Carbide-reinforced Aluminum Research Articles

Microstructure and Mechanical Properties of Silicon Carbide-Reinforced Aluminum Matrix Composite Based on Al–Mg–ZnO Phase

Microstructure and Mechanical Properties of Silicon Carbide-Reinforced Aluminum Matrix Composite Based on Al–Mg–ZnO Phase

Optimization of milling tool parameters and experimental study of cryogenic minimum quantity lubrication (CMQL) for SiCp/Al composites

Silicon carbide-reinforced aluminum matrix composites (SiCp/Al) have excellent physical properties, but the presence of SiC particles in the reinforcing phase causes severe tool wear and more serious surface defects during cutting, which seriously hinders the machining efficiency of SiCp/Al composites. To improve the surface quality of SiCp/Al composites and improve the tool wear problem, it were carried out that simulation and experimental verification of the milling tool parameters of SiCp/Al composites and experimental study of CMQL with the selected tool parameters. The results show that the cutting tool with rake angle of 4° and relief angle of 10° can achieve efficient cutting of SiCp/Al composites. The CMQL condition can effectively reduce the surface roughness, improve the surface microstructure, reduce tool wear and increase tool life; The increase of cutting speed can reduce the machined surface roughness, while the increase of feed and cutting depth will lead to the increase of surface roughness.

Comparative Analysis and Optimization of Thermoelectric Machining of Alumina and Silicon Carbide-Reinforced Aluminum Metal Matrix Composites Using Different Electrodes

In this paper, a comparative experimental analysis of die-sinking electric discharge machining (EDM) to two most exhaustively used aluminum metal matrix composites (AMMCs) has been performed using Copper and Tungsten as tool electrodes. AMMCs containing silicon carbide (SiC) and alumina (Al2O[Formula: see text] as reinforcement (10[Formula: see text]wt%) were fabricated by stir casting method. The Box–Behnken Design (BBD) approach of response surface methodology was used to develop experimental models for material removal rate (MRR) and surface roughness (SR). Effect of input parameters such as current ([Formula: see text]–12[Formula: see text]A), gap voltage ([Formula: see text][Formula: see text]V), pulse-on time ([Formula: see text]s), and duty factor ([Formula: see text]–6) on the output responses has been investigated with response surface plots. Effectiveness of design of experiment (DoE) and evolutionary algorithm-based multi-objective optimization (MOO) technique have been compared to find the best feasible optimal solution. ANOVA analysis reveals that for alumina reinforced AMMC interaction between [Formula: see text] has significant effect on both MRR and SR using Cu electrode. But for tungsten, electrode interaction between [Formula: see text], [Formula: see text], and [Formula: see text] have major role on MRR whereas SR is mostly influenced by interaction between [Formula: see text] and [Formula: see text]. The parametric analysis reveals that an increase of current from 4[Formula: see text]A to 12[Formula: see text]A at a higher pulse-ontime increases the MRR more significantly, and higher MRR occurs in cases of alumina-reinforced AMMC. Increase of pulse-ontime at low current (4[Formula: see text]A) reduces the MRR in AMMC/Al2O3. Good surface finish can be obtained by combining high voltage (60[Formula: see text]V) with either small current (4[Formula: see text]A) or small duty factor (4) for both AMMCs. Both DoE and metaheuristic-based MOO technique reveals that copper electrode should be preferred for die-sinking EDM of AMMC/SiC. Metaheuristic approach should be preferred for optimization of die-sinking EDM of AMMCs using different electrodes because it requires low current for effective machining of different AMMCs.

Heat transfer characteristics in discontinuous silicon carbide-reinforced aluminum multiphase composites containing nano-graphene additives: a micromechanics-based multistep technique

Heat transfer characteristics in discontinuous silicon carbide-reinforced aluminum multiphase composites containing nano-graphene additives: a micromechanics-based multistep technique

Interrelating the Breaking Strength of Novel Nano Tungsten Carbide Reinforced Aluminium Alloy Composites with Al-Mg-Cr Alloy

Interrelating the Breaking Strength of Novel Nano Tungsten Carbide Reinforced Aluminium Alloy Composites with Al-Mg-Cr Alloy

Microstructure, Mechanical Properties, and Corrosion Behavior of Boron Carbide Reinforced Aluminum Alloy (Al-Fe-Si-Zn-Cu) Matrix Composites Produced via Powder Metallurgy Route

In this paper, Al-Fe-Si-Zn-Cu (AA8079) matrix composites with several weight percentages of B4C (0, 5, 10, and 15) were synthesized by powder metallurgy (PM). The essential amount of powders was milled to yield different compositions such as AA8079, AA8079-5 wt.%B4C, AA8079-10 wt.%B4C, and AA8079-15 wt.%B4C. The influence of powder metallurgy parameters on properties’ density, hardness, and compressive strength was examined. The green compacts were produced at three various pressures: 300 MPa, 400 MPa, and 500 MPa. The fabricated green compacts were sintered at 375 °C, 475 °C, and 575 °C for the time period of 1, 2 and 3 h, respectively. Furthermore, the sintered samples were subjected to X-ray diffraction (XRD) analysis, Energy Dispersive Analysis (EDAX), and Scanning Electron Microscope (SEM) examinations. The SEM examination confirmed the uniform dispersal of B4C reinforcement with AA8079 matrix. Corrosion behavior of the composites samples was explored. From the studies, it is witnessed that the rise in PM process parameters enhances the density, hardness, compressive strength, and corrosion resistance.

Mechanical and tribological characteristics of boron carbide reinforcement of AA6061 matrix composite

The use of boron carbide-reinforced aluminium matrix composites has grown rapidly in critical applications of aerospace industries, automotive sectors, military, and nuclear engineering. However, boron carbide reinforcement within AA6061 alloy is worthy of investigation in terms of its mechanical and tribological properties. Novel aluminium matrix composites were developed with three different reinforcements (i.e. 5, 10, and 15 wt% of B4C) by using the stir casting process. The developed samples were then tested for performance in terms of mechanical properties (i.e. tensile strength, bending strength, impact strength, shear properties, and micro-hardness). The microstructure of the developed samples was analysed using a scanning electron microscope. By adding 5% B4C reinforcement, the samples display enhanced mechanical properties (high bending, increased resistance to impact test, and shear strength). The micro-hardness tends to increase by increasing the percentage of reinforcement. The novel composites have superior wear resistance due to an increase in the content of B4C particles. The measurements indicate that the wear rate resistance is significantly higher for the composite material with a large amount of B4C particles when was compared with AA6061 alloy. The patterns of surface analysis reveal a homogeneous distribution of ceramic reinforcements in 5 and 15 wt% of B4C samples, as well as a low agglomeration of embedded particles.

Applicability of Boron Carbide Reinforced Aluminium 7075 Composites for Aircraft Wings and Engines

It has become a prerogative of any industry to aim for lightweight materials, having promising strength for all of its major applications. Right from car manufacturers, aiming to incorporate lightweight materials, to substantial Space Research organizations, also aiming to reduce their functional weight, every organization puts forth voluminous efforts to achieve this goal. In such a scenario, Aluminium 7075 and Boron Carbide composites are found to be promising. This article briefs an experimental observation using these Aluminum-Boron Carbide composites which were synthesized using stir casting technique with varying particulate weight fraction (3%, 6%, and 9%). The experimental observation yielded promising outcomes of using this composite for lightweight applications. The composites are found to have greater strength and better weight ratio and are conveniently suitable for lightweight applications. This research work proposes this composite be applied in aircraft wings and engine.

Preparation of Silicon Carbide Reinforced Aluminium Matrix Composites (SiC/Al) by Selective Laser Melting

Silicon carbide reinforced aluminium matrix composites (AMCs) attracted a lot of attention owing to their low density, high specific strength and specific stiffness, and good wear resistance. Selective laser melting (SLM) technique has been widely used in the preparation of complex structural product with high precision, short production cycle and low cost. In this paper, silicon carbide (SiC) powders and aluminium (Al) powders were mixed together firstly with a weight ratio of 15:85 and then used to prepare AMCs by SLM technology. The effects of laser power on the microstructures, microhardness and flexural strength of formed AMCs were studied. The results show that the relative density, microhardness and flexural strength of the as-prepared samples can be improved with increasing the laser power. Meanwhile, the samples prepared at higher laser power exhibit lower friction coefficient.

Micro and Nano Silicon Carbide Reinforced Aluminium Matrix Composite Prepared by Conventional and Electric Resistance Sintering Process

Micro and Nano Silicon Carbide Reinforced Aluminium Matrix Composite Prepared by Conventional and Electric Resistance Sintering Process

The Development and Characterization of Silicon Carbide Reinforced Aluminium Alloy LM12 Metal Matrix Composite

The Development and Characterization of Silicon Carbide Reinforced Aluminium Alloy LM12 Metal Matrix Composite

Processing of heat-treated silicon carbide-reinforced aluminum alloy composites

ABSTRACTThe present study investigates the processing of heat-treated silicon carbide (SiC) particle-reinforced 6061 aluminum alloy (AA) composites. As-received SiC powders were heat treated at 1300ºC, 1400ºC, and 1500ºC in nitrogen atmosphere for 2 h, and the 6061 AA–SiC composites were developed by spark plasma sintering at 560ºC and 60 MPa for 5 min in argon atmosphere. The amorphous silicon nitride is found to form in SiC particles as a result of heating at 1400ºC. The microstructure of the composites exhibited uniform distribution of SiC or SiC/Si3N4 particles in 6061 AA matrix. Further, the heat-treated SiC-reinforced 6061AA composites exhibited improved mechanical properties. A typical combination of UTS of 240 MPa and elongation of 21% is obtained for the 6061 AA composites prepared using SiC powders heated at 1400ºC.

Material removal mechanism in rotary ultrasonic machining of high-volume fraction SiCp/Al composites

High-volume fraction silicon carbide-reinforced aluminum matrix (SiCp/Al) composites are widely used in many industrial fields due to their excellent material properties. However, these composites are regarded as one of the most difficult-to-machine materials, owing to the presence of many hard and brittle SiC reinforcements. Rotary ultrasonic machining (RUM) is an effective processing method for SiCp/Al composites. The material removal mechanism in RUM of SiCp/Al composites was investigated by comparing the deformation characteristics of the composites in ultrasonic vibration-assisted scratch (UVAS) tests and conventional scratch (CS) tests which were performed on a rotary ultrasonic machine. The influence of ultrasonic vibration on the machining process was analyzed. Furthermore, the morphologies of the scratching surfaces, scratching forces, and material removal process were evaluated in detail. The theoretical and experimental results revealed that ultrasonic vibration changes the interaction between the cutting tool and the workpiece. The vibration enhanced the Al matrix and facilitated SiC reinforcements removal by increasing the cracks in them. Therefore, the scratching forces in UVAS were smaller and more stable than those in CS. The coefficient of friction (COF) was also smaller than that of CS and hence, the adhesion effect of Al matrix during the scratching process was weakened. This study shows that the removal mode of SiC reinforcements plays a decisive role in the formation of the machined surface. These results can serve as a guide for selecting appropriate processing parameters to obtain improved machining quality of SiCp/Al composites.

Study of silicon carbide-reinforced aluminum matrix composite brake rotor for motorcycle application

With weight reduction and component reliability being the top priority while designing automobile components, the selection and use of materials of a high strength-to-weight ratio is of vital importance. Less weight ensures low fuel consumption and hence low emissions thus having a great impact on the environment on a large scale. Brake rotors are one of the most important components in an automobile, which aid in stopping the vehicle by converting the kinetic energy of the moving vehicle into heat energy by means of friction. This study focuses on the use of abrasive particle (SiC)-reinforced aluminum metal matrix composite material for brake rotors which is expected to generate less heat during braking (due to friction) and also reduces the unsprung mass of the vehicle resulting in better handling. This paper discusses the design, structural, and thermal analysis; the manufacturing method; and the testing of silicon carbide-reinforced aluminum (Al 6061) matrix composite material for motorcycle brake rotor.

Distribution of supercritical nucleation centers during the crystallization process in the presence of a flow as illustrated by the example of boron carbide-reinforced aluminum

Distribution of supercritical nucleation centers during the crystallization process in the presence of a flow as illustrated by the example of boron carbide-reinforced aluminum

Finite element modeling of effective thermomechanical properties of Al–B4C metal matrix composites

The present work aims to investigate the influences of thermal residual stresses and material properties on the thermomechanical deformation behavior of Al–B4C composites. Boron carbide-reinforced aluminum matrix composites having 4, 8, and 12 vol% boron carbide were fabricated using squeeze liquid stir casting method for experimental characterization of their microstructure, effective elastic moduli and effective CTEs at room temperature as well as elevated temperatures. Next, the thermomechanical behavior of fabricated composites was investigated using finite element modeling. The effects of thermal residual stresses on the effective material properties were examined by simulating the cooling process of MMCs from processing temperature to room temperature. The effective elastic moduli and the effective CTEs were predicted considering linear elastic as well as elastoplastic deformation of aluminum matrix, and the results obtained were compared with the experimental values. The effects of voids on effective material behavior are studied by simulating the void growth and nucleation using Gurson–Tvergaard–Needleman model.

Influence of pretreatment of SiC on microstructure and properties of SiCp/A390

In this paper, two pretreatment methods of silicon carbide (SiC) particles were adopted: washing by hydrochloric acid (HCl) and high-temperature oxidation after washing by hydrochloric acid. The powder metallurgy method was used for better controllability of the prepared particles of the silicon carbide-reinforced aluminium alloy composites of A390. The changes in the morphology and composition of the silicon carbide particles after different pretreatment methods were studied; at the same time, the effects of the different pretreatment methods on the microstructure and mechanical properties of the composites were analysed. Research shows that washing by hydrochloric acid of the silicon carbide particles is mainly for cleaning, and high-temperature oxidation of the silicon carbide particles after washing by hydrochloric acid is mainly for producing a passivation effect, producing silicon dioxide. The high-temperature oxidation of the silicon carbide particles in the composites leads to the following: the particles distribute well; the interface bonding density improves; the resulting composites are without holes; the tensile strength and the relative density of A390 composites, reinforced by silicon carbide particles, after oxidation treatment, increased by 36% and 2·64%, respectively, compared to those of the original state of the silicon carbide particle-reinforced composites of A390.

Workability Behavior of Powder Metallurgy Carbide Reinforced Aluminum Composites During Hot Forging

Experimental study was conducted to assess the consequence of titanium carbide (TiC), molybdenum carbide (Mo2C), iron carbide (Fe3C), and tungsten carbide (WC) reinforcements on the composite aluminum compacts. The hot deformation of the carbide reinforce aluminum compacts, Al-2TiC, Al-2WC, Al-2Fe3C, and Al-2Mo2C, with aspect ratios of 0.4 and 0.6, was carried out and the workability behaviors of the same were determined. The effect of carbide reinforcement and preform geometry on the relative density, stress ratio, σθ/σeff, and formability ratio was studied.

Effect of Machining Process on Surface Microhardness of Titanium Carbide Reinforced Aluminium LM6 Composite

Due to the fact that material is being removed from the bulk material, all machining operations have some impact on the resulting surface integrity of the machined components. This paper presents an investigation on surface microhardness on machining of TiC reinforced aluminium LM6 alloy composite using uncoated carbide tool under dry cutting condition. The experiments that were carried out consisted of different cutting parameters based on combination of cutting speed, feed and depth of cut as the parameters of cutting process. The microhardness of machined surface at a range of cutting speed, feed and depth of cut were measured. The results show that the microhardness was generally found to be higher near the machined surface layer than the hardness of the matrix in the bulk material during machining for all cutting condition. Microhardness increases beyond the bulk hardness of material occurred 50 μm below machined surface, and then microhardness starts to decrease and reaches the bulk hardness. The microhardness values increases with increased the feed and depth of cut. The highest microhardness recorded was 68 HV0.5 when machining at a lower cutting speed of 100 m min-1, feed of 0.2 mm rev-1 and depth of cut of 1.0 mm.

Processing of surface-treated boron carbide-reinforced aluminum matrix composites by liquid–metal stir-casting technique

Boron carbide is one of the potential neutron-shielding materials and its use can be maximized for structural shielding application by dispersing it into metal matrixes such as aluminum. Dispersion of B4C and its interfacial stability is a major issue during its processing. This investigation is on the synthesis of B4C-reinforced 6061 aluminum matrix composite by liquid–metal stir-casting technique under optimized conditions after solving the issues related to the processing, and evaluation of the structural, mechanical, and interfacial characteristics. During processing of composites, pretreatment of B4C particles is necessary to improve its dispersion. However, higher preheating temperatures above 300°C lead to particle agglomeration in the matrix due to the formation of B2O3 phase during preheating. B2O3 is formed due to the surface oxidation of B4C particles above 300°C and this glassy phase leads to particle sintering and lump formation. Incorporation of particles preheated at 250°C has shown uniform distribution of particles in the composite. Interfacial characterization of the composite and the extracted B4C particles from the matrix has shown the presence of interfacial reaction products such as AlB2, Al3BC, AlB12, and AlB10.