Carbide Metal Matrix Composites Research Articles

Aluminum boron carbide metal matrix composites for fatigue-based applications: A comprehensive review

Metal matrix composites (MMCs), known for their low density and superior stiffness, have gained significant attention in various load bearing and fatigue-prone applications. These composites offer distinct advantages over traditional monolithic metals, including enhanced mechanical and tribological properties, making them prime candidates for lightweight structural applications. Among ceramic reinforcements, boron carbide stands out due to its lower density, high elastic modulus, excellent refractoriness, and superior hardness, positioning it as an ideal reinforcement material. This review delves into the processing techniques, material properties, and microstructural characteristics of boron carbide-reinforced MMCs, with a focus on aluminum LM6 alloy as the matrix. Additionally, the paper explores the latest advancements and emerging opportunities for employing these composites in fatigue-critical applications, highlighting their potential to revolutionize industries requiring high performance and durability under repeated loading conditions.

A Detailed Study on using Novel LM 25 Aluminium Alloy Hybrid Metal Matrix Nanocomposite for Nuclear Applications.

This article describes the use of graphite(Gr) and boron carbide (B4C) as multiple nanoparticle reinforcements in LM25 aluminum alloy. Because boron carbide naturally absorbs neutron radiation, aluminium alloy reinforced with boron carbide metal matrix composite has gained interest in nuclear shielding applications. The primary goal of the endeavor is to create composite materials with high wear resistance, high microhardness, and high ultimate tensile strength for use in nuclear applications. Science and Technology have brought a vast change to human life. The human burden has been minimized by the use of innovation in developing new and innovative technologies. To improve the quality of human life, fresh, lightweight, and creative materials are being used, which play a vital role in science and technology and reduce the human workload. Composite materials made of metal are being used because they are lightweight. Neutron absorption, high ultimate strength, high wear resistance, high microhardness, high thermal and electrical conductivity, high vacuum environmental resistance, and low coefficient of thermal expansion under static and dynamic conditions are all demands for the hybrid metal matrix composites utilized in nuclear applications. • Stir casting is used to create the novel LM 25 aluminum alloy/graphite and boron carbide hybrid nanocomposites. • The mechanical properties such as ultimate tensile strength, yield strength, percentage of elongation, microhardness, and wear behavior are calculated. • Three analyses are performed: microstructure, worn surface analysis, and fracture analysis of the tensile specimen. • Stir casting process< • Tensile, Hardness, Wear Test • Materials Characterization - FESEM, Optical Microscopy, EDS< Results: The mechanical properties values are 308.76 MPa, 293.51 MPa, 7.8, 169.2 VHN, and 0.01854mm3/m intended for ultimate tensile strength, yield strength, percentage of elongation, microhardness, and wear behavior, respectively. This implies that the synthesized composite may be used in nuclear applications successfully. The subsequent explanation was drawn from this investigative work: • The LM 25/B4C/Gr hybrid nanocomposite was successfully manufactured by employing the stir casting technique. For nuclear shielding applications, these composites were prepared with three different weight percentages of nanoparticle reinforcements in 2,4,6% Boron carbide and constant 4 wt.% graphite. • The microhardness values of the three-hybrid nanocomposite fabricated castings were determined to be 143.4VHN, 156.7VHN, and 169.2VHN, respectively. • The hybrid nano composite's microstructure revealed that the underlying LM 25 aluminum alloy matrix's finegrained, evenly dispersed nanoparticles of graphite and boron carbide were present.<br></br> • The microtensile test was carried out and it was found that the ultimate tensile strength, yield strength and percentage of elongation values are 281.35MPa, 296.52MPa, 308.76MPa, 269.43, 274.69, 293.51 and 3.4, 5.7, 7.8 respectively.<br></br> • Deformation caused the hybrid LM 25/B4C/Gr nanocomposite to fracture in ductile mode. Dimples and cavities are seen in the fracture because of the nanoparticle reinforcements and the matrix's tight connection.<br></br> • The wear loss of nanocomposite based on the input parameter applied load, sliding velocity and sliding distance values are 0.02456, 0.02189, 0.01854, 0.02892, 0.02586, 0.02315 and 0.02682, 0.02254, 0.02015 mm3/m, respectively.<br></br> • The LM 25 alloy's elemental analysis displays the aluminum alloy phase as the largest peak and the remaining elements as smaller peaks; also, the spectral analysis reveals the presence of boron (B), graphite (C), silicon, and ferrous in the aluminum alloy LM 25.<br></br> • Through worn surface FESEM investigation, it was shown that under sliding and high load situations, debris, delamination, and groove develop. Further rupture, fine, and continuous grooves were seen when low stress and sliding circumstances were applied to the LM 25/B4C/Gr and stir cast specimen. This result implies the presence of mild adhesive and delamination wear processes.</P>.

Study on the Tribological Characteristics of AA5010/Fly Ash/ Boron Carbide Metal Matrix Composites using Response Surface Methodology

In this study, a metal matrix composite (MMC) made from an AA 5010 base alloy with reinforcements of fly ash (FA) and Boron carbide (B4C) was tested for its wear and frictional behavior using a stir casting technique. Fly ash of 3, 6, 9, and 12 wt. % and 3, 6, 9, and 12 wt. % of B4C reinforcements were used to accomplish the goal. The mechanical characteristics acquired at 12 wt. % of FA and B4C were determined upon first through the use of mechanical experiments. The tribology characteristics of the composite were evaluated through a pin-on-disc (POD) device in dry circumstances after being manufactured using 12 wt. % FA and B4C reinforcements. The effects of distance (1200 m, 2400 m, and 3600 m), speed (2, 4, 6 m/s), and applied load (15, 25, and 35 N) on the wear parameters of dry sliding were studied. Experiments and determining the best wear parameters can be done reasonably and accurately using a response surface methodology (RSM). The RSM was also useful in determining the most influential factor, which turned out to be the rate of wear. Finally, it was determined that the load being applied is the single most important element in determining the rate of wear. It was that the performance indicator is less sensitive to changes in sliding velocity and sliding distance.

Properties, Selection, Processing, Characterization and Applications of Aluminium - Boron Carbide Metal Matrix Composites: A Comprehensive Review

Properties, Selection, Processing, Characterization and Applications of Aluminium - Boron Carbide Metal Matrix Composites: A Comprehensive Review

Prediction of Wear Rate in Al/SiC Metal Matrix Composites Using a Neurosymbolic Artificial Intelligence (NSAI)-Based Algorithm

This research paper delves into an innovative utilization of neurosymbolic programming for forecasting wear rates in aluminum-silicon carbide (Al/SiC) metal matrix composites (MMCs). The study scrutinizes compositional transformations in MMCs with various weight percentages of SiC (0%, 3%, and 5%), employing comprehensive spectroscopic analysis. The effect of SiC integration on the compositional distribution and ratio of elements within the composite is meticulously examined. In a novel move for this field of research, the study introduces and applies neurosymbolic programming as a novel computational modeling approach. The performance of this cutting-edge methodology is compared to a traditional simple artificial neural network (ANN). The neurosymbolic algorithm exhibits superior performance, providing lower mean squared error (MSE) values and higher R-squared (R2) values across both training and validation datasets. This highlights its potential for delivering more precise and resilient predictions, marking a significant development in the field. Despite the promising results, the study recognizes that the performance of the model might vary based on specific characteristics of the composite material and operational conditions. Thus, it encourages future studies to authenticate and expand these innovative findings across a wider spectrum of materials and conditions. This research represents a substantial advancement towards a more profound understanding of wear rates in Al/SiC MMCs and emphasizes the potential of the novel neurosymbolic programming in predictive modeling of complex material systems.

Weight Optimization of Chassis of an Automotive Vehicle using ANSYS

The objective of this paper is to find out the most favourable material and immensely fitted cross-section for TATA 11O9 TRUCK ladder chassis. This research aims to optimize the weight of the chassis. For this we have taken three materials like structural steel, carbon fiber and Aluminium silicon carbide metal matrix composite. The automotive chassis is the vehicle's base, providing strength and support to the numerous body sections such as suspension, engine, power train, and so on. Recent advancements in the realm of automobiles have expanded rapidly, particularly in the current context. Problem faced by modern days vehicle is the heavy weight. So here we try to decrease the weight of chassis frame by using various method and increase the strength, efficiency of chassis. Reducing the weight of chassis results in increase in performance of vehicle, reduce fuel consumption, less wear and tear of tire. The designing of the chassis is done on software SOLIDWORKS and further analysis is done on ANSYS19.2. The current chassis mass with traditional material is 1560 Kg which is made up of structural steel, whereas the chassis mass with Aluminium carbide metal matrix composite material is 523.45 Kg. According to the analysis, the chassis mass has been reduced by 66.44%, which would eventually hinder the vehicle's performance.

Effect of the B4C content on microstructure, microhardness, corrosion, and neutron shielding properties of Al–B4C composites

Aluminum–Boron Carbide (Al–B4C) metal matrix composites (MMCs) are frequently studied because of their high thermal conductivity and ability to absorb neutrons, as an alternative material for the manufacture of baskets in spent fuel casks in the nuclear industry. Keeping in mind, this study aimed to produce Al–B4C MMCs and examine their properties to shield against neutron radiation. The Al-xB4C (x = 5, 10, 15, 20, 25, 30, 40, 45, and 50 wt%) composite powders were prepared by a high-energy planetary ball milling. The prepared powders were compacted with uniaxial cold compaction at 500 MPa and sintered in a tube furnace at 600 °C for 1 h under an Argon atmosphere. The microstructure of the obtained MMCs was characterized by using X-ray diffraction (XRD) and scanning electron microscopy with energy-dispersive X-ray spectroscopy (SEM/EDX). The XRD result indicates that the synthesized Al–B4C MMCs have a predominant phase of Al and B4C. The SEM images show the distribution of B4C reinforcement inside the Al matrix. The relative density, measured by the Archimedes principle decreased from 99.95 to 91.55% as the B4C ratio increased. The microhardness value was increased in the beginning from 44 to 75.5 HV and then decreased to 36.5 HV as the B4C ratio increased. The polarization curves show that the corrosion current density and the corrosion rate were significantly increased from 52.25 to 375.36 μA cm−2 and 0.573–4.121 mm/year as the B4C ratio increased. The simulation results, computed by the MCNP6.2 program show that the thermal neutron cross-section and the fast neutron cross-section was increased from 4.5 to 40.1 cm−1 and 0.13 to 0.15 cm−1 as the B4C ratio increased. Further, the neutron equivalent dose rate was calculated experimentally with the 241Am–Be neutron source and the data was completely agreed with the computational results.

Effect of hybrid ultrasonic-electromagnetic field on cracks and microstructure of Inconel 718/60%WC composites coating fabricated by laser cladding

In this study, a novel hybrid ultrasonic-electromagnetic (UEM) field was introduced into laser cladding (LC) to fabricate Inconel 718/60% tungsten carbide (WC) metal matrix composites (MMCs) coating on Inconel 718 substrate. Effects of hybrid UEM field on macrostructural, microstructure, phase composition, crack propagation and microhardness of MMCs coating were studied. Results show that under hybrid UEM field, the height of the MMCs coating increases, the cracks in MMCs coating can be effectively eliminated, the distribution of WC particles in the coating becomes more homogeneously, and the heat damage degree of WC particles is significantly decreased. Moreover, hybrid UEM field helps refine the microstructure and promote the transition of coarse carbide precipitates to the smaller spherical carbides. As a result, the microhardness of MMCs coating distributes more evenly in the coating under hybrid UEM field.

Determination of prediction model and optimization of process parameters for fabrication of Al-SiC composite using response surface methodology

ABSTRACT The study attempted to optimise the fabricating process parameters for Aluminium silicon carbide (Al-SiC) metal matrix composites (MMCs) in a centrifugal casting machine. The effects of centrifugal casting die speed, melting temperature, the wt.% of reinforcement, and particle size were investigated experimentally based on wear performance and coefficient of friction (CoF). The wt.% of reinforcement (SiC) varied from 10% to 20% and particle size from 40 to 100 µm. While the die speed and melting temperature varied from 800 to 1200 RPM and 800 to 900°C respectively. Experiments were performed according to the central composite design model. For optimisation and investigation of individual and interaction effect of each variable on wear loss, and CoF response surface methodology tool was used. The statistical study of experimental results showed that reinforcement wt.% is the most influential factor on wear, followed by die speed, particle size, and melting temperature, respectively. The increased wt.% of reinforcement, die speed, and particle size results in decreased wear loss. At the same time, the effect of melting temperature on wear loss was also observed. The effect of melting temperature on wear and CoF was the least, and an increase in melting temperature increases the wear loss, while particle size was the second most influential factor found after reinforcement wt.% on CoF. Abbreviations: MMCs Metal Matrix Composites PMCs Polymer Matrix Composites CMCs Ceramic Matrix Composites D.O.E. Design of Experiment FGMMC Functional Grade Metal Matrix Composites CoF Coefficient of FrictionCCD Central Composite Design RSM Response Surface Methodology ANN Artificial Neural Network GRA Grey Relational Analysis ASTM American Society for Testing and Materials ANOVA analysis of variance Al-SiC Aluminium Silicon Carbide

Investigation of microstructure and mechanical characteristic of underwater friction stir welding for Aluminum 6061 alloy – Silicon carbide (SiC) metal matrix composite

Demand for metal matrix composites (MMCs) is expected to increase in these applications, such as ‎in the aerospace and automotive sectors. Adequate joining techniques, which are important for ‎structural materials, have not yet been developed for Metal Matrix Composite (MMCs), however. ‎This work aimed to demonstrate the feasibility of ‎friction stir welding (FSW) and ‎underwater friction stir welding (UFSW) for joining Al 6061/5, Al 6061/10, and Al ‎‎6061/18 wt. %SiC composites have been produced by utilizing reinforce stir casting technique. Two ‎rotational ‎speeds,1000and 1800 rpm, and traverse speed 10mm \ min were examined. Specimen ‎composite plates 10 mm thick have been successfully welded by FSW. For FSW and UFSW, a tool ‎made of high-speed steel (HSS) with a conical pin shape was used. The result revealed that the ‎ultimate tensile strength of the welded joint by FSW and UFSW at rotation speed 1800 rpm for (Al ‎‎6061/18 wt. ‎‎% SiC composites) was 195 MPa and 230 MPa respectively. The ultimate ‎tensile ‎strength of the welded joint by FSW and UFSW (Al 6061/18 wt.% SiCe composites) was 165 MPa ‎and 180 MPa at rotation speed ‎‎1000 rpm respectively. The microstructural assessment showed that due ‎to larger grain sizes at FSW and UFSW, most of the fractures are located in the thermal ‎mechanically affected zone (TMAZ) adjacent to the weld nugget zone (WNZ). It is observed that in ‎failure, most of the joints show ductile features. As the volume fraction of SiC (18 wt.%) increases, ‎the friction stir welded and underwater friction stir welded efficiency decreases.

Investigation of Al-B4C Metal Matrix Composites Produced by Friction Stir Additive Processing

Aluminium—boron carbide metal matrix composites (Al-B4C MMCs) belong to the class of materials extensively used in the nuclear industry as a thermal neutron absorber in spent fuel casks. This article investigates a novel production method of Al-B4C MMCs—Friction Stir Additive Processing (FSAP)—as an alternative production method to casting or sintering. FSAP is derived from friction stir welding, which can be used to local modifications of microstructure, or it can be used to incorporate the second phase into the processed material. During this study, a variant of FSAP for MMC production was proposed, and its mechanical and thermal neutron absorbing properties have been investigated. Further, the influence of neutron irradiation on mechanical properties has been studied. Results show that FSAP can successfully produce Al-B4C MMCs with 7 mm thickness. Neutron irradiation causes only a slight increase in hardness, while its effect on tensile properties remains inconclusive.

Evaluation of mechanical properties of Al-B4C and Al-SiC metal matrix composites – A comparison

This paper deals with the comparison of Mechanical properties of aluminum alloy (LM 25) with boron carbide and aluminum alloy with silicon carbide metal matrix composite. The boron carbide of particle size 35 to 40 µm and silicon carbide of similar particle size were used as reinforcements. This addition gives excellent hardness and good impact strength. The fabrication was done by using stir casting., The samples are prepared and mechanical testing like tensile, hardness, and impact was done. It was found that aluminum alloy with boron carbide showed better tensile and impact strength whereas aluminum alloy with silicon carbide showed better hardness. The structure was characterized by using optical microscope.

Optimization of external roller burnishing process on magnesium silicon carbide metal matrix composite using response surface methodology

Optimization of external roller burnishing process on magnesium silicon carbide metal matrix composite using response surface methodology

Impact of Magnetic Field Environment on the EDM Performance of Al-SiC Metal Matrix Composite.

In the present work, a hybrid magnetic field assisted powder mixed electrical discharge machining had been carried out on the Aluminum-Silicon Carbide (Al-SiC) metal matrix composite. The aim of the study was to obtain higher surface finish, and enhanced material removal rate. The dielectric mediums employed were plain EDM oil, SiCp mixed and graphite powder mixed EDM oil for flushing through the tube electrode. The magnetic field intensity, discharge current, T-on/off duration and type of dielectric were the control variables used for present investigation. From the results, it was observed that the machining variables for instance, discharge current, T-on/off duration and type of dielectric conditions remarkably affected the material removal rate, micro-hardness and surface roughness of the machined composite material. The MRR augmented considerably with an increase in the magnetic field intensity along with peak current. Subsequently, the composite with lesser vol.% of SiC particulates witnessed sharp rise in MRR in maximum magnetic field environment (0.66T). In addition, quality of the machined surface improved significantly in graphite powder mixed dielectric flushing condition with intermediate external magnetic field environment. Besides, an enhancement of micro-hardness was quantified as compared to base material due to the transfer of the material (SiCp) during powder mixed ED machining.

Optimisation of Drilling Parameters of Metal Matrix Composites using Genetic Algorithm in the Taguchi Method

This work presents the machining parameters optimization on machining metal matrix composites using genetic algorithm in the Taguchi method with the objectives of minimization of surface roughness, cutting force, maximization of metal removal rate, cutting power, specific cutting energy, cutting power and machining time. Experiments were conducted on aluminium silicon carbide Metal Matrix composite using TiN coated HSS twist drills. Optimal setting of parameters have been identified using Taguchi Technique and Genetic algorithm. Genetic algorithm is developed in ‘C’ language. The presented work gives a better results and it can be used for any machining parameter optimization in solving multiple response problems.

Experimental investigations on mechanical properties of Al-B4C metal matrix composites

The new aluminium boron carbide metal matrix composites are used in a wide range of fields including aerospace, aviation, marine, automobile, electronics, golf clubs, turbine blades, brake pads, etc. Many manufacturing techniques for aluminium carbide metal matrix composites (Al-B4C MMC's) are available. Stir casting route is simple, less costly, and used in mass production among the different methods. This paper analysed a 3.5%, 7.0%, and 10.5% reinforced mechanical properties of boron carbide aluminium. The composite Al-B4C Metal Matrix is made using stir casting technique. Fabricated composites were distinguished by their mechanical properties such as hardness, tensile strength and yield strength.

Experimental analysis of Al-AlN-B4C hybrid composite material for automobile disk brake

To meet the increasing demand of fuel efficiency and low weight components in automobile sectors have led to the improvement of advanced material parts with increased performance. A special class of MMC which had gained a lot of attention due to its potential was aluminium metal matrix composites (Al-MMC). Product performance investigation of Al-MMC was presented in this paper. The aim is to identify the possibility of replacing the traditional cast iron brake disc with Al-MMC brake disc. The simulation results stated that the MMC brake disc provided better thermal and mechanical performance. Though, the Al-MMC brake disc dissipated higher maximum temperature compared to cast iron brake disc's maximum temperature by conducting thermal conductivity test. Furthermore, better thermal dissipation and thermal conduction at disc brake rotor surface played a major influence on the stress. By finding the maximum tensile stress, impact stress, wear loss, hardness values by conducting different tests on the Al-MMC brake disc (Al-Aluminium nitride- Boron carbide metal matrix composites are introduced) to obtain a better performance in disc brake with stir casting method.

Dielectric Fluid Parameter Optimization in Machining of Composite Material using WEDM Process

Wire Electric Discharge Machining (WEDM) has become most popular among the non-conventional machining processes because of precise machining and accuracy of parts. The process is preferable for accurate machining of complex geometries in hard materials such as Aluminium Silicon Carbide metal matrix composite. In this work, an attempt is made to analyze and optimize the dielectric fluid parameters in machining of Al/SiCp 10% work material. The input variables such as volume flow rate, flow velocity and chemical composition of dielectric medium used in the WEDM are chosen for this. Taguchi’s L9 orthogonal array is used to conduct experiments in WEDM machine and ANOVA results have confirmed the influence of chosen parameters on the output responses. Computer simulation model of the WEDM tank with dielectric fluid, work piece and nozzle is presented using Fluent software. The Fluent model is analyzed based on the maximum removal of debris in the work material. Optimization is carried out to maximize the Material Removal Rate (MRR) and minimize surface roughness. The results obtained from Taguchi’s optimization and Fluent analysis have been validated by carrying out tests on WEDM. The study shows that volume flow rate and flow pressure can adequately influence MRR and surface roughness.

Multi-objective optimization of process parameters in dry sliding wear characteristics of Al/sic composites using Taguchi grey relation analysis

Aluminium/ silicon carbide (Al/SiC) metal matrix composites are widely used in the automotive applications owing to its remarkable tribological properties. In this study, the metal matrix composites with 7.5% SiC (weight proportion) are prepared by stir casting method. To study the influence of process parameters, experiments are designed using L09 orthogonal array. Three parameters, namely sliding speed, load and Sliding Distance, are considered in the present work. The effect of these parameters on friction and wear rate of Al 6061/ SiC metal matrix composites are analyzed. Testing is conducted to access the wear rate and friction. Taguchi grey relation analysis is used to estimate the optimum process parameters. An Analysis of Variance (ANOVA) is conducted to identify significant and non-significant factors. The load applied is found to be the most significant factor. The optimal process parameters are found to be the sliding distance 500 m, load 10 N and sliding speed 4 m/s. The R2 value of the Taguchi grey-based model is found to be 99.44 percentage. Confirmation tests are conducted to verify the optimized results. Metallurgical analysis confirms the defect-free Al/Sic composites with improved tribological properties.

Investigations on morphology and material removal rate of various MMCs using CO2 laser technique

The efficient machining of metal matrix composite becomes important factor with respect to the high strength and hardness properties. The presented research work observes the influence of CO2 laser processing parameters on various metal matrix composite materials in terms of material removal rate (MRR). A comparison has been explored between various composite materials such as silicon carbide (SiC), aluminum oxide (Al2O3), and zirconium oxide (ZrO2) metal matrix composites for MRR. This results in novel research in context of MRR that examines the microstructure of machined work material. In the present study, to determine MRR various weighing evaluations and topography of machined surface were studied. The results indicated that the focal position, cutting speed and reinforced particles are the significant parameters for MRR. The morphological and metallurgical changes such as formation of recast layer have been analyzed using scanning electron microscope. The chemical composition of machined work materials and formation of new compound have been identified using EDS/XRD technique.