Discontinuous Reinforcement Research Articles

Reinforcement induced microcracking during the conversion of polymer-derived ceramics

This study investigates the role of discontinuous reinforcement on the microcracking of a preceramic polymer matrix during polymer to ceramic conversion. The material system comprised a carbosilane-based, preceramic polymer reinforced with mullite particles. The preceramic resin slurry was formulated for photopolymerization on a digital light projection 3D printer. Micro X-ray computed tomography, using a synchrotron light source, monitored a printed composite part during pyrolysis. The conversion of the carbosilane matrix into Si(O)C generated microcracks in the matrix that radially extended from particles. The likelihood of microcrack formation positively correlated with particle size. The largest particles (>104 µm3 volume or >60 µm side length) always abutted microcracks, while the matrix surrounding smaller particles (<5 µm) was free of microcracks. Numerical calculations showed the particles resist the shrinking matrix during its conversion. This created tensile stresses within the matrix. The driving force for microcrack growth was also analyzed with regard to the influence of matrix material parameters, particle form-factor and crack length. These results reveal the need to consider the form factor of discontinuous reinforcements, with regard to the material properties of the polymer-derived ceramic, in order to reduce or eliminate defects in the final part.

An integrated experimental and analytical approach on mechanical characterization of advanced powder metallurgy aluminium metal matrix composites reinforced with different particulates

Over the last few decades, ‘Discontinuously Reinforced Particulate Composites (DRPCs)’ are a popular class of composite materials with considerable challenge in processing, characterization and machinability because of their increased strength-weight ratio, stiffness, specific strength and oxidization when compared to various metals and their alloys. This paper discusses experimental and numerical investigation on mechanical characteristics of aluminum metal matrix reinforced with various reinforcement particulates such as silicon carbide, aluminium oxide, and zirconium oxide, compaction pressure (kN) and hold time (s) based on Design of Experiments (DOE) and Finite Element Analysis. Initially this paper discusses the process optimization of Aluminum Matrix reinforced with different particulates experimentally to identify the favourable processing conditions by varying reinforcement materials, compaction pressure (kN) and hold time (s) based on TDOE (Taguchi’s Design of Experiments). Further, this paper concentrates to determine ‘maximum principal stress, equivalent elastic strain and equivalent (von-mises) stress’ based on Finite Element Analysis (ANSYS Workbench-2023R1). The results of the experimentation showed that the highest hardness values were achieved with ZrO2 reinforcement material. Increasing the compaction pressure from 8 to 12 kN resulted in a slight decrease in surface roughness and porosity. Higher compaction pressures have assumed to facilitate better particle distribution and improved interfacial bonding, leading to smoother surfaces and lower void content. The simulation results showed that the maximum principal stress achieved were (2235.8 MPa) SiC, (3444.4 MPa) Al2O3, and (3582.5 MPa) ZrO2. The equivalent elastic strain achieved was (0.2488) SiC, (0.2421) Al2O3 and (0.262) ZrO2. The equivalent (Von Mises) stress achieved was (28751 MPa) for SiC, (24880 MPa) for ZrO2 and (26972 MPa) for Al2O3. This experimentation and simulation demonstrated that the PM process can be used to fabricate DRAMMC with different reinforcement particulates. The understanding gained experimentally and analytically from this research can be applied for future processing of Aluminum Matrix Reinforced with different particulates.

Influence of the architecture on the strength of a unidirectional composite with recycled discontinuous fibres

Recycled fibre composites are made of discontinuous fibres that are not of the same length. Their mechanical behaviour depends on the load transfer between fibres and in particular on the overlaps between fibres of different lengths. The objective of the study is to show the influence of the architecture on the failure of a discontinuous reinforcement composite. A numerical model was developed to simulate different overlap lengths between fibres. The influence of defects, in this study small overlap length between fibres, and of their distribution in the architecture, was thus highlighted. Experimental tests allowed to validate the model. The model makes it possible to calculate a critical overlap length, length from which the composite strength reaches its maximum. In particular, simulations showed that discontinuous fibre architectures with small overlap lengths at the edge strongly decrease the strength of the composite. On the contrary, defects in the core of the architecture are tolerable. These results open perspectives for the choice of architectures based on recycled fibre in order to optimize the final properties of the composite.

Probabilistic Modelling of Fracture Toughness of Composites with Discontinuous Reinforcement.

The results presented in the paper are related to the prediction of the effective fracture toughness of particulate composites (KICeff). KICeff was determined using a probabilistic model supported by a cumulative probability function qualitatively following the Weibull distribution. Using this approach, it was possible to model two-phase composites with an arbitrarily defined volume fraction of each phase. The predicted value of the effective fracture toughness of the composite was determined based on the mechanical parameter of the reinforcement (fracture toughness), matrix (fracture toughness, Young's modulus, yield stress), and composite (Young's modulus, yield stress). The proposed method was validated: the determined fracture toughness of the selected composites was in accordance with the experimental data (the authors' tests and literature data). In addition, the obtained results were compared with data captured by means of the rule of mixtures (ROM). It was found that the prediction of KICeff using the ROM was subject to a significant error. Moreover, a study of the effect of averaging the elastic-plastic parameters of the composite, on KICeff, was performed. The results showed that if the yield stress of the composite increased, a decrease in its fracture toughness was noticed, which is in line with the literature reports. Furthermore, it was noted that an increase in the Young's modulus of the composite affected KICeff in the same way as a change in its yield stress.

Investigation on microstructure characteristics of tool wear and machined surface mechanisms while milling: kenaf vs glass fiber-reinforced composites

In composites' secondary/machining process, there is still a requirement for a comparative assessment of microstructure features of tool wear and machined surface mechanisms while machining natural fiber against glass fiber-based composites. This experimental study uniquely investigates the dry-end milling of two polypropylene (PP)-based composites made of 30 wt.% discontinuous reinforcements - kenaf and glass fibers (GF). Surprisingly, though, GF are much harder (GF:5.84 GPa > kenaf:0.15 GPa) and abrasive (silicon content, GF:24.16% > kenaf:0.57%) than kenaf inclusions, cutting GF/PP resulted in relatively lower tool wear (≈0.08 mm) but contrarily showed adverse machined surface finishes (>8 μm) depicting tearing-dragging mechanisms with fuzzy textures. This cautions on the appropriate consideration for the tool's life-determining criterion – i.e., whether it should be based on the tool wear or surface finish. While machining GF/PP material, the tool wear growth on the cutting edges was significantly restricted by the formations of continuous-robust microstructural transfer protective film (TPF) characterized by strong Si + O, Al + O, and Fe + O tribo-chemical reactions through the interesting wear mechanisms associated with tribological phenomena. However, thin-patch type microstructural TPFs consisting of weak Si + C bonds occurred on tool edge regions while machining kenaf/PP. Better mechanical properties and fiber-matrix adhesion of GF/PP influenced by fiber dimensions and their higher aspect ratios (GF:27.60 > kenaf:7.20) decisively seem to have a dominant effect on limiting the tool wear. Chip micrographs clarified the cutting of GF/PP and kenaf/PP occurred by predominant melt-extrusion and shearing respectively.

Processing and Mechanical Characterisation of Titanium Metal Matrix Composites: A Literature Review

Today, Discontinuously Reinforced Particulate Titanium Matrix Composites (DRPTMCs) have been the most popular and challenging in consideration with development and heat treatment due to their significant weight-saving capacity, high specific strength, stiffness and oxidising nature compared with other metals and alloys. Owing to their excellent capabilities, DRPTMCs are widely used in aerospace, automobiles, biomedical and other industries. However, regardless of the reinforcements, such as continuous fibres or discontinuous particulates, the unique properties of DRPTMCs have dealt with these composites for widespread research and progress around the domain. Even though DRPTMCs are one of the most studied materials, expedient information about their properties, processing, characterisation and heat treatment is still scattered in the literature. Hence, this paper focuses on a literature review that covers important research work that has led to advances in DRPTMCs material systems. Further, this paper also deals with broad details about the particulates, manufacturing processes and heat treatment processes.

Role of discontinuous fiber core material on the mechanical behavior of hybrid sandwich polyester composites

This study investigated the potential for improving the mechanical behavior of glass fiber polyester composites by using symmetric hybrid sandwich configurations that combine continuous woven composite and different discontinuous reinforcements used as a core. The discontinuous reinforcements included sheet molding compound (SMC), bulk molding compound (BMC), and the discontinuous prepreg based platelets that were chopped from the woven trim scrap. Hybrid sandwich configurations using different core materials exhibited improvements in flexural mechanical properties, while providing more progressive failure under both flexural and compressive loading. Compressive strength in polyester SMC and woven laminate was significantly lower than flexural strength, while BMC and chopped platelets exhibited similar levels of strength in flexure and compression. Overall, hybridized compression molding produced sandwich structures can be used to control the failure progression and to improve the structural characteristics of composite, especially under flexural loads. The trim scrap core sandwich configuration had mechanical properties comparable with the BMC core hybrid. Therefore, trim scrap upcycling can be an efficient approach to reducing the amount of material waste during the manufacturing.

Creep resistance improvement of a polycrystalline Ni-based superalloy via TiC particles reinforcement

In order to develop highly efficient aircraft engines, the use of alloys for turbine blades that combine high creep resistance and lower density brings substantial benefits. That may be achieved by the introduction of a reinforcing phase, such as a discontinuous reinforcement. So far, most researched particle-reinforced Ni-based superalloys made use of sub-micrometer particles, such as oxides and borides, often produced by in-situ reactions. These are proposed solely as dislocation immobilizers, in a role comparable to that carried out by γ’ precipitates, while metal matrix composites (MMCs) containing micro-scale particles offer a load-transfer potential. To combine both approaches, a recently designed polycrystalline Ni-based γ’-strengthened superalloy reinforced with TiC particles was produced by low energy mixing of powders, followed by pressure sintering. The composite, along with a non-reinforced reference, was submitted to compression creep tests at 973 K (700 °C), with stresses varying from 280 to 500 MPa. Selected specimens had their microstructure evaluated with techniques such as EBSD and XRD. When simulating a working turbine, the material density influences directly the centripetal forces acting on a section of a turbine blade, and consequently the creep rates. In the proposed composite, not only an increase in the threshold stress by a load-transfer component was obtained, but also the density reduction affected remarkably the creep rates. Moreover, the presented MMC not only presented a superior creep resistance in relation to the non-reinforced alloy, but also exhibited higher stability of primary and secondary γ’ volumes after 500 h in creep tests.

Achieving the strength-ductility balance of boron nitride nanosheets/Al composite by designing the synergistic transition interface and intragranular reinforcement distribution

The distribution state of reinforcement in matrix plays a significant role in affecting the strength-ductility relationship in metal matrix composites. Restricted by the great distinction in geometrical size, intrinsic properties and the poor wettability, the discontinuous reinforcement particulates are commonly accustomed to being distributed at grain boundaries and thus being stuck in the disadvanced stress concentration near the interface. Herein, we report a strategy to realize the special in-situ intragranular AlN nanoparticles together with a well-bonded intergranular two-dimensional transition nanosheets/metal interface structure in boron nitride nanosheets (BNNSs)/Al system through the integrated segmented ball milling (SBM) and reaction sintering route. It is revealed that the BNNSs-AlN-Al transition interface can effectively alleviate the stress partitioning at the interface in the initial stage of plastic deformation. And the coherent intragranular AlN/Al interface benefits to a strong interfacial bonding and leading to the multiplication of intragranular dislocations during the subsequent deformation. The combined effect improved the deformation uniformity of the composites and delayed the crack propagation. As a result, a high strength-ductility balance was achieved in BNNSs/Al composites. The present work may provide a new protocol for achieving high strength-ductility synergy for metal matrix composites.

Novel closure approximation for prediction of the effective elastic properties of composites with discontinuous reinforcement

The paper introduces a novel closure approximation method for the determination of the fourth-order orientation tensor in terms of known second-order tensor. The fourth-order orientation tensor must be known to predict the effective elastic properties of composites with misaligned fibres but very often only the second-order orientation is available. The proposed method operates on a set of outcomes of optimization based on a genetic algorithm. In consequence, it leads to obtaining distributions of effective elastic constants instead of deterministic quantities. Results obtained by using the novel approach have been compared with results based on exact fourth-order orientation tensor, tensor known from experimental data and determined by using popular closure approximations from literature. Furthermore, the obtained results have been compared with results of finite element analysis based on geometrical models representing the microstructure which contains several hundred fibres. The new method provides high accuracy of elastic constant predictions for all studied fibre orientation distributions, which distinguishes it from the closure approximation methods known from the literature. Moreover, results obtained in form of distributions give an insight into the uncertainty of the predictions.

Influence of different geometric arrangements of discontinuous reinforcement on tensile strength and fracture behavior of carbon/epoxy laminates

This study presents the influence of different geometric arrangements of butt joint formed by plain weave fabric prepreg layers on mechanical and fracture behavior of carbon/epoxy laminates tested under tensile loading. The experimental test results showed a reduction of up to 17% on the tensile failure load, due to the presence of the discontinuity in the reinforcement, when compared to the continuous fiber reinforced composites. However, statistical analyses demonstrated that the different staggering methods of the butt joints did not affect considerably the tensile mechanical behavior of the laminates. The stress concentration in the embedded joint regions was observed by finite element analysis results, which predicted the tensile failure load and also the failure region, according to Hashin criterion. SEM analyses revealed that all specimen configurations exhibited fracture in the butt joint regions, with the occurrence of cohesive failure of the matrix originated in the co-curing process, associated with a strong interfacial adhesion with the fibers. This behavior evidences a high interfacial strength of the co-cured plies joints, which is attributed to the good quality of the prepreg material associated with the efficiency of the laminate manufacturing process. The numerical studies showed a good fit with the available experimental results regarding tensile failure load. Therefore, the implemented finite element model proved to be adequate to accurately predict the tensile strength of plain weave fabric laminates containing layer joints.

Taguchi based fuzzy logic model for optimisation and prediction of surface roughness during AWJM of DRCUFP composites

From last two decades, plant fiber reinforced polymer/polyester composites have been effectively used in structural and automotive applications. Researchers and manufacturers are looking forward for an effective utilization of these composites. However, despite the outstanding properties in terms of load bearing capacity and environmental sustainability of plant fibers the uptake of these composites are limited due to its poor machinability characteristics. Hence in this paper, Taguchi based fuzzy logic model for the optimization and prediction of process output variable such as surface roughness during Abrasive Water Jet Machining (AWJM) of new class of plant fiber reinforced polyester composites i.e., Discontinuously Reinforced Caryota Urens Fiber Polyester (DRCUFP) composites has been explored. Initially machining experiments has been carried out using L27 orthogonal array obtained from Taguchi Design of Experiments (TDOE). Finally, Taguchi based fuzzy logic model has been developed for optimisation and prediction of surface roughness. From the extensive experimentation using TDOE it was observed that the optimum cutting conditions for obtaining minimum surface roughness value, water pressure (A): 300 bar, traverse speed (B): 50 mm, stand of distance: 1 mm, abrasive flow rate: 12 g/s, depth of cut (C): 5 mm and Abrasive Size:200 microns. Further from FLM, it is observed that minimum water pressure (A): 100 bar, traverse speed (B): 50 mm, stand of distance: 1 mm, abrasive flow rate: 8 g/s, depth of cut (C): 5 mm and abrasive size:100 microns gave higher surface roughness values (3.47 microns) than that at maximum water pressure (A): 300 bar, traverse speed (B): 150 mm, stand of distance: 4 mm, abrasive flow rate: 12 g/s, depth of cut (C): 15 mm and abrasive size:200 microns the surface roughness values (3.25 microns).

Friction stir processed Al 7075 matrix composites with addition of SiC coated graphene nanoplatelets

Friction Stir Processing (FSP) is a surface modification technique that has been commonly used while preparing surface composites. Through FSP, the surface properties such as strength, hardness, wear, and corrosion resistance could be enhanced by adding discontinuous reinforcements in the base alloy. The present experimental investigation involves nano reinforcements i.e graphene nanoplatelets (GNP) and SiC coated GNP was reinforced into Al 7075 and fabricated nano surface composite via Friction stir processing (FSP). A nano SiC granular and layered coating over GNP was obtained from FESEM studies. The Surface morphology, tensile strength, microhardness, and wear studies were explored. The hardness and ultimate tensile strength values of FSP'ed Al 7075, GNP, and SiC coated GNP in Al 7075 were 96.2, 128.4, 139.3 HV, and 344.8, 383.2, and 417.5 N/mm2 respectively. The hardness and ultimate tensile strength significantly increased by 44% and 21%. In similar lines, the specific wear rate also decreased 80% compared to other samples due to its lubricant property. X-RD analysis affirms the existence of Al, SiC, GNP phases that match with the lattice planes. Microscopic studies revealed the presence of SiC particles on GNP as a form of coating and also dispersed uniformly in Al 7075 composites.

Modelling and FE Simulation of HVC Using Multi Objective Response Surface Optimization Techniques

The purpose of an automotive chassis is to maintain the shape of the vehicle and bear the various loads that are applied to the vehicle. The structure typically accounts for a large portion of the development and production costs of the new vehicle program, and the designer has many different structural concepts available. Choosing the best is important to ensure acceptable structural performance under other design constraints, such as cost, volume and method of production, product application, and more. The material selection for chassis depends upon various factors like lightness, economy, safety, recyclability, and circulation of life. The current study aims to perform optimization of the design of a heavy vehicle chassis using central composite design &amp; optimal space fill design scheme (s) with the material tested is Al6092/SiC/17.5p MMC. Different design points are generated using design of experiments. The equivalent stress, deformation and mass are evaluated for each design points. The CAD modelling and FE simulation of heavy motor vehicle chassis is conducted using ANSYS software. From the optimization conducted on chassis design, response surface plots of equivalent stress, deformation and mass are generated which enabled to determine the range of dimensions for which these parameters are maximum or minimum. The use of Discontinuously Reinforced Aluminium-Matrix Composites Al6092/SiC/17.5p MMC aided to reduce weight of chassis by 66.25% and 66.68% by using CCD and Optimal space fill design scheme respectively, without much reduction in strength of chassis.

Effect of morphology and content of nano-C on grain growth behavior of copper matrix composites

This study compares high-temperature grain growth behavior in copper matrix composites containing nano-carbons in the form of fullerenes, carbon nanotubes (CNTs), and graphene to investigate the effect of volume fraction and shape of nano-carbon reinforcement on grain growth suppression. The grain growth was significantly suppressed when the nano-carbon content was 5 vol%, but the suppression efficiency was reduced when nano-carbon particle loading increased above 20 vol%. Furthermore, CNTs induced better grain growth suppression than fullerenes and graphene. Grain growth was observed both near the nano-carbon interfaces and in the bulk matrix. The poor wetting ability between copper and the nano-carbons accelerates lattice diffusion at the reinforcement interface. Owing to differences in the thermal expansion coefficients and elastic moduli between copper and the nano-carbons, due to the presence of the reinforcement, stress distribution will be inhomogeneous. In composites containing discontinuous reinforcement, the stress is concentrated at the tip of the reinforcement and at its minimum at the center of the reinforcement. Inhomogeneous stress fields are formed in the far away from the reinforcement, which in turn causes the suppression of overall grain growth in the composites.

Effect of stacking sequence on impact resistance performance of hybrid composites laminated with continuous and discontinuous fiber-reinforced layers

In the present study, we introduce a thermoplastic composite, hybridly laminated with continuous and discontinuous fiber-reinforced layers. The hybridization intends to mutually compensate poor mechanical performance of the discontinuous reinforcement and limiting shape complexity due to the continuity. The mechanical performance of the hybrid composite is the main concern of the present study. Especially, the impact response of the hybridly laminated composite plates with various stacking sequences is studied through drop-weight impact tests. It is obviously found that a panel stacked with only the continuous fiber-reinforced layers exhibits the strongest impact performance. The present study also shows that, although half of the stiff layers at the impact side are replaced with relatively ductile discontinuous fiber-reinforced layers, almost the same impact performance can be achieved. The energy absorption capability of the discontinuous fiber-reinforced layer is again observed when the ductile layer is situated between the two brittle layers; the in-between ductility due to the discontinuous reinforcement effectively delays successive brittle failure of the continuous fiber-reinforced layers. However, the alternate stack weakens the impact performance. Overall, the impact resistance is increased with the number of the continuous fiber-reinforced layers.

Analytical and Numerical Analysis of Extrusion Force, Stress and Strain Development During Extrusion Al6063-SiC Composite

Nowadays composite material are highly interesting in different areas like, aerospace, thermal management, automotive application, and electronic products etc. Aluminium based metal matrix with silicon carbide as particle reinforcements called discontinuous reinforced metal matrix composite materials. It has excellent mechanical properties like high yield strength, wear resistance, corrosion resistance and vibration resistance. During the development of discontinuous reinforcement metal matrix composites compression process like, extrusion is an advisable secondary process for homogenous distribution of the reinforcement’s materials through the metal matrix. This research was investigated the metal flow behavior of extrusion load, stress and strain distribution of Al6063/Sic based discontinuous reinforcement metal matrix composite. The billets extruded from round billet to square shape and are used for different applications. Third order polynomial and cosine die profiles were used as extrusion dies for this research by taking 30%, 60% and 90% area reductions. Depends on these three different area reductions upper bound and DEFORM 3D finite element analysis method were used to analyze analytically and numerically respectively. Due to these different area reductions, the extrusion load was minimum in cosine die profiles both analytical and numerical results. In 30% of area reduction cosine die profile has optimum load (878.59N) and it used to extrude Al6063/20%SiC composite billet materials from 20mm input diameter to 14.8x14.8mm output square sides. Therefore, 30% area reduction cosine die profile has minimum extrusion load as compare other area reduction of cosine die and 3rd order polynomial dies. It is used as extrusion die for Al6063/SiC composite materials to optimum extrusion loads in different % of area reduction of square shape extruded.

Dynamic-mechanical-thermal analysis of hybrid continuous–discontinuous sheet molding compounds

Sheet molding compounds (SMC) are very promising for the production of lightweight structural components, due to the specific mechanical properties combined with the suitability for a large-scale manufacturing process. Automotive industry already implements SMC materials for structural components in their vehicle concepts. Polymeric materials, hence also fiber reinforced polymers, show a viscoelastic behavior and dynamic-mechanical-thermal analysis (DMTA) is an important method of determining the influence of temperature and loading speed of this material class. In this work, SMC which based on a novel hybrid resin system were examined under bending loads using a electric-dynamic test system to realize high-force dynamic-mechanical-thermal analysis. The examined SMC materials were either discontinuously (Dico) or continuously (Co) reinforced. In addition a hybrid continuous–discontinuous reinforcement was realized by stacking different SMC materials. The mechanical characterization aimed to investigate the influence of the reinforcement architecture and the effect of hybridization on the temperature- and frequency-dependent material properties. Glass transition temperature of the hybrid SMC was comparable to glass transition temperature of the discontinuous glass fiber reinforced component. Compared to the continuous carbon fiber SMC, the decrease of storage modulus of the hybrid SMC could be shifted to higher temperatures and damping was also significantly increased due to hybridization.

Long fiber thermoplastic pellets of glass fiber/polypropylene from pultrusion process

Long fiber thermoplastic pellets (LFTP) are composite materials that consist of thermoplastic and discontinuous reinforcement fibers with an aspect ratio more than critical aspect ratio. LFTP are high modulus, high strength and excellent impact resistance. Normally, commercial LFTP were produced by hot melt impregnation process or combinding between pultrusion and extrusion process. In this research, Thermoplastic pultrusion process was used for production of LFTP. The thermoplastic pultrusion process is uncomplicated process and machine less than hot melt impregnation process. The glass fibers were used in LFTP as a reinforcement and polypropylene (PP) fibers were used as a matrix of LFTP. General full factorial design of experiment was used to determine the optimal condition for un-impregnation on specimen from pultrusion process of LFTP. The study focused on three factors including the filling ratio, the molding temperature and pulling speed. The specimens were investigated on impregnation of resin in LFTP by microscope. The results show that un-impregnation decreased with an increase of filling ratio. Un-impregnation decreased with an increase of molding temperature. Finally, un-impregnation had increased with an increase of pulling speed. However, the void content has a little effect to molding temperature and pulling speed, or they have not almost effect. From statistical analysis, the optimal condition for the pultrusion process of LFTP was filling ratio of 104.73 %, molding temperature of 230 °C and pulling speed of 10 cm/min, which was given the lowest un-impregnation value of 5.85 %.

Experimental investigation of mechanical and tribological properties of Al6061–ZrC–B4C hybrid composites

Aluminium metal matrix composites (ALMMCs) have been widely used because of their superior properties such as high strength to wear ratio, high wear resistance, and higher heat conduction rate. The addition of reinforcements in the form of discontinuous particles leads to an increase in the properties of metal matrix composites (MMCs). In the present study, ALMMCs were fabricated with the addition of discontinuous reinforcement particles of zirconium carbide (ZrC) and boron carbide (B4C). The mechanical properties such as tensile strength, hardness, and impact strength were tested as per ASTM standards. The tribological properties were tested using a pin-on-disc setup under different loading conditions (10, 20, 30, 40 N). Moreover, the morphological characterisation of the ALMMCs was carried out by scanning electron microscope (SEM) analysis. Furthermore, differential thermal analysis (DTA) and thermogravimetric analysis (TGA) were performed to find the thermal stability of the ALMMCs. The findings show that variations of reinforcement of ZrC added gave improved properties such as hardness, tensile strength, impact strength, and wear resistance.