Aluminium Hybrid Research Articles

Tribological and Mechanical Properties of Al 6061/SiC/ GO Hybrid Composites Produced with Stir Casting

A constant prerequisite for technological advancement is the improvement of composite materials’ mechanical properties. In this study, stir casting was used to create hybrid Aluminium Matrix Composites (AMC). To enhance the mechanical properties, silicon carbide and graphite were used as reinforcement. AMC are made by adding different volume fractions of SiC (3%, 6%, 9% and 12%), whereas composites use a fixed volume fraction of graphite (5%). Mechanical Properties like Hardness, Tensile and wear characteristics of the manufactured AMC samples were evaluated. Under various loads 10N-40N and sliding velocities 0.6m/s-2.0 m/s the wear rate was calculated. The mechanical characteristics of manufactured AMCs are compared with Al 6061 alloy. From the experimental results, the addition of silicon carbide and graphite particles improve the mechanical characteristics. The wear rate increases with increase in applied load. However, sliding velocity surges up to 1.8 m/s before sharply declining.

Identification of tool wear and surface morphology measurements in sustainable milling of Al 6082 hybrid metal matrix composite

Aluminium hybrid metal matrix composites have significantly increased in many advanced applications owing to their unique properties. However, these hybrid composites are difficult to machine because of hard reinforcements in the matrix. After identifying the optimum cutting conditions, it's crucial to identify the tool wear mechanisms to keep surface roughness within the desired range, especially with hybrid composites. Hence, the present work mainly focuses on identifying the wear mechanism of PVD-coated TiAlN cutting tool inserts during the end milling of Al 6082 hybrid metal matrix composites. MQL, CO2, and a combination of MQL + CO2 cooling conditions were employed over the cutting zone to decrease tool wear. In the context of 300 mm of cutting length, employing CO2, MQL, and MQL + CO2 conditions led to a significant reduction in tool wear by 34.5 %, 50.1 %, and 74.7 %, respectively, compared to dry cutting. The results showed that the MQL + CO2 condition produced better results than the other cooling conditions, improving tool life and surface quality.

Numerical simulation of linear reciprocating wear mechanism of hybrid aluminum metal matrix composite using finite element method

This work aims to analyze the wear properties of the hybrid aluminum metal matrix composites (HAMMCs) using finite element analysis (FEA). A dry sliding linear reciprocating wear mechanism is analyzed using ANSYS 19.1. Aluminum 7075 alloy and HAMMC reinforced with ZrB2 (1, 3, and 5 wt.%) and fly ash (2 wt.%) is taken as sample material. A steel ball (EN 52100) is utilized as a counterpart in the dry sliding wear properties study. The deformation of the steel ball during the wear process is assumed to be negligible. Under various circumstances, a 3D point-to-surface connection is built to analyze the dry sliding wear process. The wear depth, contact pressure, and wear volume are analyzed using FEA. The analytical results are compared with the experimental results with the help of ANSYS to analyze the process parameters. The ANOVA analysis is employed for optimization, which exhibits that the load had the most significant impact on the material’s wear rate, followed by the material’s composition and temperature. The wear depth, wear rate, and contact pressure at optimum input parameters for the HAMMCs are 0.47 μm, 11.31 × 10−6 mm3 Nm−1, and 0.33 MPa, respectively. The Simulated results support the experimental results, and the average error is 9.82%.

Effect of T6 Heat Treatment on Mechanical and Tribological Properties of Fabricated AA7075/ZrB2/Fly Ash Hybrid Aluminum Metal Matrix Composite by Ultrasonic-Assisted Stir Casting Enroute

Effect of T6 Heat Treatment on Mechanical and Tribological Properties of Fabricated AA7075/ZrB2/Fly Ash Hybrid Aluminum Metal Matrix Composite by Ultrasonic-Assisted Stir Casting Enroute

Wear behaviour of hybrid (boron carbide-graphite) aluminium matrix composites under high temperature

Aluminium MMCs are among the many metal composites and are regarded as progressive engineering materials in numerous industries because of their advantages compared to standard aluminium alloy. Among the reinforcements in MMCs, ceramic particles are preferred for their superior wear resistance, temperature resistance, and adhesion to their matrix, making them a popular choice. This research work has been carried out to synthesise ceramic particle-reinforced aluminium metal matrix composites and to evaluate their tribological properties at different temperatures (50–300℃). Al2618 alloy was selected as the matrix, and boron carbide (B4C) and graphite (Gr) were selected as reinforcements. Hybrid composites are prepared through stir casting by varying the wt.% of B4C and Gr reinforcement particles with a ratio of 3:2. Microstructural observation shows the uniform distribution of B4C and Gr particles throughout the matrix without any agglomeration, and it also exhibits excellent scanning electron microscope (SEM). X-ray diffraction analysis (XRD) was performed to verify the presence of different constituents in the developed material. Samples S4 (Al 2618 + 12 wt.% B4C—8 wt.% Gr) and S5 (Al 2618 + 15 wt.% B4C—10 wt.% Gr) exhibit enhanced wear resistance (16.45%) due to the incorporation of a higher quantity of Gr solid lubricants alongside B4C within the temperature range of 50 to 300℃. The thickness and stability of the glazed layer exhibited adequate resistance to wear.

Synergistic corrosion protection of stir-cast hybrid aluminum composites reinforcing CeO2 and GNPs nano-particulates

PurposeThis study aims to investigate the corrosion behavior of stir-cast hybrid aluminum composite reinforced with CeO2 and graphene nanoplatelets (GNPs) nanoparticulates used as cylinder liner material in the engines (automotive, aerospace and aircraft industries).Design/methodology/approachThe composites were prepared using the stir-casting technique, and their microstructure and corrosion behavior was evaluated using scanning electron microscopy (SEM) and potentiodynamic polarization test, respectively.FindingsThe results showed that the addition of CeO2 and GNPs improved the corrosion resistance of the composites, and the optimal combination of these two nanoparticles was found to be 3 wt.% CeO2 and 3 wt.% GNPs. The enhanced corrosion resistance was attributed to the formation of a protective layer on the surface of the composite, as well as the effective dispersion and uniform distribution of nanoparticles in the matrix. The 0.031362 was noted as the lowest corrosion rate (mmpy) and was noticed in 94% Al-6061 alloy + (3 Wt.% CeO2 + 3 Wt.% GNPs) sample at room temperature and at elevated temperatures; the corrosion rate (mmpy) was observed as 0.0601 and 0.0636 at 45 °C and 75 °C, respectively.Originality/valueIn the vast majority of the published research publications, either cerium oxide or graphene nanoplatelets were utilized as a single reinforcement or in conjunction with other types of reinforcement such as alumina, silicon carbide, carbon nano-tubes, tungsten carbide, etc., but on the combination of the CeO2 and GNPs as reinforcements have very less literatures with 2 wt.% each only. The prepared hybrid aluminum composite (reinforcing 1 wt.% to 3 wt.% in Al-6061 alloy) was considered for replacing the cylinder liner material in the piston-cylinder arrangement of engines.

Influence of synthesizing parameters on surface qualities of aluminium alloy AA5083/ CNT/MoS2 nanocomposite in powder metallurgy technique

Aluminium alloys are indispensable in all manufacturing industries, particularly mechanical engineering. The objective of this study is to enhance the mechanical, wear, and corrosion properties of aluminium alloy AA5083 by incorporating nanoparticles as reinforcements, thereby creating hybrid aluminium nanocomposites. The base material utilised in this study was AA5083, with the reinforcement nanoparticles selected as Carbon nanotubes (CNTs) and Molybdenum disulfide (MoS2) at concentrations of 5 % and 3 % respectively. Nanocomposites were fabricated using the Powder Metallurgy (PM) technique, employing specific contrasting parameters including Ball mill speed (280, 320, 360, and 400 rpm), Mixing time (20, 30, 40, and 50 min), Compaction pressure (300, 350, 400, and 450 MPa), and Sintering time (2, 3, 4, and 5 h). The operating parameters of powder metallurgy were assessed using the Design of Experiments (DOE) L16 Orthogonal Array, and their corresponding outcomes were analyzed. The results revealed that there is a significant correlation between the mixing time and microhardness of the nanocomposites. The wear and corrosion reduction rates had a significant impact on the sintering time parameter. The present study determined that the highest recorded microhardness value was 136 VHN, while the lowest observed rates of wear and corrosion were 0.192 mm3/m and 0.00081 mm/year, respectively. Scanning electron microscopy (SEM) images clearly depicted the presence of various structural defects, such as pits, cracks, delamination, voids, and cusps, in the wear and corrosion samples that exhibited reduced strength.

Wear Behavior of a Novel Hybrid Aluminium Based Nanocomposite

Wear Behavior of a Novel Hybrid Aluminium Based Nanocomposite

Advancing the Performance of Ceramic - Reinforced Aluminum Hybrid Composites: A Comprehensive Review and Future Perspectives

Advancing the Performance of Ceramic - Reinforced Aluminum Hybrid Composites: A Comprehensive Review and Future Perspectives

A comparative study on the effect of nano-additives on performance and emission characteristics of CI engine run on castor biodiesel blended fuel

Biodiesel is a promising alternative fuel because of its renewable status, biodegradability, non-toxicity, and low pollution levels. However, other limitations such as high viscosity, low thermal energy content, poor atomization, greater densities, and higher (NOx) exhaust emissions hinder its adoption as a prospective diesel alternative. The current study focuses on comparing and analyzing the performance and emission effects of introducing single and hybrid cerium oxide (CeO2) and aluminum oxide (Al2O3) nanoparticles to a fuel blend of 20 % castor biodiesel and 80 % diesel (CB20) made from castor seed oil. The pulsed plasma in liquid technique, a straightforward one-step procedure, was used to create cerium oxide (CeO2) nanoparticles. When Al2O3 nanoparticles were added to the CB20, the cylinder pressure and rate of heat release increased. Therefore, in this study single and hybrid cerium oxide (CeO2) and aluminum oxide (Al2O3) nanoparticles are introduced. The tests were conducted on a single cylinder compression ignition engine at varied engine speeds between 1250 and 3200 rpm while keeping a constant engine load. Using a water bath and sonication, two concentrations of the nanoparticles—80 and 100 ppm—were introduced to the fuel blends, along with Tween 80 and span 80 surfactants to improve blend stability. Different tested fuel samples, including pure diesel CB0, CB20, CB20C100, CB20C80, CB20A100, CB20A80, CB20A40C40, and CB20A50C50, were examined for their physiochemical properties, such as density, viscosity, cloud point, pour point, flash point, and fire points, as well as engine performance parameters, including torque, power, fuel consumption, BTE, and EGT. CB20A50C50 and CB20A40C40 both had an average brake power that was higher than diesel fuel by 6.14 % and 1.25 percent, respectively. The average brake-specific fuel consumption decreased by 3.21 % to 8.29 % when using hybrid and single nano-additive blended fuels compared to CB20. CB20A50C50 exhibited a 20.38 % higher brake thermal efficiency than CB20. Notably, CB20C100 showed a 29.52 % reduction in HC and a 38.32 % reduction in CO, while CB20A50C50 demonstrated a 10.24 % decrease in NOx compared to CB20. Overall, the results of this study indicate that the generated fuel blends combining castor biodiesel and aluminum oxide/cerium oxide nanoparticles hold promise as alternate fuels for diesel engines, with positive impacts on engine performance and emissions.

A multistep approach for the hygrothermal assessment of a hybrid timber and aluminium based facade system exposed to different sub-climates in Norway

A multistep approach for the hygrothermal assessment of a hybrid timber and aluminium based facade system exposed to different sub-climates in Norway

Fabrication of hybrid aluminum matrix composites and prediction of physical characteristics using artificial network

This study looks at how to make LM16 aluminum alloy-based Hybrid Aluminum matrix composites and how to forecast their physical properties (HAMC). The goal of this research is to forecast the Brinell hardness number (BHN) and density of Hybrid Aluminum matrix composites (HAMC). The Levenberg-Marquardt algorithm of a multiple-input multiple-output artificial neural network is used to make predictions (ANN). The HAMC with Nickel coated Graphite (Ni-Gr) and Silicon Carbide reinforcement into the LM16 aluminum alloy is prepared using the stir casting technique considering the brake lining applications. The L9 orthogonal array was chosen for testing to see how process parameters such Nickel coated Graphite (Ni-Gr) reinforcement, Silicon-Carbide (SiC) reinforcement, stirring speed, and stirring time affect the results. The Brinell hardness number (BHN) and density of the material are the output parameters investigated. The determination coefficient (R2) and mean square error were used to assess the ANN's prediction performance (MSE). The average R2 and MSE of 0.99 and 0.0041, respectively, suggest that the ANN fit the experimental experimental response variable values effectively. The correlation coefficient (R) of 0.99721 also supports the findings.

Study on wear and corrosive behavior of novel Al/Al2O3/SiC/WS2 hybrid composites

Hybrid Aluminum composites, in addition to solid lubricants and hard ceramics as particle additives, are next-generation self-lubricating materials for the automotive industry. In this paper, mechanical, wear, and corrosive properties are represented as the key characteristics concerning adding WS2 as reinforcement in Al-SiC-Al2O3 composite. All the compositions in this study have 5 wt% of SiC and Al2O3 concentration each. For the present investigation, WS2 particles are added at varying concentration of 0 wt%, 1 wt%, 4 wt%, and 9 wt% and 16 wt%. The fabricated method is powder metallurgy at 560 Mpa (compaction pressure) and 600 0C (sintering temperature). XRD and SEM analysis reveal the phase identification with topographical features. Enhancements of 32 % in microhardness of Al-SiC-Al2O3-WS2 composites were observed at 9 wt% WS2 as compared to Al-SiC-Al2O3 composite. The experimental results reveal that the best theoretical density (2.98 g cm−3) with the minimum of 1.02 % porosity, highest Vickers hardness (125 ± 2.87 HV), lowest mass loss (0.67 mg for 5 N, 1.5 m/s), with 0.131 lowest coefficient of friction were obtained for Al-SiC-Al2O3-WS2 composites at 9 wt% WS2 concentration. The corrosive resistance is very high (0.0034 mm/year at 120 hrs.) for 81 wt% Al- 5 wt% Al2O3- 5 wt% SiC- 9 wt% WS2 hybrid composite. All results showed that WS2 has been more effective in hybrid reinforcement up to 9 wt% in Al hybrid composites. Hybrid composites made of Al-Al2O3-SiC-WS2 also provide better design freedom and durability for potential components for both normal and corrosive environments.

Assessment of Microstructure and Investigation Into the Mechanical Characteristics and Machinability of A356 Aluminum Hybrid Composite Reinforced with SiCp and MWCNTs Fabricated Through Rotary Centrifugal and Squeeze Casting Processes

Assessment of Microstructure and Investigation Into the Mechanical Characteristics and Machinability of A356 Aluminum Hybrid Composite Reinforced with SiCp and MWCNTs Fabricated Through Rotary Centrifugal and Squeeze Casting Processes

Synergetic effect of reduced graphene oxide and reticulated open-cell aluminum hybrid composite foam for high-performance electromagnetic wave absorption

In the present work, open-cell aluminum-reduced graphene oxide composite (Al-rGO) foam with varying concentrations of reduced graphene oxide (rGO) was fabricated through the template method and foam's electrical, mechanical, and electromagnetic shielding behavior was studied. The reticulated Al-rGO foam allows the electromagnetic wave (EMW) to go inside the structure and resulting in multiple scattering which enhances the wave absorption capacity of the material. Adding rGO into open-cell aluminium foam (OCAF) enhances its shielding properties, particularly the absorption component. The Al-rGO3 foam shows a total EMI shielding of ∼62 dB at 8.4 GHz frequency and out of which 61.34 dB (> 99% of total shielding) is the absorption component. The Al-rGO foam also exhibited maximum compressive strength of 2.96 MPa and EMI shielding of ∼62 dB at 1.5 wt% rGO, even though the electrical conductivity reduces with rGO content. This may be due to a greater degree of multiple scattering of EMW inside the cellular structure and different energy losses at rGO-Al interfaces. This work shows a new way to use the lightweight metallic structure for high EMW absorption applications with good mechanical stability in the defense and aerospace sectors.

Investigations on the diffusion bonding of titanium alloy and aluminum alloy using copper at low bonding pressure

This research investigates the diffusion bonding of hybrid aluminum (Al)–titanium (Ti) joints using a copper (Cu) interlayer in a vacuum environment. At 610 °C and 1 MPa pressure, partial melting of Al caused deformation and misalignment, while 520 °C showed no melting of Al–Cu at the interface. A rod-shaped precipitate with primarily Al was observed at 550 °C, and grain coarsening occurred at 580 °C at the interface, accompanied by increased Cu diffusion within the Al matrix for a bonding time of 45 min. A Ti–Al-based intermetallic layer formed on the Ti side, but voids and cracks were present in the Al–Cu diffusion region at 580 °C. Hardness variation resulted from microstructural changes due to bonding temperature, particularly near the bond line due to hard intermetallic compounds. Shear strength averaged 41 MPa at 550 °C and decreased to 33 MPa at 580 °C due to grain growth, voids, and crack propagation, causing brittle joint failure at the interface. X-ray diffraction on the fracture surfaces revealed that the failure of diffusion-bonded joints is attributed to fractures through the Ti–Al-based intermetallic compounds at the interface and unbonded region.

A novel stepped AlGaN hybrid buffer GaN HEMT for power electronics applications

In this paper, a novel p-type gallium nitride (p-GaN) high electron mobility transistor (HEMT) is proposed and investigated for high power electronic applications. In the proposed device, a stepped hybrid Aluminium GaN (AlGaN) buffer layer with low Al content has been introduced to improve the performance of the device. The low aluminium mole concentration decreases the surface defects which reduces the leakage current, thereby increasing the breakdown voltage of the device. To validate the simulation results, calibration of the device models has been performed with experimental results. Results present that the proposed device exhibits high breakdown voltage, high transconductance and low small signal capacitances. The proposed device achieves improvement in breakdown voltage, transconductance and small signal capacitances as compared to the conventional hybrid buffer high electron mobility transistor (HB-HEMT). Furthermore, the processing steps have been proposed for the possible fabrication of the proposed device. Also, the optimization is performed to achieve the optimal device performance with respect to breakdown voltage. Finally, the performance of the proposed device has been compared with the state-of-the-art devices.

Mechanical property analysis and tribological response optimization of SiC and MoS2 reinforced hybrid aluminum functionally graded composite through Taguchi's DOE

Pistons and cylinder liners in automotive engines often experience wear, requiring mechanical and tribological characteristics that are not attainable with conventional metals and alloys. This study explores the viability of an Al11Si2CuFe functionally graded composite, produced through centrifugal casting, reinforced with 5 wt% SiC and 3 wt% MoS2 for these applications. Microstructural and tribo-mechanical characteristics were investigated, and wear properties were statistically analyzed using Taguchi's method, considering parameters such as sliding distance (750–1750 m), load (10−30N), and sliding velocity (1–3 m/s). Microstructural analysis revealed a gradient reinforcing particle distribution and particle clusters, alongside θ-Al2Cu phase formation confirmed through transmission electron microscopy. Mechanical property examination of the outer layers indicated an improvement of 17.3 and 27.34 % in tensile strength and micro-hardness, respectively, over the inner layers owing to the centrifugal force, increased dislocation density, and effective bridging effect between the reinforcing particles and matrix. Wear studies identified applied load as the influential parameter, with optimal wear occurring at 10 N, 750 m, and 2 m/s, as confirmed through analysis of variance studies. Worn surface analyses revealed abrasion, fatigue, and tribo-chemical wear regimes, characterized by the formation of wear tracks, particle pull-outs, delamination layers, mechanically mixed and oxide layers.

Aluminium hybrid composites: A review of reinforcement materials and reinforcement philosophies

Aluminium hybrid composite reinforcement technology is a response to the demands of advanced engineering materials. The motive behind the use of aluminium hybrid components in the transport, agriculture and mining sectors is based on the requirement for weight reduction and in pursuit of high efficiency and performance at a reduced cost. The performance of these materials is largely dependent on selecting the right combination of reinforcing materials, since most of the physical, chemical, mechanical properties and processing parameters such as particle size, weight percent of reinforcement and fabrication method were largely associated with the reinforcement. This paper attempts to review the different materials that have been used as reinforcements and the reinforcement philosophy adopted by several researchers with a view to establishing the effects of the reinforcement materials on micro structural, mechanical and tribological properties of hybrid composites. The processing methodology and its effects on aluminium hybrid composites have also been reviewed with a view to suggesting the best applications of aluminium hybrid composites.

Optimizing the machining conditions in turning hybrid aluminium nanocomposites adopting teaching–learning based optimization and MOORA technique

Optimizing the machining conditions in turning hybrid aluminium nanocomposites adopting teaching–learning based optimization and MOORA technique