Enhancement Of Tensile Strength Research Articles

Microstructure, Process Optimization, and Strength Response Modelling of Green-Aluminium-6061 Composite as Automobile Material

The use of ashes derived from various waste sources as supplements to synthesized ceramic reinforcement in metal matrices has been established. However, studies involving a combination of particulates from three different sources are rare. In a bid to further knowledge in this aspect of research and develop a green aluminium composite for automobile applications, the present investigation studied the implication of adding palm kernel shell ash (PKA), rice husk ash (RHA), and waste steel particles (STP) to the morphology and strength behaviour of Al-6061-T6 alloy. The experimental design was undertaken via the Box–Behnken design (BBD) of the response surface method. A 4% STP at a constant dose was mixed with PKA and RHA at varying proportions and stirring temperatures according to the BBD. The experimental outcome revealed that the responses were greatly influenced by microstructural evolution. From the surface plots, 2–4% RHA and PKA enhanced tensile and flexural strengths, while 4–6% led to a decline in strength. Meanwhile, 2–6% of the particles are favourable to the enhancement of tensile and compressive strengths and moduli. Temperatures between 700 and 800 °C favored response improvement, whereas temperatures between 800 and 900 °C were detrimental to responses. Developed regression models for the responses were validated to be good representations of the experimental outcomes. The optimum mix was obtained at 4.81% PKA, 5.41% RHA, and a stirring temperature of 803 °C. The validation experiment conducted portrayed reliable responses with <5% deviation from the predicted values, thereby certifying the models to be statistically fit for future predictions.

Atomic investigation on optimal interfacial bonding for enhanced fracture properties in polymer nanocomposites

Functionalization of nanofillers is known to have stiffening and strengthening effects on nanocomposites through improved interfacial bonding. However, the optimality in the interfacial bonding is generally not reported in the literature. This issue is addressed here through a series of reactive molecular dynamics simulations on carbon nanotube reinforced polymer nanocomposite. For various degrees of functionalization, uniaxial tension conditions are simulated to study the stress–strain behavior, crack propagation, and fracture toughness. The J-integral is used to quantify the fracture toughness. Through these simulations we demonstrate the existence of an optimal degree of functionalization for maximum enhancement in elastic property, tensile strength, ductility, and fracture toughness. The underlying mechanics behind this optimality is identified through careful studies on crack propagation mechanisms, including crack arresting and formation of new crack surfaces. This optimality, which might also be expected in other material systems, will help in designing efficient nanocomposites.

Natural sepiolite modified PVDF electrospun films for mechanically robust and high-performance triboelectric nanogenerators

In this work, natural sepiolite and polyvinylidene fluoride (PVDF) electrospun composite films with improved mechanical strength were prepared successfully, in which the natural sepiolite not only decreased fiber slippage, but also promoted the polar β-phase formation to reduce surface potential. It was found that the 25 wt% natural sepiolite modified PVDF film (PVDF-25) achieved a 3.2-fold enhancement in tensile strength. The surface potential decreased to −1.439 V in the 15 wt% natural sepiolite modified PVDF film (PVDF-15). Furthermore, through utilizing this mechanically robust film as triboelectric material, the triboelectric nanogenerator (TENG) held superior output performances, including the open-circuit voltage of 740 V, short-circuit current density of 60 mA/m2, maximum power density of 94.08 W/m2 and the long-term stability over 1000 cycles. This work may provide new insights in developing mechanically and electrically robust triboelectric materials by combining natural clay materials.

Effectiveness of Austempering Holding Time in Epoxidized-Transesterified Cotton Seed Oil Bath

The influence of austempering holding time on the mechanical properties and microstructures of high carbon (AISI 1070) steel using epoxidized transesterified cotton seed oil (ETO) as quenchant has been studied. Initially, steel samples were austenitized at 850°C for 1 hour, then quenched interruptedly in an oil bath maintained at 280°C at different holding times from 15-75 minutes at regular interval of 15 minutes. Subsequently, the samples were removed and air cooled to room temperature. Mechanical properties test and microstructural examination were carried out. Obviously, except at 75 minutes austempering period; the results revealed significant enhancement in tensile strength (1580 MPa) at long holding time. Additionally, higher improvement in hardness value (430 HBN) and impact strength (12.7 J/mm) at short time was noticed. In the SEM (scanning electron microscope) images, bainitic structure (acicular), retained austenite and martensite were observed. Accordingly, 15 minutes austempering condition produced austempered high carbon steel (HCS) with the best mechanical properties.

Effect of Nanoalumina on Physical and Thermal Properties of Polypropylene-Glass Fiber Reinforced Nanocomposites

The present study examines the effect of nanoalumina on the mechanical and thermal properties of glass fiber and elastomer reinforced PP/EPDM/GF/Al2O3 with an aim to develop suitable composite material for orthotics. In present study, PP/GF, PP/EPDM/GF composite and PP/EPDM/GF/Al2O3 nanocomposites with specific composition were fabricated using melt-blending technique. Prepared composites were characterized through scanning electron microscopy (SEM), X-ray diffraction (XRD), thermogravimetric analysis (TGA) and differential scanning calorimetry (DSC). The mechanical characteristics including tensile strength, tensile modulus, notched Izod impact strength and elongation at break of the prepared composite were studied in accordance with ASTM guidelines. PP/EPDM/GF/Al2O3 composites showed the mechanical properties of PP/EPDM/GF/Al2O3 composites showed 62%, 145%, 15% and 165% enhancement in tensile strength, tensile modulus, notched Izod impact strength and elongation at break, respectively as compared to PP/GF composites. The mechanical properties and thermal properties of PP/EPDM/GF/Al2O3 were also compared with PP/EPDM/GF composites. The use of nanoalumina significantly and brilliantly balances the complimentary tensile and elongation properties in PP/EPDM/GF/Al2O3 composite, which is an essential requirement for fabricating composite material capable of being thermoformed to orthotic devices.

Optimisation of EDMed fly ash and rice husk ash reinforced hybrid Al-based composite using improved COPRAS and entropy method

Rice husk ash (RHA) and fly ash (FA) pose a hazard to human health environment and are available abundantly across the globe. Attempts are being made to use such waste materials to create aluminum-based composite materials that can be used in a spectrum of uses. The Al6061/RHA/FA hybrid composite was prepared with 2.5 wt. % of each RHA and FA particle using a stair casting technique. This paper discusses mechanical characteristics like tensile strength, hardness, percentage elongation, and surface morphology, which were investigated using SEM. In addition, machinability investigations have been carried out using electric discharge machining, targeting the productivity of the component, quality, and accuracy. Taguchi's L9 array was used to investigate the impact of parameters like pulse current, duty-cycle, pulse ontime, and gap voltage on output parameters MRR, tool eroded, and radial overcut. Enhancements in tensile strength and harshness have been observed by the reinforcement of FA and RHA particles. [Submitted 15 July 2021; Accepted 17 September 2021]

Submicron-Sized, High Crystalline Graphene-Reinforced Meta-Aramid Fibers with Enhanced Tensile Strength

Submicron-Sized, High Crystalline Graphene-Reinforced Meta-Aramid Fibers with Enhanced Tensile Strength

Emulsification of castor oil using poly (N-vinyl-2-pyrrolidone) for functional finishing of cotton fabric

Castor oil (CAO)/poly (N-vinyl-2-pyrrolidone) (PVP) hybrid was synthesized at different reaction conditions including PVP/CAO weight ratio, temperature, and time. The results indicated that the optimum conditions to synthesis that hybrid is reacting of PVP having a molecular weight of 40,000 Da with CAO at a weight ratio of 30% and temperature of 150°C for 60 min. The synthesized hybrid was characterized via FTIR. Emulsification of such hybrid in water results in a white stable emulsion. The TEM analysis proved that the prepared emulsion of a particle size ranges from 320 to 370 nm. The technical feasibility to apply the produced emulsion for functional finishing of cotton fabric was studied. The results obtained indicated that treating cotton fabric with easy care finishing bath containing the synthesized emulsion results in enhancement in nitrogen content, tensile strength, whiteness index, stiffness, and antibacterial activities along with a decreasing in resiliency, wettability, and surface roughness properties of treated fabric, compared to the control sample. Moreover, incorporation of zinc oxide nano-particles (ZnO-NPs) or dihydroxybenzophenone (DHBP) in the above mentioned finishing bath enhances the functional properties of the finished fabric. Furthermore, dyeing fabric samples with different reactive and direct dyes followed by finishing using the aforementioned finishing bath, in absence of ZnO-NPs and DHBP, gives rise to an enhancement in the color strength of such samples compared to the dyed samples. The fastness to washing and perspiration of only the direct dye dyed/finished sample was improved. Almost all the dyed/finished samples exhibited an improvement in their fastness to the wet rubbing and alkaline perspiration along with a reduction in fastness to light. In addition, the SEM, as well as EDX analysis of treated fabric, was investigated.

Enhancement of tensile strength of bamboo fibre reinforced titanium laminate by addition of portunus filler compared with bamboo titanium composite

The aim of this work is to enhance the tensile strength of bamboo fibre reinforced titanium laminate by the addition of portunus filler and compared with bamboo titanium composite. The material used for this work is bamboo fibre reinforced titanium composite by the addition of portunus filler. In this work bamboo fibre reinforced titanium composite filled with portunus filler (5, 10 wt%) was kept as the experimental group and bamboo fibre reinforced titanium composite without portunus filler was kept as the control group. Totally 60 samples were used for evaluation of tensile strength. The mean tensile strength obtained for the bamboo fibre composite filled with portunus filler is 63.6965 Mpa and without filler is 32.5845 Mpa. From the ANOVA analysis, the significance value among the experimental group and the control group for the tensile strength is 0.001 (P < 0.05). Within the limits of the study , it was concluded that the addition of 10 w.t % portunus filler improved the tensile strength significantly in bamboo fibre reinforced titanium composite.

Greener bio-based spherical nanoparticles for efficient multilayer textile fabrics nanocoating with outstanding fire retardancy, toxic gases suppression, reinforcement and antibacterial properties

Herein, sustainable and innovative textile fabrics nanocoatings were developed achieving textile fabrics with superior fire safety, antibacterial, reinforcement and toxic gases suppression properties. Hence, spherical rennet casein nanoparticles were synthesized for the first time using energy saving and green magnetic stirring tool at ambient condition yielded nanoparticles of an average size of 116 nm. Moreover, spherical chitosan nanoparticles of an average size of 26 nm were also synthesized using the same approach. The size and distribution of newly developed nanoparticles were optimized using varied stirring time intervals (24–96 h). The developed spherical nanoparticles were elucidated using dynamic light scattering and microscopic tools. Then, the fabricated polyanions rennet casein nanoparticles and polycations chitosan nanoparticles were utilized as an alternating bilayer for constructing nanocoating on the surface of cotton and polyester fabrics individually by layer-by-layer approach. The bilayers coating number was altered in 3, 5 and 10 multilayers. The flame retardancy of developed textile fabrics was significantly improved achieving zero rate of burning and 34% of limiting oxygen index (LOI) value compared to 119 mm/min and 18.5% for uncoated cotton sample. This is in addition to outstanding toxic gases suppression achieving 76%, 73% and 64% for CO2, CO and SO2, respectively. Additionally, significant enhancement in tensile strength of coated fabrics was attained recording 241% improvement. The newly developed textile fabrics coatings inhibit the growth of Escherichia coli bacteria on surface of both cotton and polyester fabrics achieving clear inhibition zone of 16 mm. The developed sustainable coatings afford durable properties to textile fabrics. Moreover, the flame retardancy, toxic gases suppression mechanisms and economic feasibility for scalable production were studied.

Polyimide/Silica Nanocomposites with Enhanced Tensile Strength: Size Effects and Covalently Bonded Interface

AbstractIn this work, the tensile strength of polyimide/silica composites with the covalently bonded interface (bonded PI/SiO2) is investigated by molecular dynamic simulation. It is found that the nanofiller with smaller size can bring out a larger number of hydrogen bonds and interfacial non‐bond energy in the composites, resulting in higher tensile strength. As the immobilization of the PI chains in the vicinity of SiO2, the covalently bonded interface is found to offer a greater reinforcing effect than the unbonded interface that is confirmed by the self‐diffusion coefficient. The tensile strength of 9 wt.% bonded PI/SiO2 composites is 11.34% higher than that of the unbounded composites. The tensile strength of PI/SiO2 composites is enhanced with the increase of SiO2 concentration up to critical mass percent (Xc), beyond which it will be decreased. To quantitatively predict Xc of PI/SiO2 composites, an empirical equation based on the non‐bond energy of the composites is proposed. The empirical equation showed that the Xc of PI/SiO2 composites ranged from 8.03 to 10.36 wt.%, which is consistent with experimental values. These results provided the understanding of size‐dependent covalently bonded interface structure, which would be beneficial to the design of nanocomposites with excellent mechanical performances.

Upcycling of PET from recycled food packaging trays via vitrimers chemistry

Poly (ethylene terephthalate) (PET) recycling process is well established nowadays for PET bottles. On the other hand, recycling of PET from food trays (tPET) is still challenging because of its lower molecular weight and the possible presence of other polymers as a consequence of the use of multi-layered trays. In this work, end-of-life PET trays have been chemically modified through the melt reactive processing into a covalent associative network, in order to enhance its performance. In particular, upcycling of tPET was obtained by the reaction of diglycidyl ether of bisphenol A (DGEBA) in the presence of zinc acetylacetonate as a transesterification catalyst, to obtain a reversibly cross-linked material, i.e. a vitrimeric material, which retains recyclability while significantly enhancing mechanical properties of tPET. Indeed, rheological test demonstrated clear crosslinking of tPET vitrimers, with a high temperature relaxation explained by the exchange of covalent bonds. Dynamic mechanical analysis showed high thermomechanical resistance, while tensile test at room temperature demonstrated strong enhancement in tensile strength and elongation at break compared to tPET. The results reported in this paper opens to the upcycling of other low grades of PET, including textiles and other goods produced with previously recycled polymer, thus contributing to the establishment of a circular economy for PET, beyond bottles.

Insights into chitosan-based cellulose nanowhiskers reinforced nanocomposite material via deep eutectic solvent in green chemistry

In the present work, the synthesis of cellulose nanowhiskers (CNW)/chitosan nanocomposite films via deep eutectic solvents (DES) changing the chemical structures were carried out. It was observed that a pure chitosan film has broadband at 3180-3400 cm−1, indicating amide and hydroxyl groups. Upon CNW incorporation, the peak gets sharper and stronger and shifts to a greater wavelength. Further, the addition of DES infuses more elements of amide into the nanocomposite films. Moreover, the mechanical properties incorporating CNW filler into a chitosan matrix show an enhancement in tensile strength (TS), Young's modulus (YM), and elongation at break. The TS and YM increase while the elongation decrease as the CNW concentration increases. The YM of biocomposite films is increased to 723 MPa at 25% CNW into chitosan films. Besides, the TS has enhanced to 11.48 MPa at 15% CNW concentration in the biocomposite films. The elongation at break has decreased to 11.7% at 25% CNW concentration. Hence, incorporating CNW into the chitosan matrix via DES can still improve the mechanical properties of the nanocomposite films. Therefore, the application of DES results in a lower YM and TS as the films are hygroscopic. In conclusion, DES can be considered the new green solvent media for synthesizing materials. It has the potential to replace ionic liquids due to its biodegradability and non-toxic properties while preserving the character of low-vapour pressure. Besides that, chitosan can be used as potential material for applications in process industries, such as the biomedical and pharmaceutical industries. Thus, DES can be used as a green solvent and aim to reduce the toxic effect of chemicals on the environment during chemical production.

Enhancement of mechanical properties and corrosion resistance of bainitic elastic rail clip (ERC) with finer microstructural morphology

Present work discusses the enhancement of hardness and tensile strength of the existing quenched and tempered elastic rail clip (ERC) by modifying the microstructure to bainite via austempering at 300ºC with various holding durations of 15 min, 30 min and 60 min after austenitization at 950ºC. Further, the corrosion resistance of these austempered ERC specimens evaluated in freely aerated 3.5 wt.% NaCl solution with the help of electrochemical tests (electrochemical impedance spectroscopy, linear polarization and potentiodynamic polarization) is better than the as-received (existing) ERC specimen with tempered martensitic structure. The variation in corrosion rate of the austempered ERC specimens is attributed to the finer galvanic couple formed between the ferrite and cementite phases in the bainitic structure. Further rust analysis using scanning electron microscopy and Raman spectroscopy after electrochemical tests shows the presence of various rust phases such as α-FeOOH, β-FeOOH, γ-FeOOH and α-Fe 2 O 3 . The higher protective ability index (α/γ*) as determined by the relative fraction of protective α-FeOOH and α-Fe 2 O 3 with dissolving β-FeOOH and γ-FeOOH phases of the austempered ERC specimen attributed further to their higher corrosion resistance. • Effect of asutempering on mechanical and corrosion behavior of elastic rail clip is studied. • Tensile strength of the austempered steel increases with increase of isothermal holding time. • Corrosion rate decreases with increase of bainite fraction in the austempered steel. • Rust constituents uniquely controls the corrosion of bainitic elastic rail clips. • High C at edge of RA near to bainitic ferrite results in higher dissolution of interface.

Significant enhancement in tensile strength of room-temperature rolled Al–8Zn–1Mg alloy induced by profuse microbands

Developing high-performance simpler alloys via simpler processing procedures is of great significance in achieving carbon dioxide emission peak and carbon neutrality. In the present study, room-temperature (RT) rolling was carried out on simple ternary Al–8Zn–1Mg alloy in order to improve its comprehensive performance by regulating microstructure evolution. Ultimate tensile strength (UTS), yield strength (YS), fracture elongation (EL%) and uniform elongation (EU%) were tested. Optical microscopy (OM), electron backscattered diffraction (EBSD) and transmission electron microscopy (TEM) were used to characterize the microstructure evolution. Phase analysis was performed by X-ray diffraction (XRD). The results show that RT rolling significantly enhances the UTS and YS of ternary Al–8Zn–1Mg alloy, which are ∼447 MPa and ∼389 MPa, respectively, with the corresponding EL% and EU% of ∼7.1% and ∼4.1%. The comprehensive tensile properties are comparable to or even better than that of their conventional counterparts with more complex compositions or produced by more complicated techniques. Compared with the as-SS alloy, the as-SS + R alloy experiences an additional 227 MPa increase in YS. The calculated results show that fine-grain strengthening and dislocation strengthening (predominantly in the form of microbands in the present study) respectively contribute to 21 MPa and 167 MPa increases in YS. The remaining 40 MPa increase is highly likely derived from the hetero-deformation induced (HDI) strengthening of the heterostructured lamellar microbands. The delicate balance between strength and elongation is mainly attributed to the profuse microbands formed by the coupling effect of high Zn solute atoms and stress. The findings shed light on a fundamental facet of how regulating microbands can develop high performance simpler aluminum alloys which have potential applications in strength-based structural materials.

Durable PP/EPDM/GF/SiO2 nanocomposites with improved strength and toughness for orthotic applications

Ankle-foot orthotics need ideal specification of being light-weight, high strength, tough, stiff, and durable. Reinforced polypropylene (PP) composites with enhanced mechanical properties are the most favorable materials being used in this field, but still, it is challenging to achieve balanced blend of strength and toughness in the composites. The present study thus aims to achieve the challenging task of simultaneous improvement in stiffness and toughness in reinforced PP composites exploring the synergistic reinforcement effect of glass fibers (GFs) and nano silica (SiO2) as multiscale fillers and ethylene propylene diene monomer (EPDM) as impact modifier. EPDM is used as toughness modifier, addressing the brittle behavior, but at the cost of the strength of the polymer. Combined use of micro and nanofillers as reinforcement in toughened polypropylene provides a potential approach to balance the strength while maintaining the toughness. GFs could offer high strength and nanofillers offer ductile fracture to the material. PP, PP/GF, PP/EPDM/GF composites and PP/EPDM/GF/SiO2 nanocomposites are fabricated through melt blending technique and are characterized through SEM, mechanical evaluation, nanoindentation and dynamic mechanical analysis. Mechanical properties are evaluated in accordance with ASTM standards. PP/EPDM/GF/SiO2 nanocomposites exhibits remarkable enhancement in Tensile strength, tensile modulus, impact strength and percent elongation at break by 49 MPa (55% increase over PP), 2450 MPa (145% increase), 145 J/m (13% increase) and 156% (160% increase) respectively. The exceptional improvement in reduced modulus and hardness reveals good interfacial properties. Loss factor decrement reveals elastic behavior of nanocomposites suitable for thermoforming of nanocomposites for orthotic device fabrication.

Enhancement of tensile strength of tapered laminates by utilizing thin-ply composites

Tapered CFRP laminates formed by dropping off plies are extensively used on modern aircraft due to the special design requirement for certain components. Thin-ply composites have recently been proven to have good damage tolerance in experimental and numerical studies. The use of thin-ply composites in tapered laminates is expected to achieve a higher taper ratio and enhance the design flexibility, which has yet to be investigated. This paper studied the mechanical behavior of tapered laminates without belt plies with different taper ratios and ply thickness under the loading-unloading tensile test. The damage behavior of tested specimens was observed through microscope imaging after the unloading process. The experimental results indicate that tapered laminates utilizing thin-ply composites have excellent mechanical properties and damage-resistant capability. And it was found that the use of thin-ply composites in tapered laminates could allow for a wider range of taper ratios. This allows for more selectivity in the design methods of tapered composite structures and enables lightweight.

Evaluating the substitution potential of SBS with crumb rubber-polypropylene blends as asphalt binder and mixture modifiers

The study aimed to assess the suitability of substituting styrene–butadienestyrene with waste crumb rubber-polypropylene blends as modifiers to enhance the performance characteristics of asphalt binders and mixtures. Six crumb rubber-polypropylene blends including three styrene–butadienestyrene percentages were used to modify a base binder and then the modified binders were used to fabricate asphalt concrete mixtures. To obtain the physical and compatibility behavior of the unmodified and modified binders, various conventional binder tests such as softening point, penetration, and storage stability were employed. Dynamic shear rheometer, multiple stress creep recovery, and linear amplitude straintests were performed on unaged and long-term aged samples to achieve a broad understating of rheological characteristics at high and intermediate temperatures. In order to assess the influence of the modifiers on asphalt mixtures, various test methods were implemented including indirect tensile strength, resilient modulus, and four-point beam fatigue and dynamic creep tests. The findings of the physical tests represented a decline in penetration and a rise in softening point by the crumb rubber-polypropylene and styrene–butadienestyrene modifications compared with the base one. Results of the storage stability test proved that only 3% styrene–butadienestyrene modified was a storage-stable blend at high construction temperatures and the instability increased by incorporating more polymer content. According to the rotational viscosity test, all of the modifications increased the viscosity, reducing the workability of the modified mixture. Based on the rheological tests, the addition of the modifiers resulted in a reduction in phase angles, and an increase in complex modulus at high temperatures, thereby decreasing binder sensitivity to permanent deformation. With increasing the percentage of the polymer, more improvement would be obtained regarding rutting resistance. At intermediate temperatures, however, the complex modulus of modified binders decreased while no notable changes were observed for phase angle compared to the base binder. Considering the mechanical test results, the crumb rubber-polypropylene and styrene–butadienestyrene modified mixtures resulted in an enhancement in indirect tensile strength, resilient modulus, four-point beam fatigue, and dynamic creep tests results which would cause better resistance against rutting, fatigue damage, and moisture susceptibility compared with the base one. Besides, a radial bias function neural network model was designed to predict tensile strength ratio, and fracture energy ratio. The results showed the high performance of this method in the estimation of these values.

Three-Dimensionally Conducting Network in Graphene-Based Composite Fibers toward Enhanced Electrochemical and Toughness Performance in Fibrous Supercapacitors

As one of the most promising energy storage devices, graphene-based fibrous supercapacitors (FSSCs) are attracting intensive attention. However, the conflict between specific capacitance and intrinsic brittleness of pure graphene fibers hinders their practical applications. Herein, we develop a strategy to fabricate graphene-based ternary composite CNT/MXene/graphene (CMG) fiber electrodes with high toughness and high electrical and electrochemical performance. These resulting properties are attributed to the three-dimensional cross-linked conducting network within graphene sheets through covalent bonding and π–π interaction among acidified carbon nanotubes, graphene sheets, and MXene, which greatly contributes to the enhanced tensile strength, toughness, and electrical transport in the CMG fiber. The CMG fiber with the optimized mass ratio of different components shows a high toughness of ∼1.7 MJ m–3 and an electrical conductivity of 420 S cm–1, which is 4- and 2-fold that of reduced graphene oxide fiber, respectively. The assembled FSSC based on the optimized CMG fiber exhibits an areal capacitance of 237 mF cm–2 and a good rate performance of 85%.

Effect of Zr addition on the microstructures and mechanical properties of ZrC–FeCrAl alloys

In light water reactors (LWR), it is necessary to decrease the thickness of the FeCrAl alloy cladding to reduce neutron absorption to further reduce the impact on the reactor cycle length. Thus, the mechanical properties of the FeCrAl alloys must be further improved. In this work, novel Zr–ZrC–FeCrAl alloys with different Zr content were designed and fabricated by mechanical alloying (MA) combined with spark plasma sintering (SPS) and hot rolling. With the addition of Zr, Fe2Zr Laves phase was successfully introduced into the Zr–ZrC–FeCrAl alloys, and thereby significantly improve the elevated temperature property and thermal stability. Meanwhile, the grain size and precipitate size are effectively refined when the Zr content reaches 0.3 wt%. Furthermore, the 0.3Zr–ZrC–FeCrAl alloy (FCA-0.3Zr) exhibits the optimum comprehensive properties, showing a 3.2% and 9.1% enhancement in tensile strength under room temperature and elevated temperature (800 °C), respectively, as compared to that of ZrC–FeCrAl alloy (FCA-0Zr). The potential application value in the field of LWR of Zr–ZrC–FeCrAl alloys is revealed in this study, which provides a beneficial reference for more work in the future.