Development Of Metal Matrix Composites Research Articles

Impact on casting die diameter size on microstructure and fractographic studies of Al2024 alloy reinforced with fly ash and SiC hybrid composites

AbstractThe development of metal matrix composites is important for industrial applications that require lightweight materials with high strength, stiffness, and wear resistance. In this investigation, Al2024 alloy was reinforced with fly ash and silicon (SiC) carbide hybrid composites using the stir‐squeeze cast technique. Two sets of composites were fabricated: one with 3 wt% fly ash and 3 wt% SiC, and the other with 3 wt% fly ash, 5 wt% SiC, and 3 wt% fly ash, 7 wt% SiC The composites were prepared using 25 and 75 mm diameter dies. Microstructural characterization of the specimens was performed using scanning electron microscope, X‐ray powder diffraction, and energy dispersive X‐ray spectroscopy analysis. Mechanical properties, such as yield strength, ultimate tensile strength, and hardness, were determined according to American Society for Testing and Materials standards. The hybrid composites fabricated in the 25 mm diameter cast iron molds exhibited superior mechanical properties compared to those prepared in the 75 mm diameter molds. The addition of fly ash and SiC particulates enhanced the mechanical properties of the Al2024 alloy. These composites showed improved strength, toughness, and ductility.

Enhancing the mechanical properties and corrosion resistance of commercially pure titanium using tungsten carbide composites fabricated via additive manufacturing

Commercially pure Ti (CP Ti) exhibits an exceptional corrosion resistance, and it is thus critical in the aerospace, marine, and petrochemical fields. However, pure Ti also displays a modest strength and limited wear resistance. Therefore, several studies have explored the incorporation of reinforcing phases, such as ceramics and carbides, leading to the development of metal matrix composites. This study investigates the fabrication of CP Ti-WC composites using an additive manufacturing process and explores the effect of the WC content on the microstructure, mechanical properties, and corrosion resistance. Regarding the mechanical properties, the tensile strength and hardness progressively increase with increasing WC content owing to microstructural refinement and solid solution strengthening caused by W. The alloy containing 5 wt% WC displays the respective maximum strength and hardness of 1042 MPa and 362.2 HV. Furthermore, WC addition enhances the corrosion resistance of CP Ti in a 70 % H2SO4 solution. Compared to those of the other samples, the alloy with 5 wt% WC exhibits the lowest mass loss (0.00242 mg/cm2) and current density in the passivation region, which are attributed to the microstructural refinement aiding in the formation of a stable oxide layer. Thus, this research highlights the potential of CP Ti-WC composites, which exhibit improved mechanical performances and corrosion resistances for use in demanding applications, with insights into microstructural control and property enhancement.

Development and evaluation of mechanical properties of aluminium alloys and boron fiber composite material by powder metallurgy route

In recent year, aluminum alloy based metal matrix composites (MMC) are gaining in the field of aerospace and automotive industries, in order to improve by the advancement of modern technology, led to a rapid development of metal matrix composites. Properties can be tailored in the metal matrix composite as per the requirement for specific applications. In these composites the prime function of the fibers is that of supporting most of the applied load, while the role of the matrix is to bind the fibers together and to transmit and distribute the external loads to the individual filaments. Aluminum has been used matrix material owing of its excellent mechanical properties coupled with good formability. Addition of boron fiber as reinforcement inaluminum systemsimprovesthe mechanical propertiesof composites. In the present investigation Al-boron fiber composite was prepared by powder metallurgy route. Powder metallurgy homogeneously distributes the reinforcement in the matrix with no internal reaction and with less porosity. Boron fiber particles containing different weight fractions (5, 10 and 15 %) and mesh size (50 μm and 125 μm) are used as reinforcement. Though Al-boron fiber possess superior mechanical properties, the high abrasiveness of the boron fiber particles obstaclewiderapplication. The Mechanical Properties of Aluminum Alloy (AL2024) were assessed and the compression test was directedatthe material under tempered condition. Al-boron fiber composite has the widest application in the aerospace industry due to high hardness and light weight material. After the development of material that specimens were tested the under the optical, physical and mechanical properties.

Experimental Investigation of Microstructure and Phase Characterization of Rice Hush Ash (RHA) for Potential Utilization in Metal Matrix Composites

Recent trends in material research and development of composite materials are geared towards reducing cost, recycling and ensuring environmental sustainability. Agricultural waste derivatives have proven to be an alternative or complimentary reinforcement material in the development of metal matrix composites. The current work is an investigation of the microstructure and phase characterization of rice husk ash (RHA) obtained through open air burning. Scanning electron microscopy (SEM) equipped with electron dispersive spectrometry (EDS) was used for the microstructural examination, X –ray fluorescence (XRF) forthe mineralogical composition and X –ray diffraction (XRD) for the determination of phases present. Results revealed that RHA is highly siliceous with 93.8% SiO2, highly porous and fibrous material with a wide surface area. EDS profile confirmed the presence of SiO2and Al2O3. The XRD pattern revealed the presence of quartz, crystabalite and anorthite phases in the RHA. Silica is a hard substance with strong covalent bonds similar to diamond with hardness rating of 7 on Mohs scale and melting point of 1713OC. Thus,RHA can be suitable used as a reinforcing material in the development of metal matrix composites for automotive components

A review on mechanical properties of aluminium-based metal matrix nanocomposites

Industrial production today requires new improved materials to meet market demands, which leads to the production of new materials with improved properties. One kind of response to those requirements is the development of metal matrix composites (MMCs) with the aim of obtaining materials with better properties when compared to conventional metals and alloys. Nowadays, metal matrix nanocomposites (MMnCs) are being increasingly investigated due to the possibility of achieving better machinability, high fracture toughness and improved ductility when compared to conventional composites. Considering the pace of development and the huge perspective of different classes of materials, this research aims to provide insight into the mechanical properties of aluminium nanocomposites. Aluminium nanocomposites are attracting a lot of attention due to their high strength-to-weight ratio, wear resistance and low costs, when compared to matrix alloy. In this paper, an attempt is made to review other research reports and make a connection between the characteristics of the microstructure and the mechanical properties, which are dependent on the method of fabrication and type and content of reinforcement.

Effects of Silicon and Deformation Ratio on the Mechanical Behavior of Nickel Aluminum Bronze (NAB) Alloy

The increasing demand for new materials to meet the challenges of adequate resistance to deformation and corrosion in various architectural and industrial sectors especially in marine environment has necessitated the development of metal matrix composites. This paper aim at investigating the influence of silicon and deformation on the mechanical properties of the nickel aluminum bronze (NAB) alloy. Materials for the NAB alloy were sourced locally; sand casting method was used to develop six different compositions with varied weight (0%, 2%, 4%, 6%, 8%, and 10%) percent of silicon addition. The developed material was subjected to 0%, 2%, 4%, 6%, 8% and 10% cold deformation (rolling). The mechanical properties of the NAB alloy were studied using hardness, tensile strength, and elongation tests. The results showed that the hardness of the NAB alloy increased significantly with increase in the silicon content, similarly with the increase in deformation ratio, the hardness also improved. The tensile strength and elongation also showed an increase with increase in silicon content and deformation ratio. Increasing the silicon content and deformation ratio led to improved mechanical properties of the NAB alloy. The findings show that further modifications in the silicon content and deformation ratio have insignificant effect on the mechanical properties of the NAB alloy.

Core-Shell Particle Reinforcements-A New Trend in the Design and Development of Metal Matrix Composites.

Metal matrix composites (MMCs) are a constantly developing class of materials. Simultaneously achieving a high strength and a high ductility is a challenging task in the design of MMCs. This article aims to highlight a recent trend: the development of MMCs reinforced with particles of core–shell structure. The core–shell particles can be synthesized in situ upon a partial transformation of metal (alloy) particles introduced into a metal matrix. MMCs containing core–shell particles with cores of different compositions (metallic, intermetallic, glassy alloy, high-entropy alloy, metal-ceramic) are currently studied. For metal core–intermetallic shell particle-reinforced composites, the property gain by the core–shell approach is strengthening achieved without a loss in ductility. The propagation of cracks formed in the brittle intermetallic shell is hindered by both the metal matrix and the metal core, which constitutes a key advantage of the metal core–intermetallic shell particles over monolithic particles of intermetallic compounds for reinforcing purposes. The challenges of making a direct comparison between the core–shell particle-reinforced MMCs and MMCs of other microstructures and future research directions are discussed.

Developments of discontinuously reinforced aluminium matrix composites: Solving the needs for the matrix

Metal matrix composites become interesting for use as constructional and functional materials. The development of metal matrix composites was primarily directed to the continuous-fibre reinforced metal matrix composites - such as boron fibre/aluminium-based matrix, continuous alumina fibres /aluminium-based matrix, graphite fibre/aluminium-based matrix or graphite fibre/magnesium-based matrix composites. Despite the successful production of these metal matrix composites, they manufacturing was limited by the concerns related to the technological processes and cost, their availability remaining a significant barrier to their manufacturing. The benefits of metal matrix composites as compared to the unreinforced (monolithic) metals or alloys include superior mechanical and physical properties that deliver improved structural performance. This concept also further implies re-using materials or using recycled materials. Therefore, discontinuously reinforced metal matrix composites are suitable for a wide range of industrial applications. This study aims to investigate the developments in area of solving the needs for the matrix material necessary for the discontinuously reinforced aluminium matrix composites. Aluminium can be recycled directly back into itself over and over again in a true closed loop.

Effect of eggshell waste and B4C particles on the mechanical and tribological properties of Al7075 alloy developed by friction stir processing

The waste and hazardous materials have the potential to be used as reinforcement materials in the development of metal matrix composites (MMCs). In this regard, aluminium based MMCs have increased demand than conventionally manufactured materials due to their high strength to weight ratio, low cost and wear resistance. In this work, an attempt is made to develop the surface composite of Al7075 alloy by utilizing carbonized, ball-milled waste eggshell powder (ESP) and B4C particles as reinforcements through the solid-state friction stir processing technique. Three different samples are developed with volume percentages of 2%, 4%, and 6% of ESP/B4C particles. The developed surface composites are validated by light microscopic images, FE-SEM images linked with EDS mapping and distribution of reinforced particles. The microstructural image shows the uniform distribution of the reinforced particles. The specimens are also characterized by their mechanical and tribological properties like tensile test with fracture analysis, hardness test and wear loss supported by worn-out surface analysis. The result revealed that while increasing the reinforcement volume percentage, an increase in mechanical properties of the developed composites is found. The maximum ultimate tensile strength (UTS) and Brinell hardness number (BHN) obtained in the study are 355 MPa and 167 BHN, respectively for the developed composites AA7075/ 6% eggshell/B4C. The minimum wear loss was observed to be 2.5 to 6.2 × 10–3 g at a sliding distance of 600 m for a 6% reinforced sample.

Influence of Future Material Nano‐ZrO2 and Graphene on the Mechanical Properties of Al Composites

Recent developments in mechanical applications have led to the development of metal matrix composites, which represent the future of composite structures. Al7010 aluminium alloy matrix with nano‐ZrO2 and graphene particle reinforced composite is created in this experiment. By adopting the stir casting procedure in two different casting, 2 percent reinforcement of zirconium dioxide and 1 percent of graphene is included in the composite materials. The composite’s metallurgical and mechanical characteristics are studied. The SEM image demonstrates uniform dispersion of the particles in the alloy matrix. The manufactured material’s ability to gather particulate matter is clearly found in SEM and EDS. The addition of zirconia particles works together to prevent the alloy matrix from dislocating, which increases the base material’s hardness as well as its tensile resistance. Similar results are also found in graphene‐casting material. Results from tensile tests reveal that adding nano‐zirconium dioxide particle (ZrO2) and graphene boosts the material’s tensile and hardness strength. In terms of the ultimate tensile strength (UTS), the Al7010/2% ZrO2 composite had a 6% increase and Al7010/1% graphene had a 5.5% increase above the Al7010 alloy. Compared to Al7010 alloy, the microhardness of Al7010/ZrO2 is 17.64% greater and Al7010/1% graphene is 14% greater.

20th Century Uninterrupted Growth in Friction Stir Processing of Lightweight Composites and Alloys

The demand for tailored properties of the materials and lightweight characteristic accelerates the development of metal matrix composites (MMCs). The conventional methods of MMCs development require several post-processing techniques like a microstructural modification or grain refinement, to fulfil the desired requirement of specific applications. In this regard, friction stir processing (FSP) can be proved as an alternative, not only for microstructural modification but also utilized for the development of surface composites. This solid-state approach is an environment-friendly process. It also refines the grain structure of the alloys and composites, which in turn, enhances the mechanical properties such as tensile strength, hardness and fatigue strength. The present work aims to focus on the state of the art research in the field of friction stir processing and to highlight its key points and merits over traditional methods. The present work also emphasizes the developments in friction stir processing, especially on aluminium and magnesium-based alloys and composite and futuristic approaches adopted in various industrial application.

Improvement in Hardness and Wear Behaviour of Iron-Based Mn-Cu-Sn Matrix for Sintered Diamond Tools by Dispersion Strengthening.

The work presents the possibility of fabricating materials for use as a matrix in sintered metallic-diamond tools with increased mechanical properties and abrasion wear resistance. In this study, the effect of micro-sized SiC, Al2O3, and ZrO2 additives on the wear behaviour of dispersion-strengthened metal-matrix composites was investigated. The development of metal-matrix composites (based on Fe–Mn–Cu–Sn–C) reinforced with micro-sized particles is a new approach to the substitution of critical raw materials commonly used for the matrix in sintered diamond-impregnated tools used for the machining of abrasive stone and concrete. The composites were prepared using spark plasma sintering (SPS). Apparent density, microstructural features, phase composition, Young’s modulus, hardness, and abrasion wear resistance were determined. An increase in the hardness and wear resistance of the dispersion-strengthened composites as compared to the base material (Fe–Mn–Cu–Sn–C) and the commercial alloy Co-20% WC provides metallic-diamond tools with high-performance properties.

Structural Analysis of Al-CNT Nanocomposite Using X-Ray Diffraction

The development of metal-matrix composites (MMCs) has mainly been driven by the growing needs of modern applications for lightweight materials yet strong enough to withstand high service loading. On the other hand, carbon nanotubes (CNTs) presenting excellent combination of mechanical and physical properties have already performed as an excellent strengthening to reinforce MMCs. In present study, an air induction furnace was used to fabricate aluminum-multiwall carbon nanotubes (Al-MWCNTs) composite. The process was benefited for better dispersion of the CNTs, which was validated during microscopic studies. Additionally, the mechanical properties were significantly augmented i.e., the yield strength from 64±3 to 115±2 MPa, the tensile strength from 82±2 to 125±3 MPa for matrix material and Al-CNTs composite, respectively. The structural analysis including, grain size, crystallite strain and dislocation density were investigated using X-ray diffraction to relate with the improvement in the properties.

Development of metal matrix composites using recycled secondary raw materials from aluminium wastes

Metal matrix composites have proven to be a class of materials with high potential to replace a large number of materials used in the automotive, aerospace, electronics, defence and manufacturing industries, where the requirement for light and high-strength parts is increasing. The possibility of combining different materials (metal–ceramic–nonmetal) provides the opportunity to change the properties of metal matrix composites, which are mainly determined by the properties of the component materials. Therefore, there is the question of finding recycling technologies, replacing new materials with recycled materials in order to minimise the amount of waste, which does not involve too much expenditure with their implementation and at the same time does not raise particular problems when applying them in industrial practice. The purpose of this study is to highlight the most efficient methods of recycling aluminium alloys in order to be applied in the practice of composites. This research concerns the liquid mixing (Vortex method) processing of composite materials with metal matrix of aluminium alloys, reinforced with ceramic particles. This technology uses common and cheap raw materials, matrix alloys in the moulded state, from recycling. This process has general economic and technological advantages, consisting of a small number of operations, with low durations and low energy consumption. Also, liquid mixing can be obtained by composite materials with a homogeneous distribution of ceramic reinforcement particles in the metal matrix. This study was carried out using laboratory installations designed and carried out within the Department of Engineering and Management of the Faculty of Engineering Hunedoara, University Politehnica Timisoara, within a doctoral program.

Zirconia Fiber Containing TRIP‐Matrix Composites Prepared via Paper‐Manufacturing Technology

Herein, the continuous further development of metal matrix composites prepared by the paper‐manufacturing technology is in focus. The composites are based on metastable austenitic stainless steel with the addition of magnesia partially stabilized zirconia particles or yttria‐stabilized zirconia fibers. The sintering conditions are profoundly investigated, to study and subsequently inhibit the formation of carbides, which deteriorates the mechanical performance of the paper‐derived materials in the past. The cellulose pulp fiber content as well as the filler particle content is adjusted with the aim to improve the mechanical performance of the paper‐derived materials during tensile load testing. In addition, the cellulose pulp fibers are partially replaced by yttria‐stabilized zirconia fibers. The improved composites that contain 3 and 6 vol% of yttria‐stabilized zirconia fibers exhibit the ultimate tensile strengths of 264 and 322 MPa. The tensile strain of the improved TRIP‐matrix composites as well as of the reference material is significantly increased (up to 10%) as compared with our previous study, where all materials show brittle fracture behavior. This can certainly be attributed to the improvements in the sintering process and the corresponding prevention of carbide formation during heat treatment upon cooling.

Statistical analysis and optimization of process parameters in development of metal matrix composite using industrial waste

Bauxite residue (BR) is the hazardous waste produced during extraction of alumina by processing of bauxite ore. BR has an adverse effect on humans and the environment due to its disposable problem. To minimize the environmental impact, BR must be effectively utilized. One such way is to use BR as a reinforcing for metal matrix composite. In this study, Taguchi’s mixed fractional factorial experimentation (L18) approach is employed in the development of Al6063/BR composite through advanced stir casting process. The process parameters considered are stirring speed (rpm), reinforcement particle size (µm), reinforcement weight fraction (wt%) by weight of the matrix phase, pouring temperature (°C), and preheat temperature (°C). Later, ANOVA results indicate that particle percentage (wt%) is the major contributor in the development of porosity content. Moreover, the interaction of process parameters was also found to have an impact on porosity content. The outcome of the study reveals that the stirring intensity at 350 rpm, particle size at 80 µm, particle percentage at 2 wt%, pouring temperature at 730 °C, and preheat reinforcement temperature at 450 °C are the optimal conditions for fabricating defect free Al6063/BR composite.

Modifications in Stir Casting Process for the Development of Metal Matrix Composites

Modifications in Stir Casting Process for the Development of Metal Matrix Composites

Mechanical damage behavior of metal matrix composites with the arbitrary morphology of particles

Metal matrix composites have significant applications in the engineering field. During service, the fracture is one of the most typical failure modes. In this study, the digital image-based technique (DIT) combined with a micro-scale damage cohesive finite element model (CFEM) was employed to reconstruct the microstructures of metal matrix composites with the arbitrary morphology of particles. The cohesive finite element in this model can predict the process of crack initiation and propagation spontaneously, and the effectiveness of the model was verified by the in-situ tensile tests of the compacted graphite iron (CGI) sample. We found that the morphology and distribution of the graphite particles play important roles in crack initiation and propagation under tensile and compressive loadings. The relationship between the graphite particle size and yield strength was established, and an optimal graphite particle size was found for the maximum yield strength, which is different from the previous results. The relationship between microstructures and tensile properties of CGI could contribute to the design and development of metal matrix composites with optimal mechanical properties.

Development of metal matrix composites by laser-assisted additive manufacturing technologies: a review

Metal matrix composites (MMCs) generally possess superior properties than the monotonic matrix alloys, and thus, they have become excellent candidate materials in various applications. Also, the ability of property tailoring at an affordable cost is of particular importance to industries. Among the many manufacturing techniques for MMCs, laser-assisted additive manufacturing (AM) techniques have emerged and drawn increasing attention in the past decade. In the literature, a wealth of studies have been carried out on the synthesis of MMCs via laser-assisted AM techniques, as well as the property evaluation of the obtained MMCs. In this paper, we review and analyze the relevant literature and summarize the material preparation, optimization of process parameters, resultant improvements, and corresponding strengthening mechanisms for each major category of MMCs. Moreover, the limitations and challenges related to MMC synthesis using the laser-assisted AM techniques are discussed, and the future research directions are suggested to address those issues.

Towards sustainable copper matrix composites: Manufacturing routes with structural, mechanical, electrical and corrosion behaviour

In the last few decades, man has become more innovative in discovering new materials to make his life more sustainable. Copper metal matrix composite is the most promising material for many engineering applications where the higher temperature resistance and good microstructural stability is required. The sustainable development of copper metal matrix composite is based on the use of ceramics as reinforcements. The choice of reinforcement material is highly influenced by their mechanical properties such as hardness, wear resistance, cost advantage, availability in market and refractory nature. In the current scenario, copper and its alloy are gaining popularity due to their high sustainability, high conductivity and good corrosion resistance. However, the relatively low wear resistance and high temperature strength restrict the use of copper in many applications. Recent developments in metal matrix composites have provided new means to produce high sustainable copper metal matrix composite materials with high wear resistance and high strength materials. It has been found that the wear resistance and strength of materials can be improved by adding hard ceramic particles such as Al2O3, SiC, TiC and ZrO2 into the metal matrix. The aim of the present study is to summarise the research work carried out in the field of sustainable copper metal matrix composites. It also reports the various manufacturing routes along with the structural, mechanical, electrical and corrosion properties. It is found that copper metal matrix composites are preferred over the conventional composites. Sustainability issues around the globe has forced the industries to adopt the eco-friendly materials with their fabrication and machining routes, which results in less carbon emission and also has less affect to the environment. Fabrication of eco-friendly composites is an emerging research area, which has made several research scopes in production of sustainable composites. It is expected that this study can be beneficial for the researcher to decide their research direction in the field of sustainable material production.