Aluminium Hybrid Metal Matrix Composites Research Articles

Effect of graphene nano plateletson microstructural and wearbehavior of AA7075/Al2O3Nano composites

Aluminum hybrid metal matrix composites are a new generation of composites that comprises of aluminum as matrix and dual reinforcements. The primary reinforcement can be ceramic oxides, borides, nitrides, carbides and secondary reinforcement can be carbonaceous nano materials. In the present work hybrid composites are manufactured with AA7075 as matrix and Al2O3 nano particles and GNPs as reinforcements manufactured by powder metallurgyprocess. The microstructural characterization is performed by SEM and XRD analysis. The results indicated uniform distribution of GNPs and nano Al2O3 in the matrix. The wear behavior of the composites was studied for different compositions and wear rate has been evaluated. The microstructural investigation of worn out surfaces indicated abrasive and adhesive wear mechanisms.

Wear Behavior and FESEM Analysis of LM 25 Alloy MMHCs Reinforced with FE3O4 and Gr by Utilizing Taguchi’s Technique

The current research is concerned with the production of an LM25‐FE3O4—Gr metal matrix hybrid composites (MMHCs) and the analysis of its dry sliding wear conditions. The hybrid composites were made out of 3 wt% Fe3O4 and 4 wt% Gr particles with a mesh size of 200 meshes and were made using the stir casting method. Wear test on Taguchi’s L9 orthogonal arrays employs three process parameters: load, sliding velocity, and distance, each changed for three levels on a pin‐on‐disc tester position. The wear behavior of hybrid composite was investigated using loads of 20 N, 40 N, and 60 N; velocities of 2 m/s, 4 m/s, and 6 m/s; and distances of 1,000 m, 2,000 m, and 3,000 m. The major parameters were developed utilizing the signal‐to‐noise ratio by selecting “smaller‐is‐better” wear rates and COF features. FESEM was used to look at the worn surfaces of the composite specimen in order to determine the wear mechanism. Wear properties are enhanced in materials having aluminium hybrid metal matrix composites. According to the ANOVA table, the load parameter has the greatest impact on wear resistance and coefficient of friction, with maximum load values of 35.64 N and 5.782 N, respectively.

Investigation on Mechanical Properties of Al5052/BN Metal Matrix Composite

The paper aims to find the Mechanical properties of HNT and Boron Nitride, reinforced with Aluminium hybrid metal matrix composites. The aluminum matrix material are reinforced with different weight percentage of HNT(3%,5%,7%) and BN(2%,3%,4%).The hybrid matrix are fabricated through sir casting technique.The mechanical Properties of like hardness, tensile, impact and micro structure of the composites are examined. The hardness and tensile of the composite are increased with increase in weight percentage of boron nitride and HNT. Also the microstructure of the composites shows the clear distribution of the composites and XRD pattern shows the presence of reinforcement in the composites. The hardness and tensile strength increases when 7% of HNT and 4% of boron nitride are added towards the base materials.

Optimization on Tribological Characteristics of Stir‐Casted AA7076/Nano Zirconium Dioxide/Boron Nitride Hybrid Composites by Taguchi Method

Aluminum alloys are currently used in a wide variety of industries, and strong aluminum alloys are required for the creation of new components. As a result, multiple scientists are experimenting with various compositions of hybrid aluminum metal matrix composites. The purpose of this experiment was to generate hybridization on aluminum alloy 7076 using stir‐casting and nano zirconium dioxide and BN reinforcements. Taguchi’s approach was used to optimize the stir‐casting process criteria in this investigation. The parameters employed in this investigation were agitation speed, agitation time, and temperature. The chosen constraints are the percentage of reinforcement (0–12%), the agitation speed, the agitation time, and the molten state temperature. We used a wear tester and a Vickers hardness tester to determine the wear and microhardness of the produced stir casting materials. By optimizing wear parameters, the least wear rate is determined.

Tribological behaviour of hybrid AMMC sliding against EN 31 steel

Hybrid Aluminium Metal Matrix Composites (HAMMCs) having significantly increasing the matrix material properties and its suited for more applications like automobile sectors, aerospace, structural elements and more. In this present research Aluminium alloy LM26 is reinforced with fly ash and graphite 5–15% with varying interval of 2.5 by using stir casting process. Four different proportions of composites have prepared and their mechanical and wear properties are measured. Microstructural investigations are confirmed graphite and fly ash reinforcements have uniformly distributed with Aluminium Alloy LM26. The result shows composites have considerably increased tensile strength and hardness values compared to unreinforced specimen. Wear rate is considerably reduced after reinforcement were added and also coefficient of friction values are reduced after reinforcement.

Investigations on mechanical properties of aluminium alloy Al6061 hybrid metal matrix composite

The present study focuses on the mechanical behaviour analysis of the hybrid metal matrix composite of AA6061 aluminium alloy reinforced with (volume fraction) various proportions of molybdenum disulphide and graphite powders. The stir casting method has been followed to fabricate the hybrid aluminium metal matrix composites (HAMMC). Studies on the effect of reinforcement on the mechanical properties of the fabricated hybrid composites have been carried out as per the ASTM Standard. Microstructural images confirm the uniform distribution of MoS2 and graphite reinforcement throughout the surface. Hardness and mechanical behaviour results show that the hybrid composite with 4% of MoS2 and graphite powders has improved mechanical properties than other composites.

Impacts of carbon nano tubes (CNT) and boron carbide (B4C) particles on material properties of al 6061

In recent years, conventional materials are replaced with composites in particular aluminium were developed for enhanced material performance such as light weight, high strength and wear resistance etc. In this paper, aluminium hybrid metal-matrix composites (AHMC) are fabricated by stir casting technique with different compositions of carbon nano tubes (CNT) and boron carbide (B4C). This research work reports the tensile strength, wear behaviour, micro structural analysis of different specimens (Al 6061 with 3% CNT & 3% B4C, Al 6061 with 5% CNT & 3% B4C, Al 6061 with 7% CNT & 3% B4C & Al 6061 with 9% CNT & 3% B4C). From these four specimens, tensile strength and the hardness of the specimen 4 is 250 MPa and 52.692 BHN respectively. By comparing the values, specimen 4 gives higher value. In addition, EDAX analysis clearly ensures the even distribution of reinforcements in different specimens. The improvements in strength are noticed when increasing the composition of CNT in Al6061 hybrid matrix composites.

Application of AI techniques for modeling the performance measures in milling of 7075-T6 hybrid aluminum metal matrix composites

The prediction of performance measures is an essential one for manufacturers to increase the service life. This paper deals with the application of Artificial Intelligence (AI) to predict the performance measures like surface roughness, material removal rate, and flank wear during the milling process from the experimental data. The milling experiments were conducted in wet conditions based on the Response Surface Methodology (RSM) design of experiments. The spindle speed, feed rate, and axial depth of cut were considered as process parameters. The experimental data were used to develop the regression model, Mamdani fuzzy inference system, Backpropagation Neural Network (BPNN), and Adaptive Neuro-Fuzzy Inference System (ANFIS) model. The output of regression, fuzzy, neural network, and ANFIS model was compared with the experimental data, and predicted results were found to be in good conformity with the measured data. The prediction capability of the quadratic and Artificial Neural Network (ANN) model was very close to experimentally measured values and the quadratic model had an accuracy of 97.89% for surface roughness, 98.38% for material removal rate (MRR), and 95.72% for flank wear.

Drilling Parameters Analysis on In-Situ Al/B4C/Mica Hybrid Composite and an Integrated Optimization Approach Using Fuzzy Model and Non-Dominated Sorting Genetic Algorithm

In-situ hybrid metal matrix composites were prepared by reinforcing AA6061 aluminium alloy with 10 wt.% of boron carbide (B4C) and 0 wt.% to 6 wt.% of mica. Machinability of the hybrid aluminium metal matrix composite was assessed by conducting drilling with varying input parameters. Surface texture of the hybrid composites and morphology of drill holes were examined through scanning electron microscope images. The influence of rotational speed, feed rate and % of mica reinforcement on thrust force and torque were studied and analysed. Statistical analysis and regression analysis were conducted to understand the significance of each input parameter. Reinforcement of mica is the key performance indicator in reducing the thrust force and torque in drilling of the selected material, irrespective of other parameter settings. Thrust force is minimum at mid-speed (2000 rpm) with the lowest feed rate (25 mm/min), but torque is minimum at highest speed (3000 rpm) with lowest feed rate (25 mm/min). Multi-objective optimization through a non-dominated sorting genetic algorithm has indicated that 1840 rpm of rotational speed, 25.3 mm/min of feed rate and 5.83% of mica reinforcement are the best parameters for obtaining the lowest thrust force of 339.68 N and torque of 68.98 N.m. Validation through experimental results confirms the predicted results with a negligible error (less than 0.1%). From the analysis and investigations, it is concluded that use of Al/10 wt.% B4C/5.83 wt.% mica composite is a good choice of material that comply with European Environmental Protection Directives: 2000/53/CE-ELV for the automotive sector. The energy and production cost of the components can be very much reduced if the found optimum drill parameters are adopted in the production.

Mechanical and wear analysis of Al6061-SiC/Al2O3/B4C hybrid metal matrix composites using stir casting process

In this present study hybrid aluminium metal matrix composites (HAMMC) were prepared by employing stir casting technique at 725 °C. Reinforcements such as Alumina (Al2O3), Silicon carbide (SiC) and Boron carbide (B4C) of 44µ size were reinforced with base aluminium matrix Al-6061 T6 alloy. Wear test, Tensile test, Flexural test and Impact test were done on the hybrid aluminium metal matrix composites as per ASTM standards. It is observed that hybrid composite with 2 wt% each of SiC, Al2O3 and B4C has high tensile strength and wear strength. Composite with 6 wt% of B4C has second high tensile strength, hardness and impact strength when compared with rest of the hybrid composites because of its excellent mechanical properties. Porosity of the samples 1 and 2 is less than the value 2.3 which indicates greater uniformity of reinforcements in the matrix. Flexural strength and Hardness was studied and analysed. Morphological study of the hybrid composites was done using Scanning Electron Microscope (SEM) observed minimal cracks on the surface of the samples due to wear test.

Study on Dry Sliding Wear and Friction Behaviour of Al7068/Si3N4/BN Hybrid Composites.

Hybrid aluminium metal matrix composites have the potential to replace single reinforced aluminium metal matrix composites due to improved properties. Moreover, tribological performance is critical for these composites, as they have extensive application areas, such as the automotive, aerospace, marine and defence industries. The present work aims to establish the tribological characteristics of Al7068/Si3N4/BN hybrid metal matrix composites prepared by stir casting route and studied using a pin-on-disc apparatus under dry sliding conditions. The hybrid composite samples were prepared at various weight percentages (0, 5, 10) of Si3N4 and BN particles. To investigate the tribological performance of the prepared composites, the wear experiments were conducted by varying the load (20, 40 and 60 N), sliding velocity (1.5, 2.5 and 3.5 m/s) and sliding distance (500, 1000 and 1500 m). Wear experimental runs were carried out based on the plan of experiments proposed by Taguchi. The minimum wear rate was found with the composite material reinforced with 10 wt. % of Si3N4 and 5 wt. % of BN. Analysis of Variance (ANOVA) was employed to analyse the effect of process parameters on wear rate and coefficient of friction (COF). The ANOVA test revealed that the weight fraction of Si3N4 has more of a contribution percentage (36.60%) on wear rate, and load has more of a contribution percentage (29.73%) on COF. The worn-out surface of the wear test specimens was studied using its corresponding SEM micrograph and correlated with the dry sliding wear experiment results.

Development & Fabrication of AL-3Mg Based SiC & Gr. Hybrid Metal Matrix Composite by Stir Casting Method

The congregation of ceramic particulates in Aluminum hybrid metal matrix composites induces a greater significance in marine and automotive engineering applications because of its strength to weight ratio, good anti-corrosive properties, and high-temperature resistance. The research work focuses on the fabrication of hybrid metal matrix composite with influences of hard ceramic particulates like silicon carbide and dispersoid of graphite in Al-3Mg matrix material, and tribology behavior routed through the liquid metallurgical vortex method. The characterizations of conglomerate like, tensile properties, hardness, compression tests were investigated. The wear resistance increases with assorted graphite compositions. Microstructural examination shows the dispersoids of graphite and silicon carbides are uniformly distributed. The test results of Al-3Mg conglomerates reveal that tensile and hardness properties were enhanced with the addition of Gr. & SiC, as silicon carbide being a harder constituent mixed with a ductile matrix.

Influence of B4C and industrial waste fly ash reinforcement particles on the micro structural characteristics and mechanical behavior of aluminium (Al–Mg–Si-T6) hybrid metal matrix composite

The expectations over composite materials have been increased especially in automotive and aerospace applications due to its high strength to weight ratio and good mechanical properties. Here, we aim to fabricate a hybrid composite of high strength and low density for automotive application to suits the above needs. In this investigation, the heat-treated aluminum alloy Al–Mg–Si-T6 was initially reinforced with industrial waste fly ash particles at five different weight fractions of 0%, 5%, 10%, 15% and 20%, respectively by stir casting process. The mechanical properties such as tensile strength, compression strength, hardness and density were tested, and microstructure of the composite was evaluated to explain the mechanical properties evolution. From the results, it was concluded that the composite with 10% fly ash shows enhanced at maximum the properties when compared to others. Then, the Al–Mg–Si-T6 – 5% fly ash was further reinforced with boron carbide particles by using three different fractions of 2.5%, 5% and 7.5%, respectively by stir casting process. The microstructural analysis, Scanning Electron Microscope analysis (SEM) and Energy Dispersive X-ray Spectroscopy analysis (EDS) were carried out for the casted samples to evaluate interfacial bonding, agglomeration, clustering and void formation in the hybrid composite samples. The casted samples were also tested for mechanical properties such as tensile strength, compression strength, hardness and density. It reveals that the optimal combination of 10% reinforcement (5% fly ash and 5% boron carbide) shows 18.7% higher tensile strength, 11.3% higher hardness and 38.6% higher compression when compared with the unreinforced Al–Mg–Si-T6 heat treated alloy. It is expected that the present hybrid metal matrix composites can be adopted for the fabrication of drive shaft in race cars.

Machinability studies on hybrid nano-SiC and nano-ZrO2 reinforced aluminium hybrid composite by wire-cut electrical discharge machining

This paper deals about the optimization and modelling of Wire cut Electric Discharge Machining factors such as pulse OFF-Time (Toff), gap voltage (Vg) and pulse ON-Time (Ton) during machining nano- silicon carbide (nSiC) and nano-zirconium oxide/zirconia (nZrO2) reinforced in Al6061 aluminium alloy matrix. Nanomaterial is synthesis in the planetary high energy ball milling and the hybrid aluminium metal matrix composite (HAMMC) was fabricated by using the stir casting technique. For performing machinability studies on the cast composite. To design the experiments, Response Surface Methodology (RSM) based central composite design (CCD) with face-centred approach is implemented. To optimize input conditions, kerf width and surface roughness were analysed. To determine the suitability of the developed model, Analysis of Variance (ANOVA) is applied and to model the process factors regression analysis is carried out. It is observed from the results that, kerf width decreases when Toff increases and increases with increase in Ton and Vg. A decreasing trend of surface roughness is observed with increasing trend of Vg and surface roughness increase with increase in Ton increases.

Development and characterization of multiwalled carbon nanotube-reinforced microwave sintered hybrid aluminum metal matrix composites: An experimental investigation on mechanical and tribological performances

Nowadays, scientists and engineers are coming together enthusiastically to develop superior lightweight materials for tribological applications, such as hybrid aluminum metal matrix composites for the internal combustion engine components. In the present study, hybrid aluminum metal matrix composite has been fabricated with A390 (Al–Si) as the matrix material and SiC (15 wt%) and multiwalled carbon nanotube (0.5 wt%, 1.5 wt%, and 2.5 wt%) as hybrid reinforcements, by following the microwave sintering route (2.45 GHz, 900 W). Microstructure and porosity of fabricated hybrid aluminum metal matrix composite has been characterized using micrographs of the scanning electron microscope and optical microscope. This is followed by the Vickers hardness characterization and composition analysis by X-ray diffraction and Raman spectroscopy. Thereafter, a comprehensive tribological investigation is carried out for A390, Al + 15% SiC, Al + 15% SiC + 0.5% MWCNT, Al + 15% SiC + 1.5% MWCNT, and Al + 15% SiC + 2.5% MWCNT. The present study reveals that the addition of multiwalled carbon nanotube (MWCNT) in microwave sintered aluminum metal matrix composite has a significant effect on wear resistance and frictional response.

Optimizing the ultrasonication effect in stir-casting process of aluminum hybrid composite using desirability function approach and artificial neural network

The ultrasonic-assisted stir-casting technique improves the uniform dispersion of nano-reinforcements in aluminum hybrid metal matrix composites. In the present study, the process parameters of the ultrasonic-assisted stir-casting method, such as ultrasonic vibration time, and depth of ultrasonic vibration along with the speed of mechanical stirrer, are optimized on A356 hybrid composite material optimally reinforced with aluminum nitride, multiwalled carbon nanotubes, graphite particles, and aluminum metal powder using the desirability function approach. The process parameters are optimized against the response factors such as porosity, ultimate tensile strength, and wear rate of the composites. The optimum combination of input factors is identified as stirring speed (600 r/min), ultrasonic vibration time (2 min), and depth of ultrasonic vibration (40 mm) among the selected range. The corresponding output response values are found to be porosity (1.4%), ultimate tensile strength (247 MPa), and wear rate (0.0013 mm3/min). The ANOVA results have revealed that depth of ultrasonic vibration showed significant contribution among the input factors. An artificial neural network model is developed and validated for the given set of experimental data.

A study on tribological evaluation of hybrid aluminium metal matrix for thermal application

Abstract This research aims to examine HAMC’s tribology’s performance-[Hybrid Aluminium metal matrix composites] reinforced with Silicon carbide, Nickel & Graphite at different temperature conditions for thermal applications. This is highly significant for applications with high-temperature. The HAMCs were developed by stir casting method by reinforcing particles like SiC (5% & 10%) and Ni.-Gr. (2% fixed) into LM26 aluminium alloy. The wear rate and friction coefficient of the material is analyzed through pin-on-disc apparatus. The parameter impact on applied load, wt%, sliding distance, and the temperature is analyzed using an L9 orthogonal array. COF and wear loss of the proposed HAMC is determined using the ANOVA method. The Tribological property of HAMC is mainly influenced by applied load and temperature. The varying hybrid % controls the COF and wear loss. The SEM analysis is used to assist the performance of the worn surface.

Study on Tribological Properities Of Aluminium Hybrid Composities For Automotive Applications

Aluminium metal matrix hybrid composites are refined through stir casting method. Aluminium A-356 is reinforced with ceramic particles like Zirconium diboride (ZrB2) and Tungsten carbide (WC) in varying weight percentages (ie. 2.5% and 5%). (The purpose is to compare the properties like of the different composite specimens). This work aims to develop aluminium metal hybrid composites for automotive applications and studying its wear characteristics. Due to low density, aluminium metal was chosen. Of the several alloys, A356 is chosen as the matrix material since it has good castability and good strength and low cost. Among the reinforcements, WC possess high durability and good wear support. Stir casting technique embraced to fabricate specimens. Then the casted specimens were machined and subjected to wear testing to examine the tribological properties through Pin on disc tribometer apparatus. The pin specimens were tested under different sliding conditions. Then the specimens were investigate under the (SEM) which is Scanning electron microscope to study the wear structure that occurred in sliding condition.

Investigation on mechanical properties of aluminium alloy A356 by reinforcing with TiB2 & WC composites

In this project, Aluminium metal matrix hybrid composites are processed through stir casting methodology. A356 is reinforced with ceramic particle-like Titanium diboride (TiB2) and Tungsten carbide (WC) in varying weight percentages of 92.5% A356 and TiB2 5% WC 2.5% of Sample 1, A356 90% TiB2 5% WC 5% of Sample 2, A356 100% of Sample 3 through stir casting technique. Under the Vickers hardness test, the Sample consisting of 90% A356 + 5% TiB2+ 5% WC exhibited superior results. Under the Tensile test, the Sample of 90% A356 + 5% TiB2 + 5% WC exhibited higher tensile strength when compared with the remaining two Samples. It is because the ceramic reinforcement particulates are harder than the A356 matrix material. Then the fractured Samples were examined under SEM and fracture mechanisms were studied.

Metallurgical and wear study of MWCNT-reinforced h-AMMC fabricated through microwave hybrid sintering

Abstract The present work deals with the outcomes of a novel approach for developing a multi-walled carbon nanotube-reinforced hybrid aluminium metal matrix composite. Microwave hybrid sintering in combination with cold compaction of the powder metallurgy route was followed for the fabrication of composites. Microwave hybrid sintering was carried out using a microwave oven operating at 2.45 GHz frequency and 900 W power. For this purpose, Al5083 was used as the matrix material, and silicon carbide (15 wt.%) and multi-walled carbon nanotubes (0.5 wt.%) the reinforcements. The fabricated composites were then characterized by hardness, microstructure, and porosity. An investigation on the wear resistance of the base alloy and the conventional and microwave sintered composites followed this. The findings of the present study reveal the fact that the addition of carbon nano-tubes in the composite and the use of microwave energy over conventional sintering have a significant effect on the property enhancement of the developed hybrid composite.