conditions by 33% and 3% compared to Wet and MQL conditions.

Mechanical characterisation and experimental analysis of AA6082 Aluminium metal matrix composites reinforced with goat bone ash

ABSTRACT Aluminium matrix composites signify a recent advancement in the progression of metal matrix composites, possessing the capability to meet the requisites of various emerging engineering applications. This study aims to concentrate on the mechanical behaviour of AA6082, which was fortified with goat bone ash (GBA). Employing the stir casting technique for casting, aluminium-based metal matrix composites were synthesized, incorporating varied weight percentages (0%, 3%, 6%, and 9%) of goat bone ash as the strengthening element. The introduction of 3% ash particles yielded a 12% augmentation in impact strength, while an even more significant enhancement of 81% in hardness was attributed to the incorporation of 9% ash particles. The material exhibited a tensile strength of 131 MPa without reinforcement, and this value was significantly enhanced by 36.6% upon adding 6% GBA. Subsequently, it was inferred that reinforcement significantly enhanced the physical and mechanical attributes of aluminium metal matrix composites.

Multi-Objective Optimization for the Sustainable Machining of Metal Matrix Composites Using Wire Electric Discharge Machining

Wire Electrical Discharge Machining (WEDM) is an electrothermal machining process used to produce complex profiles electrically conductive materials. In this investigation, multiobjective optimization using hybrid approach of Taguchi method (TM) and Principal Component Analysis (PCA) has been performed to find the optimal input process parameters like pulse-on time ([Formula: see text]), pulse-off time ([Formula: see text]), peak current (I), wire speed (WS) for output parameters, namely, cutting velocity (CV), power consumption (PC), and surface roughness (SR). Three different Aluminum based Metal Matrix Composites (AMMC) were fabricated using three different reinforcements i.e. 10[Formula: see text]wt.% Aluminum Oxide (Al2O3), 10[Formula: see text]wt.% Silicon Carbide (SiC), and combining 5[Formula: see text]wt.% Al2O3 with 5[Formula: see text]wt.% SiC through the stir casting process. The experiments were conducted based on the L9 orthogonal array approach of Taguchi methodology and regression equations were developed based on the experimental data for the prediction of output parameters. The results of analysis of variance (ANOVA) shows that WS and I are the two most significant factors for CV of all three developed composites whereas for SR, [Formula: see text] and I play critical role. The optimal results show that for machining of Al6061/Al2O3 and Al6061/SiC optimal input parameters are [Formula: see text][Formula: see text][Formula: see text]s, [Formula: see text][Formula: see text][Formula: see text]s, [Formula: see text][Formula: see text]A, and [Formula: see text][Formula: see text]m/s. For hybrid MMC (Al6061/Al2O3/SiC), optimized input parameters are [Formula: see text][Formula: see text][Formula: see text]s, [Formula: see text][Formula: see text][Formula: see text]s, [Formula: see text][Formula: see text]A, and [Formula: see text][Formula: see text]m/s. At optimal input parameters though the CV decreases by 1.53% the PC and SR decreases by 8.95% and 15.47%, respectively, in case of hybrid composite. The machined surface at optimal input parameters were examined by the Scanning Electron Microscope (SEM). This study will help to identify the input parameters for sustainable machining of AMMC for different reinforcements with WEDM.

Optimization of piston material with aluminium alloy based metal matrix composites

Piston failure is caused by a combination of mechanical and thermal loads is a frequent occurrence that can be expensive to repair or replace. In this paper, analysis is carried out to evaluate and improve the performance of a piston intended for deployment in a four-stroke SI engine with a single cylinder. To determine the most suitable material for the piston, different materials, alloys and aluminium based metal matrix composite are examined. Piston is designed using CAD software and static structural analysis and thermal transient analysis is done using finite element analysis. Based on the analysis, Al 6061–1.5% B4C- 1.5% SiC metal matrix composite material is found to be the most desirable choice among the five materials considered due to lower value of deformation (31% to 76% less in comparison) and mechanical stresses (0.38% to 0.83% less in comparison).

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

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