Aluminium Hybrid Metal Matrix Composites Research Articles

WITHDRAWN: Evaluation on abrasive water jet machined AA7075 aluminium based composites

The present study, based on the preparation of aluminium hybrid metal matrix composite using a stir casting process. Al 2 O 3 and SiC as reinforcements to fabricate Al7075 HMMC's by using the stir casting technique. This composite is machined using an abrasive water jet machine based on the Taguchi L18 Orthogonal Array approach. The inputs that are taken to machine composite are Abrasive flow rate, Pressure, Stand of distance (SOD), Nozzle diameter. The obtained outputs are Average kerf width and Material Removal Rate (MRR) and the highest average kerf width is obtained at 18 Run with pressure 360 MPa, lowest avg kerf width is obtained at 16 Run with the pressure of 300 MPa. The highest MRR is obtained at 18 runs SOD is 2.5 mm and the lowest is obtained at 1 run SOD is 2 mm. It shows that MRR increases with increases of Stand of distance in mm.

Selection of suitable metal matrix composite for design application using MCDM approach

Metal matrix composite is widely accepted in many new engineering applications due to its superior design properties. Among all, MMC based on aluminium adds an advantage of lightweight to strength ratio. Aluminium hybrid metal matrix composite is used in many structural applications such as aerospace, automobile, space, etc. In AHMMC matrix material and reinforcement material together play a vital role to achieve the desired mechanical and physical properties. Therefore, to achieve optimum results aluminium hybrid metal matrix composite (AHMMCs) needs to fabricate with the optimum matrix material. Fuzzy AHP and Topsis are one of the tools among many MCDMS for solving complex problems. In this research, parameters are selected such as tensile strength, hardness, density and cost and optimize it for fabricating AHMMCs using MCDM. The hybrid matrix material is 5XXX of aluminium alloys. Using Fuzzy AHP and Topsis a pairwise comparison is carried out for all criteria for fabricating a suitable matrix. After analysing it has been found that AA5083 is the suitable matrix materials for achieving desired property among all aluminium hybrid metal matrix composite.

Effect of dry sliding wear parameters on the tribological behavior of aluminum hybrid metal matrix composites

Abstract The influence of different weight percentages of Tungsten Carbide (WC) and Graphite (Gr) in an Aluminium LM6 Alloy (Al-Si12) was investigated for the Tribological aspects. Aluminium is known to possess poor tribological characteristics – this research work primarily focuses on how it’s possible to enhance the tribological characteristics of aluminium by incorporating the reinforcements Tungsten Carbide and Graphite. Tungsten Carbide is an extremely hard compound with a Vickers hardness number of about 2600. On the other hand, Graphite and graphite powder, which are highly refractory, are valued in industrial applications for their self-lubricating and dry lubricating properties. We performed standardized tests on the aluminium hybrid metal matrix composite specimens and determined the exact weight percentage of reinforcement for optimum wear properties as well as for tensile strength. The Pin-on-Disc sliding wear test was performed under the action of different contact loads following the ASTM G99 Standard. We then performed statistical analysis by Taguchi’s Technique and Analysis of Variance (ANOVA) to determine the most dominating factor that influences Wear Rate for the optimum weight percentage of reinforcement. By enhancing wear resistance of Aluminium, the material can be used in applications where low weight, high strength and corrosion resistance are key factors in addition to high wear resistance.

A fuzzy-AHP and TOPSIS based approach for selection of metal matrix composite used in design and structural applications

Composites are widely accepted in design, structural and automotive applications but metal matrix composite have an edge due to its excellent design properties. Various Metal Matrix Composite (MMCs) such as Titanium, Magnesium based, are widely used but, MMCs based on aluminium provide light weight to strength ratio and of course due to this novel property it is widely accepted in automobile and space industries. In AHMMC both matrix and reinforcement material play a significant role to achieve required design properties. Therefore, to obtain better results aluminium hybrid metal matrix composite (AHMMCs) are required to fabricate with best quantity of matrix material. Fuzzy AHP and TOPSIS are the MCDM tool which are widely used for complex problem solving. In this paper, parameter such as tensile strength, hardness, melting point, density and cost are selected and optimize using MCDM. The hybrid matrix material is 7XXX series of aluminium alloys. Using Fuzzy AHP and TOPSIS, all criteria are comparing among them pairwise for fabricating a suitable matrix. After obtain proper results, it has been found that AA7075 are considerable and appropriate matrix material.

Retracted] Synthesis, Mechanical, and Tribological Performance Analysis of Stir‐Casted AA7079: ZrO2 + Si3N4 Hybrid Composites by Taguchi Route

Currently, the aluminum alloys are utilized more in level of all industries for different applications; furthermore, industries need high‐strength alloys for making innovative components. For those reasons, many researchers hope to prepare hybrid aluminum metal matrix composites at various composition levels. In this experimental work, we intended to prepare the hybrid metal matrix composites such as aluminum alloy 7079 with reinforcement of ZrO2 + Si3N4 through stir‐casting process. Major findings of this work, as to optimize the stir‐casting process, can be to continually conduct wear test and evaluate the microhardness of the stir‐casted specimens. Optimization of stir‐casting process parameters is a preliminary work for this research by Taguchi tool. The chosen parameters are % of reinforcement (0%, 4%, 8%, and 12%), agitation speed (450 rpm, 500 rpm, 550 rpm, and 600 rpm), agitation time (15 min, 20 min. 25 min, and 30 min), and molten temperature (700°C, 750°C, 800°C, and 850°C). The prepared stir‐casted materials are tested by wear analysis and microhardness analysis, through Pin‐on‐Disc wear tester and Vickers hardness tester, respectively. Wear parameters are optimized, the minimum wear rate is evaluated, and also the wear worn‐out surfaces are examined through SEM analysis.

Review: Synthesis and characterization of silicon nitride and graphite reinforced aluminium hybrid metal matrix composites

Abstract In the last decade, as demand for high quality materials are increased, the development of lightweight aluminum (Al) also increased especially in aerospace and automotive industries. It has been well known that Al based metal matrix composites (MMCs) offers a very low thermal expansion coefficient, high specific strengths, wear and heat resistance as compared to conventional Al alloys. In order to combine all these properties, MMCs have become a very attractive method for various industrial applications. The interest in Silicon Nitride (Si3N4) and Graphene as reinforcements for aluminum (Al7475) has been growing considerably. Efforts have been largely focused on investigating their contribution to the enhancement of the mechanical performance of the composites. In this present research paper emphasis, the effect of Silicon Nitride (Si3N4) and Graphene content on the Physical properties of the composites like Wear Test, Hardness Test & Microstructure Testing was investigated.

Implications on the influence of mica on the mechanical properties of cast hybrid (Al+10%B4C+Mica) metal matrix composite

Hybrid aluminum metal matrix composites have prominence than conventional metals. Aluminum is used as base metal in many metal matrix composites, as it is widely used in industries and researches. The low density that is obtained after alloying is the major advantages of hybrid composite. The present study involves synthesis of Al6061/B4C/Mica hybrid metal matrix composite using stir casting method by mica particles as 3, 4, 5, 6wt.%, while maintaining 10wt.% of boron carbide. The best mechanical properties are reported by inclusion of 3wt.% of mica, while further addition of mica more than 3wt.% pulls down the mechanical properties and hence not sensible. The early-stage of strain hardening, and high tensile strength-yield strength ratio is observed, which concludes the fabricated hybrid aluminum composite is well suitable for automotive-related sheet forming operations.

Investigation and optimization of friction stir welding process parameters of stir cast AA6082/ZrO2/B4C composites

Abstract In the present investigation, aluminium-based alloy (AA6082) is stir-casted with 3 % ZrO2 and 5 % B4C reinforcement particulates to fabricate Aluminium Metal Matrix Hybrid Composites (AMMHCs) which are further friction-stir welded at different welding conditions to develop a welded joint with optimum ultimate tensile strength (UTS) and microhardness. This newly developed AMMHC will find its specific application as bulkhead partitions in the hull of a ship due to its excellent properties, such as lower weight, higher specific strength, superior resistance to wear, and lower thermal expansion coefficient than that of AA6061 and AA5083 composites. The friction-welded butt joints performance of AA6082/3%ZrO2/5%B4C is generally determined by varying the FSW process parameters such as tool rotational speed (TRS), welding speed (WS), axial load (AL), tool tilt angle (TTA), tool pin profile (TPP), shoulder diameter (SD), etc. In the present work, the empirical relationships are established between parameters highly influencing FSW process (TRS, WS, and AL) and their responses (UTS and weld nugget microhardness (WNH)). The desirability approach is employed for predicting the optimal UTS and WNH. The corresponding values of input process parameters are TRS of 1030.95 rpm, WS of 38.5 mm/min, and AL of 5.88 kN. The calculated UTS and WNH for the present investigation are 239.98 MPa and 94.2 HV, respectively, and these values are consistent with the results of validation experiments.

Tribological behavior of aluminum and magnesium-based hybrid metal matrix composites: A state-of-art review

Abstract Global issues related to the scarcity of natural (or monolithic) materials need extensive research in the field of materials science. Aluminum (Al) and magnesium (Mg) based hybrid metal matrix composites (HMMCs) having properties like a light in weight, better stiffness, hardness, strength to weight ratio, and wear resistance are the best alternatives and has fulfilled the existing problems in all aspects of engineering and medical applications so far. ‘Tribology’ is an important mode which deals with the inter-linked study of friction, wear and lubrication of interacting surfaces in relative motion to examine the tribological properties of fabricated composites. This article provides all the significant attributes of tribological behavior of HMMCs, based on the critical review of the existing literature, stir casting found to be the best fabrication technique, and pin on disc tribometer for the wear analysis is highly recommended for Al and Mg-based HMMCs.

Prediction of mechanical properties of hybrid aluminium composites

Abstract The modern manufacturing industry needs highly characterized materials for a variety of applications, which leads the material researchers were focuses on hybridization in the aluminium metal matrix with various reinforcements. In this research investigates the mechanical properties of aluminium alloy Al 6061 with the reinforcement of silicon carbide and eggshell particles in various proportionalities. The stir-casting method is used to prepare the Al 6061 based hybrid aluminium composite material by varying the weight percentage of both silicon carbide and eggshell particles; the reinforcement material of eggshell increases the hardness of the material with least expensive. The Al 6061 based hybrid aluminium metal matrix test specimens were fabricated as per ASTM standards in the water jet machining process. The Al 6061 based hybrid aluminium metal matrix composite was characterized by various mechanical tests such as tensile load, tensile strength, percentage of elongation, yield load, yield strength, compressive strength, impact strength, impact energy and Rockwell hardness. In the tests reveals that performance of the pure aluminium alloy Al 6061 considerably lower value in impact tests. The 8 wt% of silicon carbide with 4 wt% eggshell particles reinforce hybrid aluminium metal matrix composite is performed very well in the tensile, compressive and hardness tests.

Recent developments in hybrid aluminium metal matrix composites: A review

This work is done by reviewing the experiments and studies done by various researchers, organizations and institutions on development and mechanical characterization of the hybrid Aluminium metal matrix composites. Metal Matrix Composites or (MMCs) has developed an ever growing interest in recent times for future applications in the aerospace as well as the automotive industries due to their superior strength to weight ratio and higher temperature resistance. MMCs are created by adding a reinforcement material into a metal matrix. Aluminium based metal matrix composites are widely considered one of the best engineering structural elements because of the fact that the possess high strength, high stiffness, high thermal stability, wear resistance and many benefits fitting to its purpose and also varies with the nature and amount of reinforcements used. The work is carried out referring various research papers, publications and educational articles by various authors. The various reinforced aluminium metal matrix composites (AMMCs) reviewed and the development techniques, mechanical property enhancements are put to the analysis. Major reinforcements include silicon carbide, boron carbide, fly ash, tungsten etc while several researches focused on the development of sustainable products by non-conventional and hybrid reinforcements.

Experimental analysis on wire spark erosion machining of aluminium hybrid metal matrix composites by Taguchi approach

AA 2024 an aluminium alloy, which is most commonly employed for various engineering fields, especially automobile components and aircraft structural applications. The materials added to increase the desired properties are called as reinforcement materials such as Al2O3 and BN, abrasive and leads to more wear on tool and poor quality in machining surface. Wire Electrical Discharge Machining (WEDM) is an advanced machining process mainly employed for machining of hard materials and also especially used for making complex shapes in any electrically conductive hard material. In this present study, an experimental analysis has been done on WEDM of AA 2024 based Hybrid Metal Matrix Composites (HMMC). Pulse on time ‘Pon’ (µs), Pulse off time ‘Poff’ (µs), and peak current (A) are considered as input process parameters in this present analysis. Material Removal Rate (MRR) and Surface Roughness (SR) are considered as preferred performance measures that are need to be optimized. Taguchi’s methodology has been implemented for designing and analyzing the experimental runs. An L27 Orthogonal Array (OA) has been employed for conducting the experimental runs. The effect of process parameters on desired outputs such as MRR and SR were investigated by Taguchi’s analysis. Multiple regression analysis has been adopted for correlating the relationship between the selected input and output process variables.

Analysis on sliding wear behavior of Al + B4C+ mica hybrid metal matrix composites

In this investigation, wear behavior of hybrid aluminum metal matrix composites (HMMCs) fabricated by stir casting technique is carried out. Boron carbide and Mica particles are added. The Mica percentage varies from 3–5% in steps of 1% with a constant reinforcement quantity of 10% boron carbide. The dry sliding wear experiments are explored on a pin on disc tribometer. The process variables considered for the study are: Mica mass fraction, sliding speed, load and sliding time, and the response analyzed is wear loss. Box-Behnken design is used for conducting the experiments. The result shown proves that 3% of Mica particle inclusion reduces the wear due to the increase in density. Further increase of mica does not improve the wear resistance. ANOVA results indicate that load and % of Mica are the profoundly influencing parameters. The pin surface is analyzed by using a Scanning Electron Microscope.

Study of mechanical and metallurgical characterization of correlated aluminium hybrid metal matrix composites

This work investigates the mechanical and metallurgical characterization of correlated Aluminium Hybrid Metal Matrix Composites (AHMMC’s) in which aluminium is used as matrix with two reinforcement materials embedded and as it gained enhanced properties over virgin material. The Aluminium alloy 6061 was taken as the base material with varying reinforcement of x weight percentages (2, 4, 6 wt%) of Silicon Carbide (SiC) and fixed value of 3 wt% Zirconium Di-Oxide (ZrO2) for this present research work. The AHMMC’s were fabricated by stir casting technique at a stirrer speed of 350 rpm for 5 min with the temperature of the melt being 740 °C and the prepared melt was poured immediately in the mould. The mechanical test results exposed that hardness, tensile strength, compressive strength, and impact energy increases with inflating the reinforcement weight percentages due to the presence of harder reinforcement particles. The metallurgical microscope results exposed that there was a good intermolecular bonding between the alloy and reinforcements is provided by its increased properties of the AHMMC’s. X- Ray Diffraction (XRD) and Energy Dispersive x-ray Spectroscopy (EDAX) opinion confirms the presence of reinforcement particles in the fabricated AHMMC’s and also conforms the presence of reinforcements and other inter metallic compound phases in the hybrid composites. It is also noted that higher AA6061 with 6 wt%SiC and 3 wt%ZrO2hybrid composites had better properties than other combinations and this AHMMC’sis recommended for automobile component replacement.

A study surface integrity of aluminum hybrid composites during milling operation

In this article, the effects of machining parameters on surface roughness and cutting force on hybrid aluminum metal matrix composites were investigated. Three reinforced composites were made by adding three compositions of SiC and boron carbide (B4C) by stir-casting method. Machining was performed on fabricated composite material using milling operation with different cutting parameters. The roughness of the machined surfaces was determined by the Mitutoyo Surftest SV-2100 Column-type surface roughness tester. Cutting forces in the y-direction was measured. Further, the results were optimized and analyzed by Taguchi method. The obtained experimental results demonstrate that the most important machining parameters are feed rate, cutting speed and depth of cut on surface roughness, and cutting force.

Hybrid particles dispersion strengthened aluminum metal matrix composite processed by stir casting

Segregation and agglomeration are the commonly reported problems in fabrication of aluminum metal matrix composites (AMCs) by stir casting route. In this study, an attempt is made to fabricate homogeneously dispersed hybrid AMC by tuning the settling velocity of the particles. Settling velocity of the particles was found by using MATLAB software. The AMCs with 5 wt% reinforcement (mixture of TiB 2 , B 4 C, Al 2 O 3 and SiC in equal amount) was prepared by gravity stir casting. Uniform hardness of 51 HV was observed at bottom and top section of the casting which indicates homogeneous distribution of the particles in the hybrid metal matrix composite.

Dry sliding wear simulation of hybrid aluminum metal matrix composites

The main objective of this work is to find the wear rate using Archard’s model in a finite element tool. The finite element model for the contact analysis of the disc and pin is built using ANSYS workbench. The material for the disc used is stainless steel and the pin material used is an aluminum alloy and its composites. A 3D surface-to-surface body-ground connection and revolute type element was utilized, under various circumstances, to display the behavior of the contact surfaces. The results of the analysis are used to compare with the experimental results, and the ANSYS data is used to analyze the process parameters. From the comparison of results, it is observed that the analytical results support the experimental results. The ANOVA analysis demonstrates that the wear rate of the material was mainly influenced by load and sliding distance than the composition of the material.

Prediction of wear strength of squeeze cast aluminium hybrid metal matrix composites using response surface methodology

This research work deals with the investigation on the study of wear behaviour of squeeze cast aluminium hybrid metal matrix composites. The reinforcement elements are zirconium oxide (ZrO2) and graphite (C).The aluminium hybrid metal matrix composites (MMCs) were produced by squeeze casting method for 6% of ZrO2 and 3% of C by varying the squeeze pressure, molte metal temperature and die preheating temperature. Dry sliding wear test was performed by using pin-on-disc to study the tribological behavior of aluminium hybrid MMCs. Response surface methodology was used to predict the wear strength of the squeeze cast aluminium hybrid metal matrix composites. Results shows that for 150 MPa squeeze pressure, 825 °C and at 250 °C the aluminiumhybrid MMCs recorded minimum wear rate. Squeeze pressure emerges as a influential parameter among the others.

Experimental investigation on the effect of tool rotation speed on stir cast friction stir welded aluminium hybrid metal matrix composite

Conventional fusion welding is limited to certain grades of alloys and materials. Solid-state joining method overcomes the disadvantages of fusion welding process. Friction stir welding (FSW) a solid state joining process, is extensively used to weld aluminium alloys for aerospace, marine automotive and numerous other applications of profitable significance. FSW uses a non-consumable rotating tool. Aluminium 6063 (AA6063) plays a vital role in the industrial metallurgy with magnesium and silicon as the alloying elements. AA6063 shows good mechanical properties and microstructural changes, when combined with reinforcements. In this study aluminium hybrid metal matrix composites (MMCs) is fabricated through stir casting process by varying the Zirconium oxide (ZrO2) (2%, 4% and 6%) and keeping the percentage of graphite (C) as constant (3%). The fabricated specimen is subjected to FSW technique by varying the tool rotation speed. Microstructure reveals that invariably all the specimens displayed recrystallized, uniformly distributed fine grained particles due to sufficient heat distribution. The maximum microhardness value of 79.18 HV was recorded for the joint made using the tool rotational speed of 1100 rpm for 6% ZrO2 and 3% C and a maximum tensile strength of 123.67 MPa for the same specimen.

Experimental investigation of aluminium hybrid metal matrix composites processed through squeeze casting process

In this experimental investigation, aluminium hybrid metal matrix composites (HMMCs) is fabricated through stir cum squeeze casting process. Zirconium Di-oxide (ZrO2) and graphite (C) is used as reinforcement. ZrO2 ceramic particles are used to increase the tensile strength of aluminium. Whereas C improves heat transfer properties that increases reliability of the product. Aluminium HMMCs used in this investigation with the following weight proportions − 100% AA6063; 95% AA6063, 3% C, 2% ZrO2; 91% AA6063, 3% C, 4% ZrO2; 86% AA6063, 3% C, 6% ZrO2 were fabricated using squeeze casting process. Microstructural study and mechanical behavior are characterized for different percentage of reinforcement on the squeeze cast metal matrix composite specimen fabricated as per ASTM standard. Microstructural study reveals the uniform and fine grain distribution of ZrO2 and C particles in the AA6063 HMMCs which in turn increases the tensile strength and hardness.