Aluminium Hybrid Metal Matrix Research Articles

A hybrid GRA-PCA-TOPSIS Technique Optimization of EDD Process Parameter on Drilling of AL8011/B4C/aloevera composites

A class of cutting-edge materials called hybrid aluminum metal matrix composites has been produced for applications such as the automobile, aerospace, and electronics industry and where weight and strengths are crucial factors. In the present research work, AA8011 composite reinforced with boron carbide particles and green aloevera has been fabricated using an economical stir casting process. In this 1% to 3% of boron carbide and 1% to 2% aloevera were used to fabricate the three different combinations of composites. The electrical discharge drilling process variables such as discharge current, pulse-on time, pulse-off time, and dielectric fluid pressure are investigated using the tubular copper electrode on drilling of hybrid composites. Performance aspects including drilling rate, roundness error, taper angle, and electrode wear rate have been analyzed, and the effect of process variables with the response surface methodology–central composite experimental design. The process parameters during the drilling of composites were optimized using a novel multi-criteria decision-making technique called the hybrid grey relational analysis–pulse component analysis–technique for order of preference by similarity to ideal solution method in order to maximize the drilling rate while concurrently minimizing other aspects. The optimum conditions were reached using the hybrid optimization method and a 1.5 mm tubular copper electrode with an input current of 9 Ampere , pulse on time 25 [Formula: see text]s, pulse off time 12 [Formula: see text]s, and pressure 60 kg/cm2. In comparison to the initial settings, the optimal condition shows a 25% faster drilling rate, with a 23% better roundness value, 14% lesser taper angle, and 7% lesser electrode wear rate.

Tribological Behavior of Hybrid Aluminum-TiB2 Metal Matrix Composites for Brake Rotor Applications

This research investigates the feasibility of hybrid aluminum metal matrix composites (MMC) incorporating TiB2 particles for brake rotor applications. The composites were produced by incorporating both in-situ, submicron-sized TiB2 particles and regular micron-sized TiB2 powders via stir and squeeze casting techniques into a A206 aluminum alloy matrix. Systematic adjustments in the fractions of in-situ and ex-situ TiB2 particles were conducted to evaluate their impact on wear behavior and mechanisms. Combination of both particle types allowed composites with up to 10 vol% of reinforcements. Composites with higher proportions of ex-situ particles demonstrated increased wear resistance compared to those solely composed of in-situ particles, control specimens without TiB2, and conventional cast iron counterparts. The lowest wear rate for the hybrid composites sliding against phenolic brake pads was 1.1 x 10-5 mm3/Nm, signifying a 3-fold reduction relative to cast iron sliding against the same pads. Wear analysis elucidated distinctive mechanisms within the hybrid composites, characterized by mild fragmented abrasive wear, adhesive wear, and plastic deformation, accompanied by the formation of an intermixed tribo-oxide layer.

Comparative tribological study of the material intended for a lightweight HAMNC brake rotor sliding against NAO brake pad material

Abstract The present work studies the lightweight Hybrid Aluminium Metal Matrix Nanocomposite (HAMNC) for brake rotor application. The novel HAMNC brake rotor material is fabricated by reinforcing 1 wt. % nano Boron carbide (nB4C) and 0.75 wt.% nano Titanium dioxide (nTiO2) employing ultrasonic-squeeze-assisted stir-casting process. The developed HAMNC and a commercial Gray Cast Iron (GCI) brake rotor material was subjected to density, hardness, thermal, corrosion, and tribological studies. The results indicated that the HAMNC brake rotor material is 60% lighter and extremely corrosive resistant compared with GCI material. Also, the dry sliding wear study done using Non Asbestos Organic (NAO) commercial brake pad as the pin material exhibited that the HAMNC brake rotor material possessed a higher wear-resistant behavior compared to GCI.

Investigation of wear characteristics of granite dust & coconut shell ash reinforced aluminum metal matrix composite using design of experiment

Recently, one of the most important issue faced by all nations is a waste management. Therefore, it is essential to search for creative solutions to waste reduction, reuse, and recycling. This can be accomplished by adding waste materials to composite materials as a reinforcements. Reusing waste materials enhances the characteristics of existing materials, while also helping the environment by solving the disposal problem. The main aim of this paper is to study the wear characteristics of hybrid aluminum metal matrix composite reinforced with coconut shell ash (CSA) and granite dust. The hybrid composite samples were manufactured using stir casting by reinforcing CSA (ranging from 0 wt% to 12 wt%) and granite dust (maintained at 2 wt%) in Al6061 alloy. SEM and EDAX analysis were performed to investigate the microstructure and elemental composition. The wear characteristics of the hybrid composites were determined via pin-on-disc tests. Finally, the Taguchi design of experiment was performed on the specimen having the best wear characteristics by selecting the L27 orthogonal array and identified the influence of process variables on the wear rate. The results of the pin-on-disc experiment showed that the wear rate decreased with increasing CSA%. The hybrid composite composed of 02 wt% granite dust, & 12 wt% CSA indicates a lower wear rate (56.25%) as compared to the matrix alloy. The Taguchi analysis prooved that the sliding distance has a greater impact on the wear rate than the other parameters. This material can be a superior substitute where high wear resistance is required.

Application of integrated entropy-COPRAS and ANN approaches for maximizing wire EDM machinability attributes of Al6082-T6/GNP/TiB2 composites

Wire Electrical Discharge Machining (WEDM) utilizes electrical sparks to cut conductive materials precisely. It employs a thin, electrically charged wire to erode the material, creating complex shapes with high accuracy, tight tolerance, and minimal material waste. The current study investigates the effect of WEDM process parameters on the various output properties of machining a hybrid Aluminium metal matrix nanocomposite (HAMMNC). A series of experiments were conducted on a composite constructed using Taguchi’s standard L18 Orthogonal Array (OA) design. The acquired responses of Material-Removal-Rate (MRR), Surface-Roughness (SR), and Kerf-Width (KfW) were optimized using integrated Entropy-COPRAS and artificial neural network (ANN) algorithms respectively. The relative significance ( Qi )values obtained for the alternatives are analyzed with the Taguchi method. The outcomes showed that the optimal setting of WEDM process variables is achieved at Servo Voltage: high volts; Pulse-on-time: 60 μs; Pulse-off-time: 16 μs; Peak Current: 6 Amp; Variable frequency: 18 Hz; Speed: 50 RPM; Sim Speed: 30 RPM respectively. The models developed from ANN were adequate and accurate from the results of error histogram and regression plots and they are best suited for the prophecy of future responses. The surface morphology studies confirmed the appearance of pockmarks, voids, and globules of debris on the Wire EDMed surfaces.

Process parameters optimization of EDM for hybrid aluminum MMC using hybrid optimization technique

This study explores how machining parameters affect Surface Roughness (SR), Tool Wear Rate (TWR), and Material Removal Rate (MRR) during Electrical Discharge Machining (EDM) of a hybrid aluminum metal matrix composite (AMMC). The composite includes 6 % Silicon carbide (SiC) and 6 % Boron carbide (B4C) in an Aluminum 7075 (Al7075) matrix. A combined optimization approach was used to balance these factors, evaluating Pulse ON time, Current, Voltage, and Pulse OFF time. Response Surface Methodology (RSM) optimized single responses, while multi-response optimization employed a hybrid method combining the Entropy Weight Method (EWM), Taguchi approach, TOPSIS, and GRA. Analysis of Variance (ANOVA) assessed parameter significance, revealing substantial impacts on SR, MRR, and EWR. Based on TOPSIS and GRA, optimized parameters achieved a desirable balance: high MRR (0.4172, 0.5240 mm³/min), minimal EWR (0.0068, 0.0103 mm³/min), and acceptable SR (10.3877, 9.1924 μm) based on EWM-weighted priorities. Confirmation experiments validated a 15 % improvement in the closeness coefficient, and a 16 % improvement in the Grey relational grade, which considers combined SR, MRR, and EWR performance. Scanning Electron Microscope (SEM) analysis of surfaces machined with optimal parameters showed minimal debris, cracks, and no recast layer, indicating high surface integrity. This research enhances EDM optimization for AMMC, achieving efficiency in machining, minimizing tool wear, and meeting surface quality requirements.

An experimental analysis of sugarcane-based hybrid aluminium metal matrix composites through powder metallurgy

An experimental analysis of sugarcane-based hybrid aluminium metal matrix composites through powder metallurgy

A Comparative and Experimental Study of Parametric Influence on Drilling Process of Hybrid AMMC

Abstract: To aim for the highest quality product quality and a high metal removal rate, metal cutting is crucial. The primary obstacle to attaining optimal quality and high production is the short tool life. The hybrid aluminum metal matrix AA 6082, with reinforcement consisting of titanium dioxide (7.5%) and cenosphere (2.5%), was optimized using the Modified Taguchi optimization method for simultaneous minimization and maximization of surface roughness (Ra), machining time, and material removal rate. The surface finish was affected by different types of geometrical precision values of the CNC drilling process parameters in order to both minimize and maximize the responses. The experiments, including call for the machining of hybrid AMMC and the use of an HSS drill bit, will be performed using a CNC with different process parameters. The L16 orthogonal array will be used for the examinations, and each experiment will be run under a distinct set of circumstances, including feed, speed, and pecking. Using the TAGUCHI design, the optimal geometrical and machining parameters were determined from the experimental output responses, and significant influences were discovered for the corresponding specific output responses.

An investigation of machinability in micro-EDM drilling of ZrB2/Fly ash/AA7075 hybrid aluminium metal matrix composite

This work investigates the importance of micro-drilling in Hybrid aluminum metal matrix composites (HAMMCs), particularly for the aerospace and automotive industries. The HAMMCs (AA7075/5% ZrB2/2% fly) ash was fabricated using the ultrasonic assisted stir casting method. Taguchi’s design of experiments is employed to optimize the material removal rate (MRR) and tool wear rate (TWR). Analysis of variance (ANOVA) is then used to determine the significance of the model. The study also utilizes a hybrid artificial neural network-genetic algorithm (ANN-GA) approach to optimize both MRR and TWR. By optimizing machining processes for HAMMCs, manufacturers can achieve high-precision micro holes. The optimal input parameters were found to be a feed rate of 10 μm sec−1, a capacitance of 1 nF, and a voltage of 85 V, achieving the minimum TWR and maximum MRR.

Optimization study of hybrid aluminium metal matrix composite using proposed Taguchi method

Optimization study of hybrid aluminium metal matrix composite using proposed Taguchi method

Synergistic approach to tribological characterization of hybrid aluminum metal matrix composites with ZrB2 and fly ash: Experimental and predictive insights

This research delves into the tribological performance of hybrid aluminum metal matrix composites (HAMMCs) incorporating zirconium diboride (ZrB2) particles and fly ash as reinforcing agents. The study employs a linear reciprocating wear test to investigate the impact of dry sliding wear on these HAMMCs under ambient and elevated temperatures. Wear mechanisms are discerned through field emission scanning electron microscopy. Optimization of wear test parameters, coefficient of friction (COF), and wear rate is achieved using the genetic algorithm. Additionally, artificial neural network (ANN) and multiple linear regression analysis are employed to formulate a predictive model for wear, estimating specific wear rate and COF under various testing conditions. The ANN predictions exhibit a deviation ranging from 0% to 1.39% from the experimental values, indicating the model's effectiveness in understanding and predicting wear behavior in the study of HAMMC.

Experimental Analysis of Polishing of Hybrid Aluminium Metal Matrix Composite Reinforced with SiC, ZrO2, and NiTi Particles Using a Developed Rotary Abrasive Float Polishing System

Experimental Analysis of Polishing of Hybrid Aluminium Metal Matrix Composite Reinforced with SiC, ZrO2, and NiTi Particles Using a Developed Rotary Abrasive Float Polishing System

Advances in hybrid aluminium metal matrix composite produced by stir casting route: A review on applications and fabrication characteristics

The sustained demand for lightweight parts, superior strength, and high-efficiency products has made material researchers interested to study and explore new materials with superior properties. One of the most promising materials for meeting this demand is aluminium metal matrix composite. Due to its tailored properties, the usage of composite is currently increasing in the automotive, aerospace, marine, electronic, defence, domestic, and sports sectors. Simplicity, affordability, and bulk production in the stir casting method have attracted the attention of many researchers across the globe. This paper reviews the need for hybrid aluminium metal matrix composites, various aluminium alloys, and reinforcement materials produced by the stir casting technique. In addition, the applications, morphological, mechanical, and tribological behavior of aluminium hybrid metal matrix composites are discussed. This review will assist materials researchers in selecting the matrix and reinforcements for a specific application of aluminium matrix composites using the stir casting route.

Fabrication and investigation of microstructural, mechanical and wear properties of in situ ZrB2/fly ash/AA7075 hybrid composite

This research explores the microstructural, mechanical and wear characteristics of hybrid aluminum metal matrix composites (HAMMCs). Initially ZrB2 is fabricated by melt reaction and then fly ash incorporated into the aluminum composite melt as secondary reinforcements to fabricate HAMMCs through the ultrasonic agitated stir casting method. Micrographic and phase analysis of the HAMMCs and base alloy is conducted x-ray Diffraction (XRD), and Energy-Dispersive x-ray Spectroscopy (EDS). A wear test was conducted to study the wear properties of alloy and hybrid composite material. The generated wear scar was analyzed using a profilometer to find the wear rate. The tensile strength and hardness of the hybrid aluminum metal matrix composites (HAMMCs) improved remarkably as compared to base alloy. The wear resistance of the fabricated composite also increases on increasing the in situ ZrB2 up to 3 weight fractions.

A critical review on the effect of various sustainable reinforcements on armor grade aluminum alloys

To deflect projectiles with kinetic energy by blunting them upon impact, armor with an exceptionally hard surface is required.In order to absorb and disperse the projectile's kinetic energy, the next material needs to be exceedingly tough and have a high work of fracture; hence, it needs to be metallic. To maximize the strength to weight ratio, it must also be composed of a versatile material, such as ceramic. Thus, the application requires a range of qualities, ranging from ceramic to metallic. Aluminum alloys (AAs) are sought-after materials for a variety of engineering and defense uses owing to their excellent low-temperature characteristics, good specific strength, and acceptable corrosion resistance. The main issues with AAs are poor heat tolerance and wear resistance, which makes them unsuitable for military applications owing to their heavy weight, which can exacerbate the deterioration of mechanical components and impair vehicle maneuverability and speed. This paper offers the possibility of modifying the properties of monolithic aluminum materials by adding reinforcement and replacing conventional particulates with low-cost wastes derived from agriculture and industry, which are rich in oxides and other debris, such as fly ash (FA) and rice husk ash (RHA). The result is the development of hybrid aluminum metal matrix composites, or HAMMCs, which combine the best features of both metals with a variety of sustainable inorganic and organic reinforcements that can enhance the mechanical and tribological performances by 40–62 % in comparison to the basic matrix. So, they can be tailored to meet the needs that make their performance superior compared to unreinforced AAs. Through a review of existing literature, this paper will provide an outline of the effect of various kinds of reinforcements on armor-grade aluminum alloys.

Synergistic effect of different high-performance fibers on the microstructural evolution and mechanical performance of novel hybrid metal matrix composites produced via friction stir processing for automotive applications

The present study aims to produce novel hybrid metal matrix composite (HMMC’s) material using a mixture of reinforcement (basalt, E-glass, and carbon fibers) in long, chopped, and flakes form via Friction Stir Processing (FSP) techniques. Subsequently, the effect of hybrid reinforcement on microstructural evolutions, mechanical performance, and the fracture mechanism of HMMC’s was investigated. The results demonstrated that hybrid reinforcement synergistically enhanced the tensile, flexural, and impact performance of FSPed HMMC’s compared to monolithic composites (non-hybrid) and received base metal (BM). The long fiber-reinforced hybrid aluminum metal matrix composites (HL) show a ~156% increment in tensile strength and ~196% increment in impact strength, while flakes-reinforced hybrid aluminum metal matrix composites (HF) show a ~101% increment in flexural strength compared to the BM. The field emission scanning electron microscopy (FESEM) analysis demonstrated a homogeneous dispersion of reinforcement and an excellent interfacial bonding of fibers with the aluminum matrix in the fabricated composites. The validation of element distribution and composition within the composites was confirmed using FESEM elemental mapping and energy-dispersive X-ray spectroscopy (EDS) spectrum.

Studies on Al-Si based hybrid aluminium metal matrix nanocomposites

A lightweight Hybrid Aluminium Metal Matrix Nanocomposite (HAMNC) is proposed for brake rotor application in this work. Hypereutectic Aluminium-Silicon (Al-Si) grade LM30 alloy is opted as the matrix with Boron Carbide (nB4C) and Rutile (nTiO2) nanoparticles as reinforcements. The brake rotor samples are produced using ultrasonic squeeze-assisted stir-casting, which is cost-effective and feasible for mass production. The hybrid nanocomposite specimens are fabricated by maintaining 1 wt% of nB4C and by varying TiO2 nanoparticles from 0 wt% to 1.00 wt% in steps of 0.25 wt%. The formulations are subjected to microstructure study and dry sliding wear test. The Field Emission Scanning Electron Micrographs (FESEM) reveal that the stir-casting method combining ultrasonic and squeeze effects aids in the uniform distribution of nano reinforcements. The tribological findings show that the hybrid nanocomposite containing 0.75 wt%. of nTiO2 has an 82.76% lower specific wear rate compared to the parent LM30 alloy. Further, the HAMNC brake rotor is 60% lighter than the brake rotors made of Grey Cast Iron making it a potential replacement material.

Numerical and experimental investigation of the mechanical properties of MWCNT/RHA reinforced AlP0507-based hybrid aluminum metal matrix composites

Numerical and experimental investigation of the mechanical properties of MWCNT/RHA reinforced AlP0507-based hybrid aluminum metal matrix composites

Evaluation of Mechanical Behavior of Hybrid Aluminium Metal Matrix by Using Stir Casting

Evaluation of Mechanical Behavior of Hybrid Aluminium Metal Matrix by Using Stir Casting

Review On Development, Nanoparticle Reinforcement and Sustainable Materials For Enhancement Of Mechanical Properties In Aluminium Hybrid Metal Matrix Composites

Aluminium alloys are popular in many advanced applications and are considered to be an essential class of engineering materials mainly due to their desirable combination of low density, high strength, and cost-effectiveness compared to competing materials. Aluminium metal matrix composites and hybrid metal matrix composites will further enhance these properties by incorporating hardened particles as reinforcements. Hybrid metal matrix composites are second-generation composites that exhibit superior mechanical properties due to the synergistic combination of different reinforcement combinations. Various combinations of reinforcing particulates are being explored. The fabrication of the hybrid composites is done using a stir casting route, which will significantly influence the mechanical properties, microstructure and reinforcement distribution. Aluminium HMMCs offer lightweight, high strength, good wear resistance, and other properties that allow them to be extensively used in the structural, aerospace, marine, and automotive industries. Hybridization of metal alloys provides flexibility in designing components and quality control during manufacturing. Thus, this review paper is focused on the fabrication and characterization of hybrid Aluminium metal matrix composites, advancements in their mechanical properties, recent developments and applications.