Aluminum Matrix Research Articles

Interfacial designability of high-entropy oxides reinforced aluminum-matrix composites via deformation-driven metallurgy towards high strength-ductility

Undesirable interfacial relationships cause the “strength-ductility trade-off” issue in conventional ceramic-reinforced aluminum-matrix composites, with interfacial structure mismatch being the key factor. The rock-salt type of High-entropy oxide (HEO), which exhibited a crystal structure and lattice parameters similar to those of aluminum, was exploited to address it. The interfacial mismatch with the pure aluminum matrix was 3.4 % after further optimization. Deformation-driven metallurgy, a solid-state preparation method, was employed to adapt the novel reinforcements. This low-temperature characteristic prevented the decomposition of the high-entropy phase, maintaining the interfacial structure. Severe plastic deformation facilitated the refinement and redistribution of HEOs, providing more interfacial bonding sites. The prepared composites exhibited a superior balance of strength and ductility (ultimate tensile strength of 304 ± 3 MPa and elongation of 33 ± 2.0 %), representing a significant improvement over conventional ceramic-reinforced aluminum-matrix composites due to the optimized interfacial relationship.

Finite Element Analysis of LED Heat Dissipation Performance Based on Graphene Composites

Abstract With the gradual development of integrated circuits to thin, high-performance and versatile of electronic products is becoming more and more powerful, and its integration and assembly density continue to improve, which will lead to the increase of its working power consumption and heat. If not timely treatment of heat dissipation problems, which will lead to heat concentration in the diode PN junction, it will reduce the service life of LED lights, and in severe cases, it will even burn the LED device. Therefore, it is crucial to improve heat dissipation efficiency of LED and reduce the junction temperature of chip. An LED structure with aluminum material and an LED structure with graphene material are analyzed by finite element method to study the heat dissipation efficiency of the graphene material. The results reveal that the heat dissipation effect of high conductivity graphene composites provides a convenient evaluation method for the subsequent use of the new materials. The research in this paper shows that the software simulation method can effectively analyze the thermal conductivity of practical engineering applications.

Wet stability soft skin electronic sensor based on biochar-polypyrrole conductive hydrogel

Hydrogels have the softness and stretchability of similar tissues and are considered as materials for smart flexible electronic devices. However, the durability and reliability of most polypyrrole hydrogels in wet environments are still insufficient, especially its wet stability in the wet environment of seawater, limiting its development as flexible conductive electrodes. In this study, the porous solid carbon material after pyrolysis of natural materials is introduced into hydrogel, which is conducive to the migration and propagation of electrolyte ions, and can improve the moisture resistance stability of hydrogel. At the same time, polypyrrole material is introduced to further improve its electrical conductivity. With this method, the conductivity of conventional hydrogel materials can be increased by 12.2 times. The triboelectric nanogenerator device prepared with polypyrrole/biochar composite hydrogel can not only accurately monitor human joint motion, but also easily light up at least 300 light-emitting diodes when rubbed with aluminum materials, which proves the practical performance of the device. This study provides an alternative material for sensing hydrogels that can be used for human health monitoring of marine operators.

The effect of unintended porosity on the first compressive stress maximum of alumina hollow sphere-filled bimodal composite metal foams

Bimodal composite metal foams made from Al99.5 aluminium and quasi-eutectic Sr-modified AlSi12 matrix were investigated, where the bimodality was introduced by two alumina hollow sphere sets with nominal diameters of Ø7.0 and Ø2.4 mm in various volume concentrations. The research aimed to determine the effect of the cell structure (especially the unintended porosity) on the first compressive stress maximum, depending on the applied matrix material. The various features of the cell structure were quantitatively measured in composite metal foams by filtering raw computed tomography analysis data. The casting porosity, the wetting porosity, the porosity from the various-sized hollow spheres, and the partially matrix-filled hollow spheres have been successfully distinguished based on volumetric and geometrical conditions, such as sphericity and compactness. The unintended porosity (as the sum of the casting porosity and the wetting porosity) influences the first compressive stress maximum of the Al99.5 matrix composite metal foams. In contrast, for the AlSi12Sr bimodal foams, the results correlated with the total porosity values. The first compressive stress maximum could be estimated well from the compressive yield strength of the matrix and the total porosity of the foam.

Effect of rotational speed on friction stir welding microstructure and properties of cast and rolled (ZrB2 + Al3Zr) particle-reinforced aluminum matrix composites

Effect of rotational speed on friction stir welding microstructure and properties of cast and rolled (ZrB2 + Al3Zr) particle-reinforced aluminum matrix composites

Influence of the Reinforcement Phase Composition on the Structure and Abrasive Wear Resistance of Aluminum Matrix Composites Reinforced with B4C and SiC

Influence of the Reinforcement Phase Composition on the Structure and Abrasive Wear Resistance of Aluminum Matrix Composites Reinforced with B4C and SiC

Microstructure and properties of a HIP manufactured B4Cp reinforced highly alloyed Al-Zn-Mg-Cu-Zr aluminum matrix composite

In this study, an aluminum matrix composite with good mechanical property and excellent corrosion resistance, B4C particles (B4Cp) reinforced highly alloyed Al-Zn-Mg-Cu-Zr matrix composite, was successfully fabricated through ball-milling, cold isostatic pressing, vacuum degassing, hot isostatic pressing (HIP), homogenization, hot extrusion, solution treatment, and aging treatment. It was found that the B4C/MgAl2O4/Al was the dominant interface structure, which was coherent and enhanced the bonding between the particles and the matrix considerably, while the B4C/Al2O3/Al was the minor interface structure. The grain boundary was very clean in both T4 and T6 aging states, without aging precipitates and O element segregation. In T4 aging state, the composite exhibited superior properties, with the mass density of 2.84 g·cm-3, the elastic modulus of 119.18 GPa, the yield strength of 576.08 MPa, the ultimate tensile strength of 655.27 MPa, the tensile elongation of 1.48%, and the very low electrochemical corrosion current density of 4.4581×10-8 A·cm-2 in 3.5 wt.% NaCl water solution. The MgAl2O4 and BO3-rich interface phases, the strengthening mechanisms and the anti-corrosion mechanisms of the composite were discussed in detail.

Microstructural Evaluation of Al-Al2O3 Composites Processed by Stir Casting Technique

The exceptional qualities of aluminum alloys, including their superior thermal properties, high specific strength and low density make them widely employed as industrial materials. By adding a tougher ceramic reinforcement phase to the aluminum matrix phase, aluminum alloy components can perform even better with improved mechanical properties. It has been discovered that the liquid state processing method is the most affordable and straightforward for processing MMCs out of all the existing ways. Primary processing, such as casting composite materials has its own restrictions on agglomerate formation and porosity. A metal matrix composite made of aluminum and aluminum oxide (Al2O3) has been chosen for the current investigation based on the literature review. A composite material including aluminum A356 and different percentages of Al2O3 (3%, 6%, 9%, and 12%) particles of 23�m size is chosen for the study. Using the SEM and EDAX test, the impact of these materials on the microstructural investigations is being investigated and the results indicates that uniform distribution of the reinforcement is difficult to achieve at higher percentages.

Study on the critical conditions for ductile-brittle transition in ultrasonic-assisted grinding of SiC particle-reinforced Al-MMCs

High volume fraction (45 %) silicon carbide particle-reinforced aluminum matrix composites (SiCp/Al-MMCs) play a significant role in various engineering fields due to their outstanding performance. However, damages characterized by SiC particle fracture during machining lead to poor surface integrity, which severely affects the fatigue performance of SiCp/Al composite structural components. Ultrasonic-assisted grinding (UAG) is acknowledged as beneficial for promoting ductile grinding in hard and brittle materials. This study focuses on the critical conditions for ductile-brittle transition in ultrasonic-assisted grinding of SiCp/Al composites and develops a mechanism and data driven model of critical undeformed chip thickness (UCT) for ductile grinding to accurately predict the material removal mode. The model thoroughly integrates considerations of chip morphology, removal mode transition mechanism, and grinding surface damage characteristics. Response surface methodology (RSM) and genetic algorithms (GA) were utilized to correct the impact of processing parameters on the removal regime. Experiments on ultrasonic-assisted side and end grinding were conducted to thoroughly discuss the effects of different undeformed chip thicknesses, grinding speeds and ultrasonic vibration amplitude on surface damage and the critical conditions for the ductile-brittle transition. The findings corroborate the experimental data with the predicted values. Ultrasonic vibration can effectively reduce the brittle fracture of SiC particles in SiCp/Al composites. Appropriately increasing the grinding speed and reducing the chip thickness can enhance the critical chip thickness for ductile grinding and decrease the proportion of brittle surfaces, thereby achieving a balance between surface integrity and grinding efficiency. This research provides guidance for high-performance machining of SiCp/Al composites.

Exploring synergistic solid lubrication for enhanced tribological performance in biochar-reinforced aluminum matrix composites fabricated by induction sintering

This study presents a pioneering methodology for the synthesis of aluminum matrix composites (AMCs) fortified with biochar, sourced from renewable biomass feedstocks. Employing a systematic approach, various biochar weight percentages were meticulously investigated to discern their impact on the mechanical and tribological properties of the resulting composites. Through a comprehensive battery of tests, encompassing evaluations of compressive strength and hardness, the study elucidated significant enhancements in mechanical robustness consequent to biochar integration. Notably, the mixture formulation with 7.5 wt. % biochar emerged as the optimal configuration, showcasing an impressive 8.83% augmentation in compressive strength and a notable 15% elevation in the hardness relative to the pristine aluminum pure matrix. The research extends beyond traditional analyses, introducing an exploration of tribological performance. The incorporation of biochar is anticipated to impart solid lubricating properties, influencing wear and friction characteristics. Future research directions may delve into the nuanced interplay between biochar content and tribological enhancements, offering insights into the tailored manipulation of mechanical and tribological properties in AMC through biochar reinforcement. The examination of wear and friction exhibited that the friction coefficient decreased by 6.4% when 10 wt. % of biochar was added. Furthermore, the wear resistance improved proportionally with the biochar weight percentage, regardless of the normal loads applied. The finite element model further demonstrated an enhancement in load-carrying capacity due to biochar incorporation. Finally, analysis of the texture of the rubbed surface presented that the inclusion of biochar in an AL matrix changed the way wear occurs and decreased the amount of weight lost during friction. The resulting materials not only exhibit improved mechanical strength but also hold promise for applications in industries that demand robust, environmentally conscious solutions with enhanced tribological performance.

Tribological performance and mechanism of the titanium fiber-SiC whisker hybrid reinforced aluminum matrix composites prepared by pressure infiltration

In this contribution, a Ti-6Al-4V fiber (Tif) and SiCw (SiCw) hybrid reinforced 5056 Al composites (Tif + SiCw/5056 Al) were fabricated, and the effects of SiC whisker contents on the microstructure, mechanical properties, and wear resistance were investigated. The mechanical properties and the hardness of the composites increased first and then decreased with the increase of SiCw contents. The optimal ratio of SiCw to titanium fibers is 3 wt%. The flexural strength of the optimal composites reached 533 MPa, and the fracture toughness reached 29.1 MPa • m1/2. Under a load of 40 N, compared with the Tif/5056 Al composites sample, the wear rate of the optimal composites sample decreased by 80.7%. The uniformly dispersed SiC whiskers promote the formation of a mechanical mixing layer (MML) on the friction surface; the wear mechanism mainly involves abrasive wear and adhesive wear.

A novel approach to improving the interfacial strength of 3D printed Al–GNP composites by modifying GNP with MgO

In this study, the MgO-coated graphene nanoplatelets (GNP)-reinforced aluminum matrix AlSi10Mg composites are fabricated by mechanical alloying and a 3D printing process. The interfacial structure of GNPs–Al has been investigated using high-resolution transmission electron microscopy, and their strengthening mechanism has been analyzed. A weak amorphous Al2O3 was found at the GNP–Al interface area in the composites made with uncoated GNPs. The structure of amorphous Al2O3 becomes distorted when load transfer is initiated, causing the detachment of GNPs from the matrix. This results in quick failure at the interface between uncoated GNPs and aluminum, restricting its overall strength. Once GNPs are coated with MgO, an Al/C mixing zone forms at the contact area, resulting in increased interface strength. The MgO coating on the GNP serves as a protective barrier, preventing the creation of a weaker amorphous Al2O3 layer at the interface and facilitating direct interaction between the GNP and Al matrix. The stress–strain curve demonstrates a 27.5% enhancement in tensile strength in the MgO-coated GNP–Al composite compared to the composite with uncoated GNPs. The strength is increased while maintaining toughness through load transmission of GNPs, bridging, and enhancing dislocation storage capacity by the Mg-rich phase. This study offers a new reference for strengthening 3D-printed aluminum alloys using GNPs.

Shape of fragments cloud behind heterogeneous screen by a space debris particle impact

Technogenic pollution of near-Earth space poses a threat to the functioning of spacecraft. Collisions between space debris (SD) and spacecraft (SC) structures can have catastrophic consequences or cause localized damage, leading to the loss of SC operability or the failure of certain functions. The SC body must effectively protect the internal equipment from various external impacts, be technologically feasible to manufacture, and have as little mass as possible. As a result, the task of designing spacecraft bodies and protective screens for low-orbit SC is particularly relevant due to the large concentration of SD in low Earth orbits.A comparative numerical study was conducted to evaluate the effectiveness of various thin shields in protecting against impacts from space debris particles. The study examined homogeneous shields made of A356 aluminum alloy and 316L stainless steel, as well as volumetrically reinforced composite shields produced using additive manufacturing with steel inclusions, and shields with a gradient distribution of steel throughout the thickness of an aluminum matrix, all with the same areal density. In all the heterogeneous plates considered, the volumetric concentration of steel was 36 %. The study covered an interaction velocity range of 2–9 km/s. Numerical modeling results indicated that the structure of the thin heterogeneous plate does not affect the shape of the debris cloud formed behind the protective shield. The findings of this study can serve as a basis for selecting materials for the development of more effective protection for spacecraft against high-velocity impacts.

Development of Automotive and Marine Appliable Aluminium Composite by Utilizing Agro-Waste Material as Performance Enhancement Particles

Aluminium-based materials are lightweight materials used for producing automotive and aircraft components. However, aluminium materials diminish in performance on exposure to degrading environments, which limits their areas of usage and applications. The degrading effect results in poor resistance to wear and corrosion, reduced properties and defective microstructure. In this work, 6063 aluminium alloy was reinforced with particles of agricultural waste (walnut shell) to produce six samples with five samples of reinforced and a control (unreinforced) sample. Each of the samples of the reinforced alloy was moulded into a 25 mm diameter by 130 mm height using the stir casting method using an industrial pit furnace. The samples were thereafter machined to a diameter of 20 mm and cut into a thickness of 10 mm for characterizations. The potentiodynamic polarization method was used to test for the samples’ corrosion resistance properties following the ASTM G102 standard in 3.65% NaCl test medium. The hardness property was investigated using the Brinell hardness machine following the ASTM A-370 standard, while the microstructure and crystallographic phase studies were carried out using SEM/EDS and XRD profiles, respectively. The unreinforced 6063 Al alloy sample exhibited the highest corrosion rate (Cr) of 0.7321 mm/year and the lowest hardness of 104.94 kgf/mm2. The 10% wt. walnut shell particles (WSP) reinforced 6063 Al alloy sample exhibited the lowest corrosion rate (Cr) of 0.1336 mm/year and the highest hardness of 109.24 kgf/mm2. This indicated that the walnut shell particles enhanced the corrosion and indentation resistance of the alloy. In addition, the SEM images indicated that the agricultural waste (walnut shell particles) reinforced samples exhibited more refined microstructure, lower porosity and smoother morphology compared to the unreinforced (control) sample. Also, the XRD profile of samples revealed some high peak intensity crystallites such as Al(ZnS), Al2O3 and (FeMn)SiO2. These high peak intensity crystallites indicated that these reinforced samples possessed chemical and microstructural homogeneity, high stability and good surface texture.

Study on the effect of thickness on sound absorption performance of foam aluminum

Abstract This paper investigates the effects of different thicknesses on the sound absorption performance of foam aluminum with different pore sizes through a combination of experiments and theoretical research. The results show that the average sound absorption coefficient of small-pore foam aluminum increases with increasing material thickness. As the thickness increases, there is a trend of the peak sound absorption performance shifting towards lower frequencies. In the mid-frequency range, although the sound absorption coefficient increases with the thickness of foam aluminum, the growth rate decreases. The average sound absorption coefficient of large-pore foam aluminum significantly increases with the material thickness and is reflected across various frequency ranges. With the increase in thickness, the sound absorption efficiency also improves, but the rate of improvement gradually slows down after reaching a certain thickness. Samples with the same thickness exhibit different performances in sound absorption coefficient, especially in frequencies above 2000Hz, where these differences are more pronounced. In the high-frequency range, the sound absorption coefficient of 100mm-thick large-pore foam aluminum material approaches 1, approximately 0.95.

Exfoliation of self-assembled 2D aluminum synthesized via magnetron sputtering

Two-dimensional materials have been rapidly developed in recent years. As a type of two-dimensional material, 2D metals exhibit many unique physical and chemical properties. Here, we prepared two-dimensional aluminum materials via magnetron sputtering. The layers were exfoliated via sonication and annealing methods (thermal exfoliation methods). After exfoliation, the layers were observed via optical microscopy, scanning electron microscopy and transmission electron microscopy. The atomic force microscopy results show that the thicknesses of the layers range from ∼1 nm to ∼45 nm. The simulation results supported those two-dimensional layers formed in a self-assembly process.

The cruciality of particle size and shape on fracture mechanism of aluminum matrix composites

Metal matrix composites are generally believed to achieve better performance with spherical reinforcements than irregular ones. In this work, through experiments and computational simulations, we have demonstrated that spherical reinforcements do not necessarily enhance the tensile ductility of composites. There exists a critical size for spherical particles. Using an Al2O3-Al2024 composite as an example, we found that when the size of spherical Al2O3 particles is less than 3 µm, they are not fractured during deformation, resulting in enhanced ductility. We elucidated the competitive mechanism between particle and matrix fracture under various reinforcement sizes and volume fractions, and constructed a deformation map that can be utilized to determine fracture mechanisms. This work clarifies the micro-mechanical mechanisms of reinforcements on material fracture behavior, providing guidance for the design and fabrication of strong and ductile metal matrix composites.

High temperature mechanical properties and tribological behavior of nacre-inspired Ti (C, N)/Al-Cu composites

In order to improve the toughness of aluminum matrix composites with high ceramic contents, nacre-inspired Ti (C, N)/Al-Cu composites are prepared via freeze casting and pressure infiltration, and their mechanical properties and tribological behavior are investigated. The prepared composites can maintain excellent compressive strength, hardness and wear resistance when the experimental temperature increases from 25 °C to 300 °C. This can be attributed to the stable load bearing capacity of the Ti (C, N) ceramic layer at high temperature, the high interface binding capability between Ti (C, N) and Al, as well as the high crack growth inhibition ability of “layered network” structures. Moreover, the tribo-oxide layer formed during the wear process can further improve the wear resistance of the composites.

Fatigue crack growth rate behaviour of aluminium matrix composites reinforced with hollow glass microsphere

This study investigates nanoindentation and fatigue crack growth rates of pure aluminium and aluminium hollow glass microsphere metal matrix composite (Al + HGM MMCs) cast plates. Using the stir casting method, pure aluminium, and Al + HGM MMCs were fabricated with hollow glass microsphere (HGM) additions ranging from 5 % to 30 % by weight. Nanoindentation techniques were utilized to assess fundamental mechanical properties such as hardness and elastic modulus. This study primarily focuses on analyzing fatigue crack growth behaviour within the linear region of da/dN vs. ΔK graphs for these stir-cast plates. Chevron-notch CT specimens were prepared following ASTM E-647 standards, and the constant amplitude increasing ΔK method was employed to generate Paris curves. Furthermore, the research investigated the influence of stress ratios (R=0.1, 0.2, and 0.3) on the fatigue crack growth rate in both Pure Al and Al + HGM MMCs. The study also determined the threshold and critical stress intensity factor ranges (ΔKth and ΔKc) for these plates. Additionally, Paris constants (C, m) were calculated to characterize the fatigue behaviour of the cast plates. X-ray diffraction analysis was conducted to reveal dislocation densities, crystalline sizes, and micro-strain responses of the fatigue-fractured specimens. Moreover, SEM fractography analysis provided insights into the fracture behaviour and crack branching observed in both pure aluminium and Al + HGM MMCs plates.

Characterizing sliding wear behavior of A1100/AlFe (p) composites produced via repeated fold-forging and annealing

Abstract Aluminum matrix/aluminum-iron intermetallic composite materials pose challenges in plastic processing due to the susceptibility of hard intermetallic compound particles to fracture. This study introduces a novel fabrication method involving pure iron mesh, hot-dip aluminum plating, and solidification. Through ten consecutive folding, forging, and intermediate annealing cycles, aluminum matrix and iron undergo diffusion, leading to the formation of Fe2Al5 and FeAl3 interface reaction layers, as confirmed by X-ray diffraction analysis. Subsequent forging cycles cause the breakage or detachment of Fe2Al5 and FeAl3 particles from the interface, resulting in the formation of large-sized Fe2Al5 and small-sized Fe2Al5 intermetallic particles. FeAl3 intermetallic particles are observed via microscopic examination. These particles can be uniformly dispersed within the aluminum matrix through plastic flow, enabling the successful fabrication of A1100/Fe2Al5 and AlFe3 composite sheets. Furthermore, the study investigates the impact of intermetallic compound content, sliding speed, and forward load on the dry sliding wear of A1100/FeAl composites. It is found that Fe2Al5 and AlFe3 intermetallic compound particles effectively mitigate adhesive wear, plowing, and oxidative wear of the composites. With an AlFe intermetallic compound content of 4.3 wt.%, the volume wear rate remains low under conditions corresponding to PV = 56.652 (equivalent to a normal load of 19.6 kPa and a sliding speed of 2.87 m s−1).