Aluminum Composite Materials Research Articles

Development of sustainable aluminum alloy‑tungsten carbide hybrid composites using industrial waste - An experimental analysis

The research article focuses on the development of aluminum alloy 6061 sustainable composites with the utilization of industrial waste through the use of the stir casting process. Recycling industrial waste is essential for reducing environmental impact. Thus, the red mud waste came from the aluminum production process, which was considered for producing sustainable metal matrix composites (MMCs). Also, tungsten carbide (WC) microparticles have been used to develop hybrid aluminum composite materials. The concentrations of red mud and tungsten carbide were 2 wt%, 4 wt%, and 6 wt%, respectively, and were used to achieve the desired strength performance of aluminum metal matrix composites. The elemental and bonding analyses of hybrid composites were analyzed using X-ray Diffraction (XRD) and Fourier Transform Infrared Spectroscopy (FTIR) analysis. Mechanical characterizations of aluminum hybrid sustainable composites were also investigated, including tensile, compression, and microhardness testing. The results show that increasing reinforcement by up to 4 wt% increases the mechanical strength of aluminum alloy composites. The tensile, compression, and microhardness of metal matrix composites are increased by 25.24 %, 40.2 %, and 20.6 %, respectively, as compared to the aluminum alloy 6061 alloy. The surface morphology of metal matrix composites was analyzed by utilizing Field emission scanning electron microscopy. The proposed sustainable aluminum composites have the potential to develop structural and automotive components due to their higher strength-to-weight ratio.

Evolving trends and advanced applications of engineering materials in contemporary aircraft: a review

This review article discusses the engineering materials used in aircraft, with a focus on aluminum alloys, titanium alloys and composite materials, including where and why they are most used in aircraft. There are many research papers that deal in detail with materials such as aluminum alloys, titanium alloys and composites used in an aircraft, including theoretical and experimental results. However, the author felt that a review of aircraft materials was necessary, both for himself and to help others interested in similar topics. In addition, the author felt the need of thinking back to the past on what materials used to be prevalent and what materials have superseded them. One such example written in this study is the case of Aluminum that used to be the predominant material in aircraft structural components, has been increasingly supplanted by polymer composites in recent years due to their advantageous properties. It is hoped that from this review article the reader will be able to understand the general trend of recent developments in aeronautical engineering materials and be able to choose which path to follow and which area to focus on in their future research.

A molecular dynamics study of the effect of initial pressure on the mechanical resilience of aluminum polycrystalline

Polycrystalline materials are essential in engineering due to their ability to withstand various forces, heat, and environmental conditions. The arrangement of atoms within these crystals significantly affects their mechanical properties. This study used molecular dynamics simulations to explore how initial pressure affects the mechanical resilience of aluminum polycrystals. Aluminum composite materials, known for their strength, flexibility, and environmental sustainability, are the focus of this investigation. We particularly investigated stress-strain reactions at 1, 2, and 3 bar initial pressures. Reduced free volume causes atomic migration to be hampered as pressure increases, therefore affecting mean square displacement and diffusion coefficient. The results show that ultimate strength and Young's modulus of the polycrystalline samples were 30 and 6.64 GPa at 1 bar pressure. Moreover, the results demonstrated a notable decrease in mechanical performance by increasing pressure; the ultimate strength and Young's modulus of the polycrystalline samples diminished to 5.66 GPa and 22.43 GPa, respectively, at 3 bar. Furthermore, the heat flux increased by rising initial pressure in the Al-polycrystalline sample due to the compression of material that reduced atomic distances. This improved atomic arrangement facilitated more efficient heat transfer. These insights are essential for engineering applications, as they establish a foundation for the production of aluminum components that maintain structural integrity in the face of extreme conditions.

Developing the hybrid BIM-BEM and jellyfish search optimization system for optimizing energy consumption and building installation costs

In recent years, the use of Building Information Modeling (BIM) with Building Energy Modeling (BEM) has become the primary research focus for reducing the energy consumption of buildings in the planning and operational phases. The combination of BIM and BEM offers advantages for the various phases of a construction project. However, there are currently very few studies that can integrate multi-objective optimization algorithms into the BIM-BEM process to achieve automatic optimization and effectively manage many aspects of building development. In this study, an EnergyPlus integrated multi-objective jellyfish search (EP-MOJSO) system was developed, utilizing an optimization algorithm to find the best thermal insulation layers for an Aluminum composite material (ACM) wall. The goal is to reduce the energy consumption and total cost in a BIM-BEM environment. In the case study, the authors successfully applied the system to a real building, resulting in a 10.7% reduction in total cost and a 65 kWh/m2/year reduction in EUI. It is expected that the results of the study will open up new ways of using algorithms for multi-criteria optimization in BIM models to optimize various project factors such as energy and total cost and thus make an important contribution to sustainable building design.

Application and performance analysis of advanced materials in engine lightweight

This paper discusses the application and performance analysis of advanced materials in engine lightening. Firstly, we analyze the properties of high performance aluminum alloy, titanium alloy and composite materials, including their composition, mechanical properties and high temperature resistance. Then, the practical application effects of these materials in key components such as automobile and aero-engine are analyzed through concrete cases. For example, the introduction of micronutrient and improvements in heat treatment processes have significantly increased the strength and corrosion resistance of high-performance aluminium alloys. Titanium alloy is widely used in the key parts of aero-engine because of its high strength and light weight, which greatly improves the performance of engine. The low density and high strength of the composite make it an ideal choice for reducing engine weight. Finally, we discuss the current challenges and future directions, and explore solutions to reduce costs, improve processing efficiency and develop new alloys, in order to provide guidance and reference for the further development of engine lightweight technology.

Experimental investigations with machine learning techniques for understanding of erosion wear in advanced aluminum nanocomposites

This article addresses the significant challenge of erosion wear in aluminum composites, particularly in industries such as automotive, aerospace and energy, where sustained material performance is crucial. The study focuses on the experimental investigation of erosive wear characteristics exhibited by advanced aluminum nanocomposites, utilizing an air jet erosion wear test apparatus. The erosion wear tests were conducted using diverse parameters, such as angles (30°, 45°, 60° and 90°), air pressures (1–4 bar) and a fixed 600-s duration, maintaining a constant sand particle feed rate of 2.0 (g/min) and utilizing stand-off distances of 10, 15 and 20 mm. Surface assessments were conducted using field emission scanning electron microscopy (FE-SEM) and energy-dispersive X-ray spectroscopy (EDS). The results revealed observable specimen wear, particularly at a 45° angle, with wear rates decreasing at higher impingement angles and reaching a minimum at 90°. Notably, the Al-4 wt.%TiC nanocomposites exhibited a 25% improvement in wear resistance compared to the base alloy. Further analysis of eroded surfaces through (FE-SEM) revealed a mechanism involving micro-cutting, plowing and grain pull-out, attributing wear primarily to plastic deformation and crack formation. Evaluating erosive wear results through six machine learning (ML) models demonstrated that gradient boosting regression emerged as the most accurate, achieving an R2 value of 0.97. This highlights the effectiveness of ML in predicting erosion wear rates and offers insights for improving aluminum composite materials in demanding industrial applications.

Utilizing Rotary Friction Welding for Joining Aluminum Composite Materials by Omani Waste Marble Reinforcement

Utilizing Rotary Friction Welding for Joining Aluminum Composite Materials by Omani Waste Marble Reinforcement

Effect of blade materials on the undershot water turbine performance

Undershot waterwheel at low flow with an average discharge of 0.12 m3/s and 613.2 W water horsepower are used to turn the waterwheel. The rotation results obtained with aluminum material is 24 RPM which has a density of 2.71 g/cm3 while the lowest rotation is owned by a galvanic of 20 RPM with a density of 7.49 g/cm3. From the experiment, it was found that the difference between the materials used was due to the different density. The efficiency of waterwheels with aluminum material has the highest value, namely 30%, while the lowest using acrylic material has an efficiency of 23%. For the highest generator efficiency using aluminum material with an efficiency of 4.2%, the second has an efficiency of 3.6% using Aluminum Composite Panel material. Aluminum has the highest efficiency because it has less density than galvanized. In addition, the thickness of aluminum is also very influential, where aluminum has a thickness of 1.14 mm while Galvanized has 0.98 mm.

Scientific and Technical Basis for the Development of an Induction Heating Unit for Milk Pasteurization

Introduction. Induction heating is a preferred heating technique for industrial, medical and consumer systems, because it has a number of advantages over traditional heat transfer methods. The advantages include energy efficiency, heating rate, safety of operation, cleanliness of the process, low metal consumption, simple design, and precise control of the temperature of the heated raw materials. An induction heating unit is especially important for farms involved in processing of milk and producing milk-based products. Aim of the Study. The study is aimed at developing a prototype unit for long-term pasteurization of milk using a container heated by induction currents and at selecting optimal operating conditions for the developed prototype unit. Materials and Methods.There was used 3D modeling in the KOMPAS-3D computeraided design system to develop the main components of a milk pasteurization prototype unit with induction heating. The container for raw materials, stirrer and lid are made of stainless steel AISI 304 and AISI 430. The inductor is a frame made of polymer material with a litz wire arranged in a spiral manner. The body of the prototype unit is made of aluminum composite material. The developing and debugging of the electronic circuit of the prototype unit power part was carried out with the use of the design program Proteus 7.10. The microcontroller Mega 2560 was used to make the power part of the electromagnetic induction generation unit. The controlled temperature was monitored by using the waterproof temperature sensor DS18B20. A thermal imager was used to visualize the propagation of the thermal field over the surface of the container walls. Results. The structure diagram of the developed prototype unit with induction heating for long-term pasteurization of milk is presented. The article gives grounds to the use of the necessary elements and actuators in the unit for pasteurization of milk in a container heated by induction currents. There are presented a diagram of the developed power part for the prototype unit and the results of testing it when heating containers made of various materials. An algorithm has been developed to control the operation and PID regulation of the milk pasteurization in an experimental unit with the use the Raspberry Pi microcomputer. The graphs of transient processes when changing the coefficients of PID temperature control are presented. Discussion and Conclusion. When testing the induction heating principle on stainless steels of different compositions, it has been concluded that for the efficiency of heating the container, there is required a ferromagnetic steel pad welded on top of the main container made of food-grade stainless steel. The developed system of inductors made it possible to create a prototype unit with two heating zones depending on the volume of processed raw materials that is important for small farms engaged in processing milk and producing milk-based products.

Investigation of the microstructure and mechanical properties of an Al/SiC/ZrO2 hybrid composite by spark plasma sintering technique

The quantum of work with silicon carbide (SiC) and zirconium dioxide (ZrO2) in the aluminum hybrid composite material has increased due to the growing demand for lightweight materials for various industrial applications. The aluminum hybrid composite with the wt% of primary reinforcement particles of SiC was kept constant at 5%, and the secondary reinforcement particles of ZrO2 were taken by 5%, 10%, and 15%. The sintering parameters were used as the temperature at 600°C, holding time of 35 minutes, and pressure at 30MPa. In this work, the aluminum composite material reinforced with 5%wt of SiC particles compared the test results with aluminum hybrid composite reinforcement of SiC and ZrO2 nanoparticles. Adding ZrO2 reinforcements enhances the aluminum hybrid composite material's better microstructure, microhardness, tensile strength, compression, and yield strength.

RANCANG BANGUN CNC PRINTER 3 DIMENSI MENGGUNAKAN ARDUINO MEGA 2560

In making this 3 Dimensional CNC Printer machine, the design and construction process is divided into several main parts. The main parts include; design for the mechanical part, design for the frame part, design for the control and calibration system. In the mechanical section, the motor type is selected and the transmission system is designed. The type of motor used is the Stepper Motor Type 17210 G Shinano Kenshi with specifications; angular movement of 1.8 degrees/pulse with a current of 1 A, voltage of 2.6 VDC, resistance of 1.5 Ohm/phase, inductance of 2.8 mH/phase and holding torque of 0.3 Nm. For transmission, it uses a pulley and belt transmission type. The frame uses Tslot 2040, Vslot 2020 and Aluminum Composite materials for the engine mount. In the control and calibration section, this 3 Dimensional CNC Printer machine uses an Arduino Mega 2560. In mechanical testing, movement trials were carried out in the x, y and z axes. The test results show that the movement is as expected. For the x-axis movement, it is 60 mm, the y-axis is 80 mm and the z-axis is 100 mm.

Inclined Curved Crack Composite Beam: Experimental and Computational Analysis with Recycled Aluminum Composite Materials and Comparison with an Artificial Neural Network.

This research focuses on an inclined curved crack model for a recycled aluminum composite beam at various crack depths and locations. The inclined curved crack equation of the motion, by governing a free vibration curved beam with a different depth of crack, is solved computationally via the differential quadrature method (DQM) and experimentally; additionally, the result of the natural frequency has been compared with various depths of curvature. For the first four modes of cracked beams, the computational method's output is used to determine the natural frequencies associated with mode shapes. The outcomes of the computational results suggested a structural health monitoring system to detect deterioration in composite structures when modal parameters have changed. An experimental set of results was validated using MATLAB2019a, and the outcomes were compared with an artificial neural network.

Design and Construction of Unmanned Aerial Vehicles Using Nano Aluminum and Carbon Composite Materials

This project aims to design and manufacture an unmanned aerial vehicle (UAV) structure using nano aluminum and carbon composite materials named “Arabian Leopard.” Over the past period, the UAV market has experienced significant growth. In 2019, at least 60 countries were engaged in the development or implementation of at least 1,300 different drones. The Kingdom of Saudi Arabia is no exception; as a result, it prioritized this sector in Vision 2030 through investment and support to localize and develop it. The ANSYS fluent software will conduct a CFD simulation of the UAV design and airfoil. The airfoil CFD simulation is used to find the lift/drag characteristics of the airfoil used in the UAV design. In this CFD simulation, we conducted an airfoil simulation using Ansys Fluent software. From here, our project is to enhance the local content, present a unique design that embodies a national identity, and introduce nano-aluminum into the airframe to increase its durability, as the aerial vehicle (AV) is the primary component of the UAV system.

Anodic Behavior of AK7 Aluminum Alloy and Composite Material of the Al–Al2O3 System within an NaCl Electrolyte Solution Medium

Anodic Behavior of AK7 Aluminum Alloy and Composite Material of the Al–Al2O3 System within an NaCl Electrolyte Solution Medium

Features of processes of high-speed milling with a complex profile tool in the processing of aluminum alloys and composite materials

Complex computational and experimental studies substantiate rational modes of milling of complex contour equiaxed surfaces with high accuracy of shape, dimensions and roughness parameters. Bars made of nanostructured carbide composite (produced by extrusion of WC-Co-Al2O3 bimodal powder mixtures) with increased strength, crack resistance and heat resistance were used as a workpiece material for the manufacture of new original tool designs. The combination of these properties is a necessary prerequisite for the effective operation of the developed designs of multi-blade cutters at high cutting speeds and under conditions of variable cyclic loads. A more complex kinematics of the joint rotational movement of the tool during milling dictates the need for new approaches when assigning rational cutting modes. To obtain reliable calculation formulas, numerical experiments were previously carried out, including simulation of the processing process using the VisualStudio integrated development environment, which supports WindowsForms technology. The ability to display graphical 3D objects was implemented using an additional software product in the form of the Open CASCADE geometric core. Numerical experiments using MathCAD software products and based on the analytical provisions proposed in the work made it possible to evaluate the influence of cutting conditions, geometric parameters of the cutting part of the tool (profile and number of teeth), kinematics of relative movement in the “tool – part” system on the shape of surfaces and contour parameters (roughness obtained during milling. A technique, algorithm and program for the automated calculation of cutting conditions has been developed, which has been verified during full-scale experiments and the manufacture of complex profile parts from aluminum alloys for drives of aerospace products (in the form of a RC profile and parts of a pinion transmission of guidance mechanisms). At the same time, on the basis of a 3D model of products, control programs for CNC machines were created using MasterCAM. The practical significance and technical and economic efficiency of the proposed design and technological solutions is to increase productivity and reduce the complexity of processing (in comparison with the basic options) through the use of new multi-edge carbide tools for high-speed milling (including when processing composite materials).

Effect of Spherical WC Content on the Microstructure and Properties of SiCp Aluminium Composite Material

In this paper, SiCp aluminium matrix composites were used as the matrix, and AlSi10Mg powder, which has a relatively similar coefficient of thermal expansion to that of the matrix, was used to prepare laser cladding Al-based coatings. The results show that the optimal process parameters are P = 4400 W, Vf = 11.3 g·min−1, and VS = 1800 mm·min−1, and, although the hardness of the coatings is lower than the hardness of the substrate, it reduces the generation of defects such as cracks and porosity. With the increase in WC reinforced phase and the hardness of the coatings, wear resistance increases, the granular cytocrysts are transformed into rod-like cytocrysts, and at the same time generate the dendritic crystals, and the undergo grain refining and generate the new phases such as Al4C3, Al4SiC4. There is no obvious defect in AlSi10Mg + 40%WC coatings, the macro morphology of the coatings is good, there is no spalling in the friction wear morphology, and the wear resistance is excellent, but there are obvious cracks and obvious spalling in the coatings of AlSi10Mg + 60%WC. Compared to the matrix hardness of 171.61 HV, the hardness of the 20%WC cladding layer increased by a factor of 1.06, while the hardness of the 40%WC cladding layer increased by a factor of 1.65 and that of the 60%WC cladding layer increased by a factor of 1.8. In terms of wear, compared to a substrate wear amount of 9.36 mg, the wear for the 20%WC cladding layer was reduced to 6.13 mg (34.5% less than the substrate), for the 40%WC cladding layer it was reduced to 4.58 mg (51.06% less than the substrate), and for the 60%WC cladding layer it was reduced to 7.35 mg (21.47% less than the substrate). The quality of the coatings decreases although the hardness is higher than that of AlSi10Mg + 40%WC. The comprehensive performance of AlSi10Mg + 40%WC coatings is optimal.

Pengaplikasian Material Aluminium Composite Panel pada Perancangan Apartemen dan Soho di Kota Surabaya

The demand for residential space continues to increase with the amount of growth in a city. This is something that is experienced by large cities such as Surabaya. The demand for residential and office space for local residents and migrants is due to the increasing number of national and multinational companies operating in the city of Surabaya. The use of technology in the creation of building materials is one of the positive impacts that can be felt due to the rapid influence of modernization and globalization. The use of ACP material with a variety of materials and colors and ease of application in workmanship. Aluminum composite panel (ACP) building facade is a combination of aluminum panels and composite materials. This building material is made of polyethylene coated with aluminum panels on both sides. Aluminum composite panel itself is a rigid and sturdy sheet but with a relatively light weight. This building material is used to line the exterior or interior walls of the building. Because this material is available in metallic and non-metallic colors, it can add an artistic and luxurious impression to the building facade. The use of ACP material used on the facade of this building has various advantages such as variations in thickness, strength and brightness and attractive facade patterns.

Enhancing Building Energy Efficiency with Aluminum Composite Material Facade: A Performance Simulation Study using Building Energy Modeling and Building Information Modeling

Building facade is an integral piece to the overall design of a building, which not only ensures adequate interior thermal comfort, minimizing cooling load rate but also lowering overall building energy consumption. In recent years, aluminum composite material wall (ACM) is a new decorative material that is increasingly being used by developers, designers, and architects, which led to many innovative building facade designs. It is a straightforward and versatile product that provides a weather-resistant, sound-insulation, heat-insulation, earthquake-resistant, and shock-resistant façade that is simple to install. As a result, this study proposes a perfomance of energy simulation with ACM material applied in building design using Building Energy Modeling (BEM). Energy simulation in buildings using a Building Information Modeling (BIM) system is proposed to reduce the Energy Use Intensity (EUI) and energy cost of building in its construction process. The results of this study are expected to assist architects and building managers in improving and enhancing the energy efficiency of buildings. These significant findings demonstrate the potential of using ACM wall to improve building energy efficiency.

Effect of nano-TiO2 particles addition on dissimilar AA2024 and AA2014 based composite developed by friction stir process technique

Aluminum composite materials have gained immense popularity in the construction and aerospace industries as these materials are lightweight, durable, and exhibit a high strength-to-weight ratio. The present study aims to develop dissimilar AA2024 and AA2014-based composite materials using nano-TiO2 reinforcement particles via Friction Stir Processing (FSP) techniques. The FSP technique is a solid-state processing method that is used to modify the properties of metal alloys without altering their chemical composition. The samples were prepared by placing a nano-TiO2over AA2024 and AA2014 aluminum alloys sheet and subjected to FSP process parameters. The microstructure, hardness, and tensile properties of the composite samples were assessed using scanning electron microscopy (SEM), Vickers hardness tester, and tensile testing machine respectively. The results showed that the FSP technique led to the formation of a homogeneous and fine-grained microstructure in the composite samples. The nano-TiO2 reinforcement also provided additional strengthening to the AA2024 and AA2014 aluminum alloys matrix resulting in improved hardness and tensile properties of the composites. The resulting composites exhibited enhanced wear resistance properties. The FSP method presented in this study has implications for extending the properties of other metal alloys, opening up new avenues for research in the field of materials science.

Vibration Control Using Modern Control System for Hybrid Composite Flexible Robot Manipulator Arm

In this research, a model of a robotic manipulator flexible structure and an equation of motion for controller design is planned. The structural material for the robot structure is chosen as a hybrid composite for this investigation along with a comparison study is carried out for the aluminium 6082 alloy of flexible manipulator arm application. To analyses, the vibration behavior and control implementation by adding joint flexibility in the system is organized. Using simulation algorithm, system parameter calculation is carried out through MATLAB software for vibration amplitude, transient period, steady-state error, and settling time of flexible robotic arm system. In a systematized way of motion equation, flexible robotic deflections are organized via the assumed mode (AM) and Lagrange techniques (LT). The graph analysis of hybrid composite and AL6082 materials with high stiffness coefficients is plotted. These obtained values from the plot are utilized for Linear Quadratic Regulator (LQR) controller design. The LQR output facts for both aluminium structural robotic arm and composite material robotic arms are established.