Aluminum Matrix Research Articles

Influence of B4C and ZrB2 reinforcements on microstructural, mechanical and wear behaviour of AA 2014 aluminium matrix hybrid composites

Considering their affordability and high strength-to-weight ratio, lightweight aluminium alloys are the subject of intensive research aimed at improving their properties for use in the aerospace industry. This research effort aims to develop novel hybrid composites based on AA 2014 alloy through the use of liquid metallurgy stir casting to reinforce dual ceramic particles of Zirconium Diboride (ZrB2) and Boron Carbide (B4C). The weight percentage (wt%) of ZrB2 was varied (0, 5, 10, and 15), while a constant 5 wt% of B4C was maintained during this fabrication. The as-cast samples have been assessed using an Optical Microscope (OM) and a Scanning Electron Microscope (SEM) with Energy Dispersive Spectroscopy (EDS). The properties such as hardness, tensile strength, and wear characteristics of stir cast specimens were assessed to examine the impact of varying weight percentages of reinforcements in AA 2014 alloy. In particular, dry sliding wear behaviour was evaluated considering varied loads using a pin-on-disc tribotester. As the weight % of ZrB2 grew and B4C was incorporated, hybrid composites showed higher hardness, tensile strength, and wear resistance. Notably, the incorporation of a cumulative reinforcement consisting of 15 wt% ZrB2 and 5 wt% B4C resulted in a significant 31.86% increase in hardness and a 44.1% increase in tensile strength compared to AA 2014 alloy. In addition, it has been detected that wear resistance of hybrid composite pin (containing 20 wt% cumulative reinforcement) is higher than that of other stir cast wear test pins during the whole range of applied loads. Fractured surfaces of tensile specimens showed ductile fracture in the AA 2014 matrix and mixed mode for hybrid composites. Worn surfaces obtained employing higher applied load indicated abrasive wear with little plastic deformation for hybrid composites and dominant adhesive wear for matrix alloy. Hence, the superior mechanical and tribological performance of hybrid composites can be attributed to dual reinforcement particles being dispersed well and the effective transmission of load at this specific composition.

Intermetallic compounds in equilibrium with aluminum in Al–Ca–Cu ternary alloying system

The structure and properties of the new (Al,Cu)4Ca, Al27Ca3Cu7, and Al8CaCu4 intermetallic compounds in equilibrium with aluminum solid solution in the ternary Al–Ca–Cu alloying system were comprehensively analyzed. The (Al,Cu)4Ca intermetallic compound is treated as a line phase based on the Al4Ca phase with Cu substituted by Al. The solubility of copper in the compound reaches 10 at.% (19 wt.%), which leads to marked changes in the crystal lattice structure, physical and mechanical properties of the compound. For instance, the density of the compound increases from 2.22 to 2.79 g/cm3 and the microhardness from HV 180 to HV 250. The Al27Ca3Cu7 phase is treated as a strict stoichiometric ternary compound with a primitive BaHg11 type crystal structure of the Pm3m space group. The lattice parameter is accepted to be 8.514 Å corresponding to a density of 3.45 g/cm3. The Al8CaCu4 phase is also a strict stoichiometric ternary compound with a tetragonal crystal lattice structure of the Mn12Th type. The phase has the highest microhardness (HV 505) and density (4.57 g/cm3). The alloys pertaining to the binary (Al)+(Al,Cu)4Ca phase field and the quasi-binary (Al)+Al27Ca3Cu7 section can be considered promising as the base for new natural aluminum matrix composites.

Deformation and fracture of SiCp/Al composites under complex loading conditions: A simulation study

An accurate depiction of the deformation and fracture mechanisms of metal matrix composites is the key to their rational structure and property design. In the present work, the Advanced Guerson Tvergaard Needleman (AGTN) constitutive model is firstly combined with an algorithm to reconstruct realistic 3D microstructures within the finite-element framework. We employ this model to probe the elastoplastic response and fracture behaviors of aluminum matrix composites with different volume fractions of reinforcing particles (7, 14, and 21 %) and under various loading conditions (tension, compression and shear). Real microstructures are referred to reconstruct the three-dimensional model of the composites. The AGTN constitutive model is integrated with the micromechanical damage model, which is capable of independently describing the constitutive behavior of various components, including the elastoplastic damage of the metal matrix, particle-enhanced elastic-brittle failure, and the interfacial traction separation. By using the conventional SiCp/Al composite system as a model material, we examine the stress state of the matrix and fracture mechanisms under different loading conditions by using triaxiality, Lode angle and statistical analysis. In general, the damage of SiCp/Al composites can be attributed to interfacial debonding and particle fracture, whereas the latter dominates when the volume fraction of SiCp is high. Furthermore, the critical volume fraction for the transition of damage mechanisms is found to be largely dependent on the loading conditions. Our work provides a comprehensive understanding of particle-reinforced aluminum matrix composite under in-service conditions.

Advances in hybrid aluminium metal matrix composite produced by stir casting route: A review on applications and fabrication characteristics

The sustained demand for lightweight parts, superior strength, and high-efficiency products has made material researchers interested to study and explore new materials with superior properties. One of the most promising materials for meeting this demand is aluminium metal matrix composite. Due to its tailored properties, the usage of composite is currently increasing in the automotive, aerospace, marine, electronic, defence, domestic, and sports sectors. Simplicity, affordability, and bulk production in the stir casting method have attracted the attention of many researchers across the globe. This paper reviews the need for hybrid aluminium metal matrix composites, various aluminium alloys, and reinforcement materials produced by the stir casting technique. In addition, the applications, morphological, mechanical, and tribological behavior of aluminium hybrid metal matrix composites are discussed. This review will assist materials researchers in selecting the matrix and reinforcements for a specific application of aluminium matrix composites using the stir casting route.

Development of aluminum matrix composites through accumulative roll bonding: a review

Development of aluminum matrix composites through accumulative roll bonding: a review

Investigation of Thermophysical Processes of Obtaining Various Aluminum Matrix Composites

Investigation of Thermophysical Processes of Obtaining Various Aluminum Matrix Composites

Ultrasonic cavitation strengthening and generation of superhydrophobicity for the surface of in situ (ZrB2 + Al2O3)/AA6016 matrix composite

To enhance the operating stability and durability of the aluminum matrix composite, the superhydrophobic surface is constructed on the substrate of in situ ZrB2 and Al2O3 nano-particle reinforced AA6016 matrix composite. The method incorporating ultrasonic cavitation treatment and low surface energy modification is applied. The performance of the obtained superhydrophobic surface is investigated through comprehensively analyzing micro and nano surface structures, roughness, water contact angle, chemical composition, and mechanical property. The results indicate that the water contact angle and water sliding angle of the specimen treated with cavitation for 9 min and then modified with fluorosilane attain 163.8° and 7.3°, respectively. High superhydrophobicity is accomplished. Long exposure to ultrasonic cavitation treatment results in the shift from hydrophobicity to hydrophilicity. The presence of particle-reinforced phases induces a pinning effect, causing the accumulation and entanglement of dislocations beneath the surface. This phenomenon leads to a 64.7 % increase in surface hardness, and the thickness of the work hardening layer reaches about 300 μm. The obtained conclusions shed light on the preparation of superhydrophobic surface for the aluminum matrix composite, and the application of aluminum matrix composites in harsh environment is expected to be broadened.

Additive manufacturing of AA5083/TiN-Diamond hybrid nanocomposite parts via additive friction stir deposition: Metallurgical structure, mechanical, tribological, and electrochemical properties

Nano-diamond (ND) is a special ultrafine reinforcement whose agglomeration properties and weak interfacial bonding limit its application in aluminum matrix composites. This study used the additive friction stir deposition (AFSD) technique to produce AA5083-H321/2.5 wt% nano TiN/ND additive manufacturing deposition hybrid composite parts (AMDCPs) and a non-composite part (AMDNCP) was also deposited for comparative analysis. The aim was to improve the microstructure and examine the effect of the deposition process parameters, which include 900, 1250, and 1600 rpm rod rotation speed and 5 and 12 mm/min feed rate. The AFSD process parameters were used to calculate the heat input. The consumable rod and AMD parts were evaluated for their macrostructure, microstructure, macro-hardness, tribological, and corrosion properties. The microstructural features were examined using an OM, XRD, and SEM equipped with an EDS. The worn and corrosion surface morphology was investigated using SEM, and hardness was also evaluated as contour maps. The results show that defect-free deposited multilayer AA5083-nano TiN/ND hybrid composite parts were successfully manufactured, and analysis revealed a lower D/H ratio, well-bonded layers, homogeneously distributed TiN/ND and fragmented IMC components, and equiaxed refined grain microstructures. The deposited composites via AFSD showed a lower corrosion rate, higher hardness, and wear resistance than the deposited AA5083 consumable rod and AMDNCP. The AMDP C900-12 demonstrates an optimized deposition process parameter (900 rpm, 12 mm/min) with superior properties, including an increase in hardness by 9.3%, a reduction in grain size by 54%, and a decrease in corrosion rate by 45.2% related to the AMDNC part.

Processing Techniques and Metallurgical Perspectives and Their Potential Correlation in Aluminum Bottle Manufacturing for Sustainable Packaging Solutions

This study explores the potential of aluminum wine bottles as a sustainable alternative to traditional glass bottles, emphasizing their recyclability and environmental advantages. It reviews the potential use of Al-Mn-Mg 3xxx alloys in beverage can bodies and examines various applications of aluminum containers in packaging, including recyclable beverage containers. The manufacturing processes for aluminum bottles, including casting, rolling, punching, and deformation techniques, are discussed in detail, with a particular focus on their impact on mechanical properties and microstructure. The preference for 1xxx aluminum alloys in impact extrusion is explained, highlighting their lower flow stress and higher formability compared to 3xxx alloys, and the microstructural changes induced by various processing steps are analyzed. Challenges related to using recycled aluminum and their effects on mechanical properties and microstructure during aluminum bottle production are also addressed. One objective is to increase the proportion of recycled alloyed material used in aluminum bottle manufacturing. Depending on the technique employed, the fraction of alloyed recycled material can vary. The percentage of recycled alloyed material (3xxx series Al alloys) in cold backward impact extrusion could be raised by 60%. High-speed blow forming could facilitate the production of aluminum bottles with a recycled alloyed material ranging from 50 to 100% of the 3xxx series aluminum can body alloys. The high-speed drawing and ironing (DWI) process can produce large-format aluminum bottles (up to 750 mL), utilizing at least 90% of the recycled 3xxx series can body stock. Furthermore, the paper discusses the importance of optimized heat treatment designs in enhancing mechanical properties and controlling microstructural evolution in alloyed aluminum materials, such as 3xxx series alloys. The study concludes with a need for further research to deepen our understanding of the metallurgical aspects of aluminum bottle manufacturing and to optimize the use of recycled aluminum in packaging solutions, with a specific focus on improving mechanical properties and microstructural integrity. This comprehensive review aims to contribute to the development of more sustainable packaging practices in the beverage industry by providing insights into the interplay between manufacturing processes, mechanical properties, and microstructure of aluminum bottles.

Quenching optimization of a hot stamping line for aluminum automotive components

The rising cost of fuel and harder environmental regulations driving the need for more eco-friendly vehicles have compelled automotive manufacturers to search for innovative lightweight solutions. Consequently, hot stamped aluminum alloys are gaining prominence due to their exceptional specific strength and improved formability compared to cold formed components. Unfortunately, the current state of knowledge in the field lacks the necessary depth to establish a reliable, fast and optimized process for aluminum hot forming. To address this gap, a collaborative effort between Mondragon Unibertsitatea (knowledge provider), Fagor Arrasate (hot stamping line supplier), and Batz (tool manufacturer) has been initiated. The collaborative endeavour aims to conduct semi-industrial trials involving the hot stamping of an authentic automobile bumper employing high-strength 6xxx and 7xxx aluminum alloys. The hot stamping trials have been performed under different in-die quenching times and mechanical properties of the stamped bumpers have been empirically tested. These results have helped to define the optimal quenching time. With that aim, first, a thermophysical and rheological characterization of the aluminum has been performed, followed by the development of a model to predict mechanical properties of aluminum alloys. This predictive model, together with the aluminum material data, has been then integrated into the simulation framework to enable accurate forecasting of mechanical properties and, consequently, the identification of the optimal quenching duration. The results revealed that quenching times as brief as 1 second could be employed while maintaining acceptable mechanical properties in a rapid cycle hot stamping process. These expedited quenching times have the potential to boost production by an impressive 70 % when compared to the conventional hot stamping process applied to the equivalent steel bumper.

Simulating equal channel angular pressing of commercially pure aluminium using Johnson–Cook model

Optimizing the Equal Channel Angular Pressing (ECAP) process for a new material can be a complex endeavour, given the multiple variables such as Coefficient of Friction (COF), channel angle, temperature, etc. To address the need for a material model that can account for temperature-dependent plastic flow, the present study applies the Johnson-Cook plasticity model for simulating ECAP. The present study reports the effects of varying the channel angle (90°, 120°, 150°) and COF (ranging from 0 to 0.15) at room temperature. The results show that the channel angle plays a significant role in influencing the behaviour of the aluminium, with stress and strain exhibiting an inverse relationship with the channel angle. Additionally, the aluminium material experiences a maximum stress distribution and higher flow stress within the COF range of 0 to 0.15 for a channel angle of 90°, as compared to 120° and 150°. This behaviour can be attributed to the restriction of movement at higher COF values. Notably, a maximum shear stress of 56 MPa was observed when the channel angle was set to 90° with a COF of 0.15. Furthermore, across all simulations involving channel angles of 90°, 120°, and 150°, an increase in COF lead to a decrease in curvature. These simulated results are consistent with existing literature. Thus, the Johnson-Cook plasticity model, with appropriate modifications, serves as a viable approach for studying the ECAP process.

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.

The role of Ga and Y on binary Al2O3-Y2O3 and Al2O3-Ga2O3 mixed oxides nanoparticles towards potential Ni water-gas shift catalysts

This work focuses on the study of binary Al2O3-Y2O3-x and Al2O3-Ga2O3-x mixed oxides with varying Y2O3 or Ga2O3 nominal loading (x=25, 50) prepared by hydrothermal synthesis assisted by Triton X-100. The mixed oxides were used to prepare Ni-based (5 wt%) catalysts for the Water Gas Shift Reaction. The Al2O3 sample presented urchin-like hollow nanosphere morphology, which evolved to solid nanospheres with Y2O3 or Ga2O3 in the mixed oxides. The physicochemical characterization indicated good integration of the mixed oxides, especially on the low-content additive oxides. The theoretical results confirmed that Ga goes deeper into the alumina matrix than Y, partially explaining the XPS and HRTEM results in which the Ni dispersion was better in the Ni/AlGa-x samples. The FTIR in-situ measurements of the reaction allowed us to propose that the reaction occurs minimally through the carbonyl mechanism at low temperatures (<300 °C) and the formate mechanism at high temperatures (>300 °C).

Comparative Study of Cantilever Biosensor for Detection of Tuberculosis

Abstract: Now everywhere in the world sensors are used to solve daily human problem. In the medical field sensors are used to diagnose various diseases. In this article for detection of tuberculosis, micro cantilever biosensor has been design and simulate. Rectangular shape cantilever biosensors with silicon, poly-silicon and aluminium material were designed and analysed the displacement. The displacements of this biosensor are compared with the other available models. The MEMS based micro cantilever biosensor were design in COMSOL Multiphysics. 10N to 100N load force are applied on the surface of cantilever for deliberate the interaction of antigen antibody. Stress generated on the surface of cantilever when antigen antibody binds together and it get deflects. This deflection is measured for 10N to 100N load force which is compare with other modules. The displacement generated by cantilever was 1.71 x 1028 µm for 100N force which is higher than all the other models, thus the proposed cantilever model is the best model for detection of tuberculosis

Optimization of thermal deformation process parameters of 2219 Al matrix composites

To investigate the deformation behavior and optimize the hot processing parameters for 2219 aluminum matrix composite, the constitutive equation and hot processing maps were established. Initially, hot compression experiments on 2219 aluminum alloy (2219A) were conducted using a Gleeble-3500 thermal simulation tester to obtain high-temperature rheological data. The deformation temperatures tested were 573, 623, 673, 723, and 773 K, with strain rates of 0.01, 0.1, 1, and 10 s−1, and a maximum deformation of 60 %. Subsequently, material parameters such as the activation energy, Zener–Hollomon parameter, power dissipation efficiency, and instability coefficient for 2219A were calculated. Analytical expressions for these material and deformation parameters were formulated, and a hot processing map for 2219A was constructed. The hot processing map, along with the Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) and the Entropy Weight Method (EWM), were used to optimize the thermal deformation process parameters. The stability processing area and the optimal processing area identified by both methods were largely consistent. According to the hot processing map, the stability processing areas were identified in the temperature ranges of 580–660 K and 690–773 K with strain rates of 0.01 s−1 and 0.01–0.6 s−1, respectively. Using the TOPSIS and EWM methods, the stability processing areas were defined between 573 and 640 K and 0.01 s−1, 640–690 K and 0.01–0.1 s−1, and 690–773 K and 0.01–1 s−1. The consistency and accuracy of these optimization results were confirmed through microstructure analysis.

Modification of cast aluminum matrix composite materials with barium

Modification of cast aluminum matrix composite materials with barium

Investigation of harvesting energy vibrations due to the feed process on milling machines

Milling machines are machines used in the production process. The time required during the machining process must be more efficient in order to obtain the desired production capacity. The aim of this paper is to utilize vibrations originating from milling machines in industry as a source of Harvesting Energy Vibration. The research was carried out by varying the feeding depth of the milling machine so that it could be seen how much stress was produced. The Lushan Model ZX32 milling machine was used in this research, where vibrations from the vibration source were measured using an FFT Analyzer connected to an Accelerometer Sensor and Harvesting energy vibration connected to an Oscilloscope. Meanwhile, the workpieces used in this research were Aluminum 5052 and PVC. The results of the research were that on PVC material with an ingestion depth of 1 mm, the vibration frequency at 210 rpm was 71 Hz, the amplitude was 1.38 mm/s2, resulting in a harvesting energy of 6.449 mV. And the results of research using aluminum at 210 rpm rotation with a feeding depth of 3 mm obtained a vibration frequency of 90 Hz with an amplitude of 1.508 mm/s2 producing a harvesting energy of 5.856 mV. The research results show that the PVC material produces higher harvesting energy vibration at a depth of 1 mm, and the aluminum material produces higher harvesting energy vibration at a depth of 3 mm

Material flow analysis and carbon footprint of water-packaging waste management

Packaged drinking water represents one of the fastest growing commodities on a global scale, and several alternatives to plastic have been proposed, such as glass, cardboard or aluminum. The research has a twofold goal: (i) first, it calculates the amount of water-packaging waste generated in Italy in 2020, distinguishing among PET, glass, aluminum and cardboard materials, and it applies the material flow analysis through the STAN 2.7.101 software; (ii) second, it evaluates the carbon footprint of the management of the primary water-packaging waste, considering recycling, incineration with energy recovery and landfilling by using the CO2ZW tool. The research estimates the adverse environmental impacts of the selected management pathways considering 1 kg of water-packaging and 1000 L of packaged water. The results show that each year 1311 kt of waste and almost 289 ktCO2eq of direct and indirect emissions are associated with recycling, incineration with energy recovery and landfilling of water-packaging in Italy. PET bottles record the highest environmental impact with 0.77 kgCO2eq per kg of treated waste, with incineration representing a significant burden (1.80 kgCO2eq per kg of treated waste) compensated by recycling. The research discusses opportunities and challenges toward a more sustainable waste management of water-packaging, highlighting the need to increase recycling rates among final consumers and reduce incineration with energy recovery, which significantly contributes to the release of carbon emissions. Last, heavy bottles should be substituted with ultralight ones, since waste management emissions can be reduced by 13% by replacing 490 g of glass bottles with 390 g ones.

Microstructure, solidification defects and mechanical properties of high-modulus and high-strength SiC/AlSi10Mg composites fabricated by selective laser melting

Since the aluminum matrix composites prepared by additive manufacturing are prone to defects such as pores and cracks, the properties of the formed composites cannot be further improved. Therefore, the preparation of SiC/AlSi10Mg composites with high modulus and high strength by selective laser melting technology is of great significance for the wide application of aluminum matrix composites. This work will further investigate the defect formation, microstructure evolution, and solidification mechanism of the composites. The matrix microstructure of the composites can be efficiently refined by adding SiC. In addition, the 5 wt.% SiC/AlSi10Mg composites showed improvements in the tensile yield strength, microhardness, bending strength, elastic modulus, and ultimate tensile strength as compared to the AlSi10Mg alloy. These increases were 21.1 %, 18 %, 8.7 %, 23.2 % and 9.2 % respectively. The strengthening mechanisms at room temperature include fine grain strengthening, thermal mismatch strengthening, solid solution strengthening and precipitation strengthening. It is also mentioned that the primary causes of the decrease in toughness are stress concentration and the existence of the brittle precipitation phase (Al4C3). The increase in high-temperature strength is attributed to the pinning role of SiC and precipitate phases relative to grain boundary and dislocation climbing.

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.