Aluminium Based Metal Matrix Composites Research Articles

Characterization and machinability analysis of aluminium-based metal matrix composites (MMC): A critical review

Hybrid nanocomposite has progressively attracted advanced industrial and automotive sectors in recent years. Hybrid nanocomposites have emerged as a viable material for a wide variety of engineering uses because of their excellent thermal, mechanical, and environmental characteristics. This article introduces reviews on the turning process of metal matrix composites (MMC) and its examination of the improvement of the machining indicators of MMCs. Furthermore, this review reviews the latest research progress in sustainable turning of aluminium based composite particularly hybrid nanocomposite. Moreover, a summary regarding the impact of machining variables on measured outputs is also discussed. Machinability evaluations, along with other factors, are considered critical analyses that directly determine the cost of machining processes. The point of this review is to focus on the impact of essential cutting variables on hybrid turning processes. Furthermore, this paper draws extensive conclusions based on experimental findings. This research also identifies potential future topics that need to be solved to improve the development and characterization of hybrid nanocomposites. In brief, the paper presents a comprehensive review for developing a sustainable machining approach for these fabricated hybrid metal matrix composites.

Enhanced mechanical and tribological properties of ultrasonically assisted stir-cast AA7075 metal matrix composites in challenging corrosive environments

Aluminum-based metal matrix composites (AMMCs) find extensive applications in aerospace, defence, automotive, and various sectors on account of remarkable mechanical properties, lightweight nature, and excellent dimensional stability. In this research, AA7075 matrix material was reinforced with tungsten carbide ceramic particles with various 0, 5, 10, 15 and 20 weight percentages (wt%) with the use of Ultrasonic assisted stir casing setup. The stir casted AA7075 MMCs were subjected to XRD, SEM, and density test to investigate the presence of elements, microstructure and density. The tensile, micro hardness, and wear test were performed on AL7075 based MMCs after conducting NaCl based spray test at the condition of spray pressure of 1.2 kg cm−2, spray duration of 120 h and PH value of 8.2 to determine the wear resistance, micro hardness and Ultimate Tensile Strength. The XRD test confirmed the presence of secondary phases such as Al2Cu, W2C, and MgZn2 with Al and WC phases. The SEM test confirmed the uniform dispersion and no more cluster formation upto 15 wt% WC addition and agglomeration of WC was occurred in the addition of 20 wt% of WC. The enhancing of wt% of WC improved the corrosion resistance, Micro hardness, UTS, wear and up to 15 wt% addition and decreases by the 20 wt% WC addition. The higher tensile strength 312 MPa was obtained from AA7075/15 wt%WC composite. The lower wear rate 0.11 mg m−1 was obtained from AA7075/15 wt%WC at 1000 m sliding distance with 1.2 m s−1 sliding velocity. The improved mechanical and tribological properties were mainly depended on strengthening mechanisms such as load transfer mechanism and dislocation strengthening mechanism.

Advancing sintering and matrix-reinforcement interaction in Al/AlN metal matrix composites through use of novel AlN reinforcement

Demand for energy-efficient transportation has led to increased use of lightweight aluminium alloys due to their exceptional strength-to-weight. Meanwhile, aluminium-based metal matrix composites (MMCs) are being developed to enhance wear resistance and strength. However, traditional ceramic reinforcements often have poor bonding with the matrix, compromising performance. Here, we demonstrate the use of a novel ex-situ AlN reinforcement powder to enhance sintering and interfacial bonding for powder metallurgy preparation of Al/AlN MMCs. We compared two series of Al/AlN MMCs featuring 10 vol.% ex-situ AlN reinforcement, one prepared using commercial AlN powder, and the other using our novel AlN reinforcement prepared by low temperature direct nitridation of Al powder. Metallic Al contained in the synthesized reinforcement significantly improved interfacial adhesion between matrix and reinforcement and enhanced densification during sintering. This resulted in a substantial improvement in tensile mechanical properties, with an 11.5% increase in ultimate tensile strength and almost five-fold improvement in ductility compared to composites prepared using the conventional ceramic AlN reinforcement. This study provides a strategy for powder metallurgy production of advanced Al/AlN MMCs with superior physical and mechanical properties.

Microstructural evolution and investigation of mechanical properties of Al 7055 –Nano Si3N4 composites

In this paper an attempt has been made to develop the aluminium based metal matrix composites. Al7055 were chosen as base material and hard ceramic particulate nano silicon nitride as reinforcement. The composites were fabricated by using bottom pouring stir casting technique by varying weight percentage of Si3N4 in steps of (3 wt%, 6 wt% & 9 wt%) respectively and particle size of 30, 60 and 90nm. Morphological characterization of composites was conducted by using HRFESEM. The SEM result reveals that there is homogeneous distribution between the matrix and reinforcement. EDS mapping for prepared composites were done to identify the presence of alloying elements and phase distribution. XRD analysis is conducted for validation of the structural composition. Mechanical tests like tensile, micro Vickers hardness and impact test were performed on developed composites. The ultimate tensile strength of the composites at 9 wt% and particle size of 90 nm found to be diminishing due to severe agglomeration. The hardness value increases at 9 wt% and particle size of 30 nm. The toughness of the composites increased at 30 nm reinforcement size and 6 wt% as compared to higher weight percentage developed composites. Corrosion test were conducted as per ASTM G31 by weight loss method for different samples by dipping composite samples in 50 g Hcl solution for duration of 6 h and it was found that the corrosion resistance of the composites was higher while increasing the wt% of Si3N4 as compared to base matrix..

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.

Ultimate Tensile Strengths and Elastic Moduli at 20 K of Additively Manufactured PA840-GSL, A6061-RAM2, and AlSi10Mg

The additive manufacturing (AM) of polymer matrix composites (PMCs) and metal matrix composites (MMC) systems presents novel opportunities for reducing the mass of aerospace vehicles. These solutions also have the potential to reduce the cost of terrestrial applications where cryogenic temperatures are present. To address this need, this paper explores the mechanical characterization of three AM materials at 20 K: a nylon-based PMC PA840-GSL, and two aluminum-based MMCs A6061-RAM2 and AlSi10Mg. A Cryogenic Accelerated Fatigue Tester (CRAFT) used for the mechanical testing is first detailed. Next, ultimate tensile strengths and elastic moduli of the additively manufactured AlSi10Mg alloy and A6061-RAM2 are obtained. Third, the mechanical performance of an additively manufactured PMC liquid hydrogen tank constituent is collected in addition to an analysis on the effect the processing parameters, such as scan spacing, have on the mechanical behavior. A6061-RAM2 exhibited superior mechanical performance and is recommended for structural applications. Variation of PA840-GSL scan spacing resulted in decreased mechanical performance.

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.

Investigate the mechanical properties of Aluminium Metal Matrix Composite

Abstract The objective of this study is to produce metal matrix composites with aluminium as the matrix material and beryl as the reinforcing particles. Given the comparable density of beryl particles to Aluminum-based alloys, it is anticipated that enhancements in strength and ductility properties will lead to increased mechanical and tribological characteristics, including hardness and wear resistance. Extensive research has been conducted on aluminum-based metal matrix composites (MMCs) in the recent past, specifically focusing on the utilisation of ceramic reinforcements such as silicon carbide (SiC), titanium nitride (TiN), Titanium Diboride (TiB2), zirconia (ZrO2), and alumina (Al2O3). Typically, the ceramic particles employed for reinforcement exhibit notable hardness and high density, resulting in enhanced hardness and improved Tribological wear characteristics. Aluminium-based metal matrix composites (AMMC) were produced by including varying concentrations of beryl (3%, 8%, and 13%) through two distinct fabrication methods: the liquid metallurgy vortex route and the powder metallurgy approach. The beryl mineral phase was initially subjected to crushing and mechanical sieving processes to get particle sizes with an average of 50 ± 10 and 100 ± 10 μm. The mechanical qualities, including hardness and tensile strength, were examined using the Brinell hardness machine and the Universal testing equipment.

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.