Distribution Of Reinforcement Particles Research Articles

FRICTION STIR PROCESSED MAGNESIUM MATRIX SURFACE COMPOSITES: A COMPREHENSIVE REVIEW

Abstract Nowadays modern materials are tailored using different manufacturing techniques. Usually, material surface is modified by even distribution of reinforcement particles/ fibres up to a certain depth. The developed surface metal matrix composites (MMCs) exhibit superior metallurgical, mechanical and electrochemical properties in contrast to base materials. These surface MMCs have potential applications in biomedical, automotive, aerospace and power industries. Many techniques have been used to develop these surface MMCs, however, the friction stir processing (FSP) has gained wide popularity. This review paper summarizes the effects of different FSP parameters on the metallurgical, mechanical and electrochemical properties of developed surface composites. Furthermore, the effects of secondary phase particles on the Magnesium-matrix surface composites are also comprehensively discussed.

Investigation of aluminum-based mono and hybrid surface composites by incorporating SiC and graphene reinforcements using friction stir processing

The present investigation focuses on the synthesis of mono (AA5052/SiC and AA5052/graphene) and hybrid (AA5052/SiC/graphene) surface composites using friction stir processing (FSP). This work examines the synergistic effect of SiC and graphene on the fabricated surface composites. Macro/microstructure, microhardness, and wear test analysis were done on these samples, and the results were compared with the base material AA5052-H32. The microstructure analysis showed that the distribution of reinforcement particles in the aluminum matrix is made more uniform by adding hard SiC with graphene nanoparticles, which can reduce the occurrence of particle clustering and agglomeration. As a result, the smallest grain size of 11.2 µm and the highest microhardness obtained was 84.1 HV obtained in hybrid surface composites. Consequently, the hybrid surface composites obtained more improved wear properties than mono surface composites. Thus, the hybrid surface composites achieved the lowest average friction coefficient of 0.304.

Investigation on corrosion behaviour of metal oxide nanoparticles reinforced magnesium composites by salt spray and immersion corrosion test methods

ABSTRACT This study explores the increasing utilisation of lightweight materials, particularly magnesium (Mg) alloy, in sectors such as automobile, aerospace, and marine due to its notable advantages such as high strength-to-weight ratio, good castability, and excellent damping capacity. Despite these merits, Mg alloy faces challenges, notably in wear and corrosion resistance. The research focuses on enhancing the corrosion resistance of Mg alloy by incorporating Zinc Oxide (ZnO), Manganese Oxide (MnO), and Titanium Oxide (TiO2) nanoparticles. The alloy AZ91D and three nanocomposites, namely AZ91D + 1% ZnO, AZ91D + 1% MnO, and AZ91D + 1% TiO2, were manufactured using a stir squeeze casting technique combined with an ultrasonication process. To confirm the even distribution of reinforcement particles, Optical Microscope (OM), Scanning Electron Microscope (SEM) and High-Resolution Scanning Electron Microscope (HR-SEM) were employed. X-ray Diffraction (XRD) analysis revealed the presence of matrix and reinforcement material with intermetallic precipitates around the grain boundaries. Corrosion properties were assessed following ASTM standards and utilising a 3.5% NaCl concentration. The study found that AZ91D + 1% TiO2 nanocomposites exhibited superior corrosion resistance compared to the AZ91D alloy, showing a remarkable 77.78% and 69.89% improvement in corrosion behaviour under salt spray and immersion environments, respectively, after 48 hours.

Effect of brass slag particles on the microstructure and hardness of Al-Si alloy matrix composites

The current study investigated the effects of brass slag particles on the microstructure and hardness of Al-Si alloy (LM30) matrix composite. Stir casting was used to fabricate a composite with brass slag particles of finesize (i.e. 100–215 μm), coarse size(i.e. 215–350 μm) and three different concentrations of 3 wt%, 6 wt%, and 9 wt%. The dynamic shear force generated by stirring prevents brass slag particles from sinking into the melt which result in uniform particle dispersion throughout the melt. Optical microscopy analysis reveals a uniform distribution of reinforcement particles in cast composites, accompanied by silicon refinement. The findings suggest that the incorporation of industrial waste (brass slag as a reinforcement) in the fabrication process enhances microstructure and mechanical characteristics of composites. 9 wt% concentration of brass slag reinforced of fine size composite demonstrated an impressive ∼60.7% improvement in hardness compared to base alloy (LM30). It was also observed that theoretical density (ρth) and experimental densities (ρex) approximately 25% and 18.4% greater than that of the base alloy (LM30).

Characterization, mechanical properties, and wear behavior of functionally graded aluminum hybrid composite

The present work demonstrates the development of SiC/TiS2/AlSi12Cu hybrid functionally graded composite using centrifugal casting and examines its microstructural, mechanical, and tribological properties. A gradient distribution of reinforcement particles was observed with the outer region being particle-rich. EBSD analysis confirms microstructural refinement owing to titanium’s grain refining properties and the formation of θ-Al2Cu intermetallic phase. The outer layer of the composite attained a maximum hardness and tensile strength of 93 HB and 202 MPa respectively, which was increased by 7.5% and 8.2%, 20.4% and 13.8%, 22.5% and 44.5% in middle, inner, and as-received alloy respectively. Tribological properties were assessed via dry sliding pin-on-disk tribometer with various process parameters such as load (10–40 N), velocity (1–4 m/s) and distance (500–2000 m), optimized using response surface methodology. The higher wear resistance was attained by the optimized process parameters of 16 N load, 1.6 m/s velocity, and 804 m distance. Results indicated increased material loss with higher load, sliding distance, and velocity, but with enhanced wear resistance in the outer zone. Worn surface analysis revealed deeper grooves, delamination, particle pull-out, and wear tracks under severe conditions. The study emphasizes the composite’s potential for high wear applications, linking its microstructural features to its superior wear behavior.

Friction Stir Welding: A Comprehensive Review of Non-Metallic Particle Reinforcement in Joints

Friction Stir Welding (FSW), a solid-state joining technique, has demonstrated superior efficiency in welding metal-matrix-reinforced composite joints. FSW has garnered significant attention in recent years as a viable technique for joining similar and dissimilar materials, particularly those reinforced with non-metallic particles. By utilizing diverse mixture of reinforcement particles and base matrices, FSW outperforms traditional fusion joining methods in terms of effectiveness and reliability. Despite significant progress, challenges persist in achieving a homogeneous distribution of Non-metallic particles in the weld zone, which directly impacts macrostructural and microstructural characteristics. Moreover, the mechanical properties of these welds are intricately linked to process parameters, influencing grain enhancement and reinforcement particle distribution. This review critically evaluates these aspects, providing insights into the current understanding and highlighting areas for future research.

Effect of Yttria-Stabilized Zirconia addition along with Cu in development of titanium based metal matrix composite via FSP technique for the application in biomedical devices

ABSTRACT The present study investigated the effect of incorporating Yttria-Stabilized Zirconia (YSZ) and copper (Cu) in the development of Titanium-Based Metal Matrix Composites (TMCs) using the Friction Stir Processing (FSP) technique. The macrostructure of the TMCs, after adding 5% YSZ and 2% Cu, displayed a defect-free, crack-free, and porosity-free surface, indicating the precision of the FSP method. Microstructure analysis revealed a uniform distribution of reinforcement particles and proper dispersion of grains, key for enhancing mechanical properties. The interfacial bonding between titanium and YSZ was exceptionally strong, devoid of cracks and porosity, attributed to the copper additive’s role. The increase in the number of grains per square inch for the Ti/5% YSZ/2% Cu composite (1176.26 grains per square inch at 500×) signified finer grain structure, contributing to a remarkable 48.04% improvement in tensile strength compared to pure titanium. The uniform distribution of reinforcement and strong bonding between titanium and YSZ are the driving forces behind the 46.34% increased in hardness. Additionally, the wear resistance of the composite improved by approximately 76.66%, a vital characteristic for applications facing abrasive conditions. The corrosion testing demonstrated an 8.33% enhancement in corrosion resistance with the Ti/5% YSZ/2% Cu composite.

Effect of laser remelting on internal defects and properties of Ni-based coatings reinforced by multi-channel WC in situ

In order to investigate the effect of laser remelting on the properties of hot work die steel, WC reinforced Ni base remelting layer was prepared on H13 steel surface. Optical metallography microscope, X-ray diffractometer and scanning electron microscope were used to analyze the macroscopic defects, phase evolution and microstructure of the coating before and after laser remelting. Microhardness tester and friction and wear tester were used to test the microhardness and wear resistance of the remelted layer, and compared with the coating without remelting. The results show that the inner porosity of the coating decreases with the increase of laser power. With the dissolution of WC/W2C ceramic particles and the uniform distribution of W element, the distribution of reinforcement particles in the coating becomes more and more uniform. When the laser power reaches 1500 W, the WC/W2C ceramic particles inside the coating basically disappear, the porosity is reduced to the lowest, the coating uniformity is the best, and the microhardness and wear resistance are the highest.

Exploration of the mechanical characteristics of al7075 metal matrix composite enhanced with fe3o4 and pksa

This research primarily focuses on Aluminum hybrid compounds that have extensive applications throughout every realm of manufacturing. Hybrid metal Matrix Composites possess greatly improved physical properties and find extensive utilization across several sectors, including vehicle components and even aviation. The investigation entails using aluminum (Al-7075) as the foundational component and then incorporating iron oxide and PKSA in weight ratios of 3%, 6%, and 9% to fabricate a strengthened Hybrid Metal Matrix Composite. A manufacturing stir-casting technique is being utilized for the fabrication of such compounds. Stirred molding technology is selected because of its advantages, including a very straightforward manufacturing process, cost efficiency, and reliable distribution of reinforcement particles. The inclusion of overall reinforcement grain Fe3O4/PKSA is essential to defining technical composite qualities. The current examination indicated enhancements in physical properties, including elasticity, compression, as well as toughness strength. A longitudinal value at a 9% wt. strengthened Fe3O4/PKSA is found to be the highest at 342 MPa, while the yield strength is measured at 248 MPa, as equated to a standard Al-7075 alloy. Furthermore, the recently manufactured Al-7075/ Fe3O4/PKSA HMMC were subjected to microstructural examinations using SEM and EDS methodologies. The investigations demonstrated a uniform and homogeneous dispersion of Fe3O4/PKSA reinforcement particulates inside the mixture matrix.

Effect of the addition of different concentrations of particulate reinforcement on the density, hardness and wear resistance of aluminum composites produced by powder metallurgy

The objective of this work is to evaluate the influence of the addition of different concentrations of particulate reinforcement in the production of commercially pure aluminum composites reinforced with blast-furnace slag via powder metallurgy. The processing of these materials was done by sieving, mixing and compacting powders of reinforced aluminum with 5, 10 and 15% of blast-furnace slag. The cold uniaxial compaction was realized at a pressure of 430 MPa. The obtained materials were sintered at 610°C for 2h under inert atmosphere. Unreinforced aluminum samples were also produced. The characterization of the materials was realized by density and microhardness measurements and wear tests. The morphological analysis was realized by scanning electron microscopy. As results, the materials had a relative density greater than 93,8%, reaching 98,6% for pure aluminum. The composites showed a homogeneous distribution of reinforcement particles and progressive improvement in microhardness with increasing slag concentration. However, regarding wear resistance, the result was the opposite. This result suggests that the reinforcing particles, being made of ceramic material, may have worked as an abrasive when released from the aluminum matrix, since commercially pure aluminum is extremely malleable and cannot hold the slag particles.

A novel counter-rotating twin-tool friction stir processing technology for fabrication of Al/SiC surface composite with improved particle distribution

The fabrication of surface composite through friction stir processing (FSP) introduces certain challenges, including insufficient heat generation and non-uniform distribution of reinforcement particles. The implementation of multi-pass FSP can partially reduce these issues; however, it comes at the cost of increased manufacturing time and labour costs. In order to address these challenges comprehensively, a novel counter-rotating twin-tool friction stir processing (CRTTFSP) technology was utilized for fabrication of Al/SiC surface composite. The presence of hard SiC particles notably improved the microhardness of the composite. High heat generation and counter-rotation of the twin-tool, contributed to better particle distribution, which led to consistent microhardness values. Hence, this technology offers uniform mechanical properties of the fabricated composite and also eliminates the need of repetitive processing over the same zone, resulting in considerable reductions in both manufacturing time and associated costs making it more suitable for industrial applications.

Identifying stir casting process parameters to maximize strength of LM13 with TiB2 and ZrC hybrid metal matrix composite

Abstract In this study, an LM13 metal-matrix composite was fabricated using two reinforcement particles (hard and soft) of titanium diboride and zirconium carbide. An experimental design was used to narrow down the trials. The significance of the model was tested using Student’s t-test and p values. The response surface statistical method was used to obtain the optimum process parameters for the high-strength hybrid metal matrix composite. From the experimental results, a maximum strength of 209 MPa was gained at a stirrer speed of 700 rpm, weight fraction of TiB2 and ZrC of 9 %, and casting temperature of 675 °C. The ANOVA results showed that TiB2 was the main influential process parameter, followed by the stirrer speed, casting temperature, and zirconium boride. The microstructure showed a fine and uniform distribution of reinforcement particles in the LM13 matrix. The fracture surface exhibited a mixed fracture pattern, which was due to the good bonding between the reinforcement and matrix at the interface.

Friction stir powder additive manufacturing of Al 6061/FeCoNi and Al 6061/Ni metal matrix composites: Reinforcement distribution, microstructure, residual stresses, and mechanical properties

Fusion based additive manufacturing (FBAM) of second, sixth, and seventh series Al alloys and their metal matrix composites (MMC) is difficult due to their higher thermal conductivity and solidification related problems namely porosity, cracks, thermal distortion, and formation of undesired phases. This paper presents friction stir powder additive manufacturing (FSPAM) process as a promising alternative to overcome these problems in producing multi-layer depositions of Al 6061 based MMCs namely Al 6061/6 wt%FeCoNi and Al 6061/6 wt%Ni. Their microstructure, distribution and elemental mapping of reinforcement particles, phase analysis, residual stresses of the MMCs and their correlation with microhardness, tensile strength, and fretting wear characteristics are investigated. Material accumulation on their advancing side was minimized by changing tool rotation direction in consecutive layers which produced smoother surfaces on both sides of their deposition. FSPAM made multi-layer depositions of Al 6061/FeCoNi and Al 6061/Ni MMCs have uniform distribution of reinforcement particles, good bonding between layers without cracks and defects, refined and equiaxed grains facilitated by dynamic recrystallization and pinning effect of reinforcement particles, compressive residual stresses of 39 and 48 MPa, no formation of deleterious intermetallic compounds due to absence of melting of matrix and reinforcement, and bowl-shaped substrate-deposition interface. Microhardness and ultimate tensile strength of the MMCs improved by 11.3% and 22.3%, and 30.5% and 31.5% respectively than Al 6061 alloy depositions, their wear resistance enhanced significantly, but % elongation reduced. This study proves FSPAM to be a potential alternative to FBAM processes for better quality multi-layer deposition of Al alloy-based MMCs.

Effect of fabrication techniques on mechanical and microstructural behavior of AA7075/SiC/ZrC hybrid composite

Aluminum composites are highly sought-after in the industrial sector due to their improved mechanical properties compared to their parent metals. The choice of fabrication technique has a significant impact on the mechanical behavior of the composite. This study investigated the mechanical behavior of an optimized weight-fractioned AA7075/SiC/ZrC hybrid composite using different fabrication techniques. Stir casting, conventional sintering, and microwave sintering methods were employed to produce the composites. By optimizing the ball milling parameters, a uniform distribution of reinforcement particles was achieved throughout the matrix material. XRD, porosity, microstructural, and mechanical tests were conducted on all three composites to analyze the major changes during fabrication. Remarkably, the composites fabricated through microwave sintering exhibited significantly higher strength than the other fabrication methods. Specifically, the microwave-sintered composites displayed a compressive strength of 389 MPa, a tensile strength of 321 MPa, and a strain-to-fracture value of 26%. In contrast, the stir-cast composites showed a larger scale of secondary phases, poor mechanical performance, and elevated porosity. Moreover, when considering the overall production cost associated with the different fabrication techniques investigated in this study, microwave sintering was the most cost-effective method for large-scale production. This suggests that microwave sintering offers superior mechanical properties and economic advantages regarding manufacturing expenses.

Heat treatment behavior of Cr in the form of collagen powder and Al2O3 reinforced aluminum-based composite material

In the present study, collagen powder in the form of Cr has been extracted from chrome-containing leather waste. Extracted collagen powder along with alumina has been used as reinforcement with AA6061 matrix material. The composite material was fabricated by the stir casting technique. Comparative behavior of composite material with and without heat treatment was observed. The microstructure image of the Al/5% Al2O3/5% collagen composite has shown the uniform distribution of reinforcement particles. Proper wettability between the collagen powder, alumina, and matrix material was observed after the solidification for Al/5% Al2O3/5% collagen composite material. Tensile strength, hardness, ductility, and impact strength of composite material were significantly improved after the heat treatment process. However, results showed that ball-milled reinforced composite has a higher Young's modulus as compared to heat-treated composite. The percent porosity of aluminum alloy was found to be 0.18%. However, the porosity of Al/5% Al2O3/5% collagen powder ball milled composite material was found to be 1%. The XRD of the heat-treated Al/5% Al2O3/5% collagen powder composite showed the presence of Al, Al2O3, Cr, and Cr2O3 phases. Thermal expansion and corrosion behavior of the composite were also observed to identify the heat treatment effect on Al/Al2O3/collagen powder composite material.

Fabrication and characterization of hybrid WE43 Mg alloy-based composite by friction stir processing with improved ductility

In the present study, WE43 magnesium alloy-based hybrid composite was fabricated by using multi-pass friction stir processing (FSP) to enhance the applicability of Mg alloys in aerial and automotive industries limited due to its lower ductility. Microstructural characterization of the double pass processed composite sample analyzed through optical microscopy and SEM-EDS revealed a more homogenous distribution of reinforcement particles (Ti, Al & Sn) with significant grain refinement (avg. grain size = 3.5um) as compared to that of base alloy (avg. grain size = 63um). Mechanical properties investigation revealed that the addition of reinforcement particles and an increased number of passes in processing resulted in enhanced microhardness and UTS with significant improvement in ductility. The percentage elongation of double pass fabricated composite was found to be 32.7%, marking an enhancement of 83% in ductility as compared to that of the substrate alloy.

Investigating the mechanical properties of titanium dioxide reinforced magnesium composites

Titanium dioxide reinforced magnesium alloy was synthesized in the current work by employing the stir casting process to alter its weight proposal. Its mechanical proportions were investigated for structural and functional applications. The microstructure of synthesized nano composites was examined with an optical microscope, and the findings revealed that the presence of nano reinforcement particulates leads to a decrease in the density of the dendritic pattern as well as a homogeneous distribution of nano reinforcement particles throughout the magnesium phase. Hardness (18.24%), tensile strength (22.12%), compressive strength (24.32%), and wear resistance (26.52%) were examined in accordance with ASTM standards. Titanium dioxide reinforced magnesium nanocomposites showed considerable improvements in their mechanical characteristics when compared to as cast alloy. This was the case when compared to the mechanical properties of as cast alloy.

Development of AA5052/TiO2/SiC hybrid surface composites using upward material flow through multipass friction stir processing

The present study employed upward material flow during friction stir processing (FSP) to develop AA5052/TiO2/SiC hybrid surface composites rather than the downward material flow that is conventionally used. The upward material flow was generated with the help of a right-handed threaded pin tool rotating in a clockwise direction causing plastically deformed material to flow in the three-dimensional region of the stir zone. The result showed that the upward material flow pattern and multipass significantly improved the properties of composites. Substantial grain refinement was obtained after each successive pass due to the uniform distribution of fragmented reinforcement particles and intense plastic deformation during FSP. The maximum microhardness of 88.73 HV and ultimate tensile strength of 220.8 MPa were obtained after the fourth FSP pass in developed hybrid surface composites. Additionally, the tribological analysis showed that wear resistance increased with the number of passes.

Study of the corrosion, electrical, and mechanical properties of aluminium metal composite reinforced with coconut rice and eggshell for wind turbine blade development

The gradual global shift from fossil fuels to renewable energy sources such as wind energy for power generation has stirred up a perpetual exigency for sustainable materials for manufacturing wind turbine blades. AMMCs are categories of materials that, over time, have proven reliable as they have been successful in meeting engineering needs in applications requiring high stiffness, moderate strength, and lightweight. The Al8112 alloy was used as the base metal in this study, reinforced with coconut rice and eggshell, to study the corrosion, electrical, and mechanical properties as a viable material for the development of the wind turbine blade. The stir-casting method was used in the preparation. Microstructures, Vickers hardness, tensile strength, electrical conductivity, and corrosion analysis (via the weight loss method) of the prepared composites were analysed. The 3 samples A, B, and C were analysed under 3 media for the corrosion study, such as rainwater, coolant (soluble oil plus water), and nano-lubricants. The results showed that introducing the reinforcements in the matrix of coconut rice and eggshell caused a rise in the hardness and tensile strength. SEM and EDX microstructural analysis revealed a uniform distribution of reinforcement particles in the matrix with the elemental reactions. The corrosion resistance of sample C of the composition (92% aluminium alloy, 5% coconut rice, and 3% eggshell) proved to be higher than that of sample B of the composition (95% aluminium alloy, 2.5% coconut rice, and 2.5% eggshell, and that of the aluminium alloy sample A, with sample C having a corrosion rate of 0.020 mg, sample B having a corrosion rate of 0.021 mg, and sample A having a corrosion rate of 0.022 mg. The composition of the AMMC that exhibits these properties is 92% aluminium, 5% coconut rice, and 3% eggshell. This newly developed material is recommended for applications involving the wind blade.

Effect of Y-groove morphology on welding performance of SiCp/Al composites in powder filled laser welding

Since there is an uneven distribution of reinforcement particles in the welding process of silicon carbide particles/aluminum (SiCp/Al) composites, a detailed study on the influence of Y-groove morphology on welding performance of SiCp/Al composites in powder filled laser welding is essentially required. By optimizing the root face height and V-groove angle, modifying the filling area of the molten pool in the process of powder filled laser welding, and combining with the numerical calculation of the cross-scale molten pool flow field, the inherent law of the molten pool flow field on the influence of the welding quality is revealed in this paper. The macroscopic morphology of the weld is analyzed by a metallographic microscope, and the tensile strength of the joint is measured by a universal tensile testing machine. It is observed that under the action of Marangoni force and virtual mass force, the flow at the bottom of the molten pool is directed from the center of the weld to the periphery. Different Y-groove morphologies change the application point of virtual mass force, and then affect the flow of molten pool. At the same time, the distribution of reinforcement particles is relatively uniform and the weldment is well formed at an optimized root face height of 0.2 mm and V-groove angle as 40°. The mechanical properties of the welded joint are the optimum, reaching 70% of the base material, and the maximum strength value is 266 MPa.