Aluminium Hybrid Composites Research Articles

MINIMIZING THE TEMPERATURE IN TURNING OF BAGASSE ASH AND GRAPHITE REINFORCED ALUMINIUM COMPOSITE

The current research is intended to reduce the temperature at the too tip interface while turning Aluminium hybrid composite. The aluminium hybrid composite is initially developed by following the squeeze casting technology with bagasse ash and graphite as reinforcement. The amount of reinforcement in aluminium matrix is varied as 4, 8 and 12%. The machining analysis is done based on the Taguchi L9 array with reinforcement percentage, feed and speed as process parameters each at three level. The machining temperature measured is analyzed through SN ratio and analysis of variance. The results confirmed the influence of reinforcement addition on the temperature developed while machining. Among the considered process variables, feed has very high influence on temperature

INVESTIGATION ON INFLUENCE OF PROCESS PARAMETERS IN WEDM OF HYBRID ALUMINIUN COMPOSITE PROCESSED THROUGH SQUEEZE CASTING

This research deals with machinability studies on developed hybrid aluminium composite. Squeeze casting method was adopted to fabricated hybrid aluminium composite with varying weight percentage of bagasse ash (4,8,12 wt.%) with constant weight percentage of graphite. Taguchi method was adopted for experiment plan and to study the influence of input parameters over output response. Results revel that increase in pulse on time increases the material removal rate. ANOVA result depicts that all input parameter have significant over output response. Optimal parameter for better output response has been obtained from main effect plot.

MULTI-OBJECTIVE OPTIMIZATION IN WEDM PROCESS OF ALUMINIUM-BAGASSE-GRAPHITE COMPOSITE THROUGH GREY RELATION ANALYSIS

In research, hybrid aluminium composite was developed by varying percentage of bagasse ash 1(4,8, 12 wt.%) with constant percentage of graphite (2 wt.%). Taguchi method was adopted for design of experiments with three level and three factors (L9). Pulse on time, pulse off time and reinforcement weight percentage are selected as input parameter. Material removal rate (MRR) and surface roughness (Ra) are selected as output parameter. Grey Relation Analysis (GRA) was adapted for attaining maximum material removal rate with minimal surface roughness. ANOVA results reveals that pulse on time have more significant over output response.

PARAMETRIC OPTIMIZATION ON WEDM OF ALUMINIUM- BAGASSE ASH- GRAPHITE HYBRID COMPOSITES BY TAGUCHI APPROACH

In this research, squeeze casting method was adopted to fabricate hybrid aluminium composite. Varying percentage of bagasse ash (4, 8 and 12 wt.% ) and constant wt.% of graphite (2 wt.%) was used as reinforcement to improve mechanical strength of Al 7075 alloy. Taguchi method was utilized to design experimental plan for WEDM process with pulse on time and pulse off time as the input parameter and surface roughness as output response. ANOVA results depicts that all the input parameter have significant over output response. Optimal parameter was attained for better surface finish. Pulse off time has maximum contribution in governing output response.

Corrosion study and quantitative measurement of crystallite size of high strength aluminum hybrid composite developed via friction stir processing

AbstractThis present study is centered on the corrosion behaviors and structural integrity of high strength aluminum‐alloy 7075‐T651 hybridized with carbonaceous coconut shell ash (CSA) and α+β titanium alloy powder in ratio of 50 : 50, fabricated during friction stir processing (FSP). The study examined the base metal – AA7075‐T651 as well as the friction stir processed AA7075‐T651 as control experiments. The Processing parameters used were plunge depth of 0.3 mm, travel speed of 20 mm/min, the tilt angle of 3° and rotational speed of 1500 min−1. The corrosion characteristics were examined with the Potentiodynamic Polarization method in 3.5 % NaCl medium while crystalline phases were studied with x‐ray diffraction (XRD). Results show that fabricated aluminum hybrid composite (AHC) AA7075‐T651/coconut shell ash (CSA)/titanium‐alloy has the highest percentage of inhibition performance efficiency (IPE) of 84.81 % resulting to 0.76938 mm/year corrosion rate and 356.51 Ω polarization resistance, whereas inhibition performance efficiency (IPE) for friction stir processed (FSPed) AA7075‐T651 was 63.99 % while the base metal – AA7075‐T651 was taken as the reference point. It was also revealed that the hybridized coconut shell ash (CSA)/titanium‐alloy powder on AA7075‐T651 enhanced the structural integrity, producing 38.5 nm crystallite size over friction stir processing (FSP) AA7075‐T651 with 41.2 nm and the base metal with 48.7 nm crystallite size.

Fabrication of Wear-Resistant Ti3AlC2/Al3Ti Hybrid Aluminum Composites by Friction Stir Processing

Hybrid nanocomposites have potential as wear-resistant materials. However, synthesizing these nanocomposites by conventional molten state methods result in agglomeration of reinforcements. To mitigate this issue, in the current study hybrid aluminum nanocomposites were synthesized using friction stir processing (FSP). For this, two blends of titanium and graphite particles were used as reinforcements. These composites were characterized using a stereo microscope, scanning electron microscope, electron probe micro analyzer, X-ray diffraction, and microhardness indenter. During FSP, ternary carbide (Ti3AlC2) and intermetallic (AlTi3) were formed in situ. These compounds improved the hardness of the composites up to four times. Further, these in situ composites were subjected to wear test using pin-on-disk tribometer at various sliding speeds. Polycrystalline alumina disks were chosen as counterface to minimize chemically induce wear. The wear rate of the composites was 5 to 13 times lower than that of the base metal. This excellent resistance to wear in composites was attributed to improved resistance to abrasion and delamination. Furthermore, it was seen that the dominant wear mechanism of the composites changed from abrasive to adhesive wear as the sliding speed increased.

Synthesis of B4C and BN reinforced Al7075 hybrid composites using stir casting method

In the present study an effort has been made to synthesize B4C and BN reinforced Al7075 hybrid composites using stir casting method by varying its weight percentage (3%, 6% and 9%) of B4C and keeping (3%) of BN constant for marine applications. Morphology of the synthesized aluminum hybrid composite and reinforced particle distribution was studied in detail using optical microscopy. It virtually shows the homogeneous distribution of the reinforcement particles in the base metal matrix and it forms Al3BC, AlB12 and AlN as interfacial reactions. Vickers micro-hardness test has been carried out to evaluate the hardness of hybrid composites. It has been found that with increase in percentage of reinforcement the hardness of the synthesized hybrid composites found to be increased compared with the Al7075 base matrix alloy. Mechanical testing has been carried out on the cast composites specimen of different compositions. It has been inferred that addition of reinforcement B4C and BN to base metal matrix added 22% strength to the hybrid composites. ASTM E9 standard has been used to evaluate the compressive properties of hybrid composites and it has been found that inclusion of harder reinforcement tends to resist the load applied and hence the compression properties of such hybrid composites has been improved. ASTM-B117 has been used to study the corrosion behavior of hybrid composites. The corrosion rate decreased by 18.5% between 3% and 6% boron carbide addition whereas it decreased by 22.4% between 6% and 9% boron carbide addition.

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.

Parametric study of aluminium-rare earth based composites with improved hydrophobicity using response surface method

In the current exploration, the specific wear rate of aluminium hybrid composites with traces amount of rare earth oxides (REOs) using pin-on-disc tribometer have been evaluated. For wear analysis, aluminium hybrid matrix composites (AHMCs) of Al-6061 alloy, with 2.5, 5 and 7.5wt% of (Al2O3+SiC) and 0.5, 1.5 and 2.5wt% CeO2 as REOs particulate reinforcement processed through stir casting route. Hydrophobicity behaviour analysis between the aluminium liquid matrix and Al2O3/SiC reinforcement can be improved by the addition of REOs as measured in terms of contact angle by sessile drop method. For parametric study of specific wear rate using response surface methodology, four different parameters namely reinforcement with different weight percent, sliding speed, load and sliding distance have been analyzed with five different levels. The investigations shows that the quantity of reinforcement with increased amount as well as increasing sliding speed decreased the specific wear rate whereas an increase amount of load as well as sliding distance promotes the specific wear rate of AHMCs with increasing nature. But from ANOVA investigations, the effect of above parameters on sliding wear rate is totally different. It was concluded that sliding distance has more dominating impact on the wear rate of the composites with 59.94%, followed by 16.39% of sliding speed, 10.49% of normal load and 4.9% of REOs reinforcement respectively. Finally the model is validated by conducting the confirmation tests. Statistical analysis has revealed that current wear model is accurate to apply in the tribological applications.

Microstructural Evaluation of Similar and Dissimilar Welding of Aluminum Metal Matrix Hybrid Composite by Friction Stir Welding

To address the challenges of reducing the CO2 emission in automotives, Aluminum metal matrix hybrid composites have been extensively used in automotive and aerospace industries for the fabrication of light weight structure. Huge demand in joining dissimilar metals increased day by day, because it reduces the weight and cost of components by utilizing hybrid structures. The friction stir welding is adopted for dissimilar AA5754 rheo-squeeze cast (RSC) with AA7075 stir casted hybrid composite. Micro sized B4C and nanosized Al2O3 are reinforced into this material. Friction stir welding of these alloys by varying the tool material, pin and shoulder profiles, rotational speed, tool traverse speed and tilt angle. Microstructure of the joint are studied and inferences drawn are presented. The better welding was obtained with triangular and square pin profile when compared to cylindrical pin whereas triangular pin profile was more better than square pin. Tapered shoulder possessed greater strength, which resulted in a good weld in contrast to flat shoulder. The high carbon high chromium steel (HCHCr) tool exhibited a higher tool wear rate than stainless steel (SS) tool and found to be an appropriate one to weld aluminum hybrid composite.

Effects of Rice Husk Ash and Silicon Carbide addition on AA6351 Hybrid Green Composites

This paper is aimed at studying the feasibility of the development of high-performance low-cost aluminium hybrid composites using silicon carbide (synthetic) and rice husk ash (agro waste) as reinf...

Potentiodynamic Corrosion Characterization of Hybrid Aluminium Composites for Advanced Engineering Applications

Corrosion characterization of Aluminium composites is a significant study planned for assessing the capability of utilizing the materials for aviation and automobile parts. Aluminium 5083 is a particular class of alloys which is known for its corrosion resistance in extraordinary conditions and is utilized in aerospace components. However, the experimentations on impact of reinforcements, for example, the effect of Silicon carbide and Flyash on corrosion properties of Aluminium 5083 alloys is still in its incipient stage and not much literature is available outlining the corrosion attributes. The present work includes the fabrication of Aluminium 5083 – Silicon carbide – Flyash composites and investigation of the corrosion conduct of these composites. The composites are fabricated by stir casting procedure, considering silicon carbide particulates varied in the scope of 3 wt.% to 9 wt.% at an intermittent intervals of 2 wt.%. The composition of fly ash in the present work is limited to 5 wt. % for restricting the porosity after conducting preliminary trials. The composite materials considered in this research are assessed for corrosion by Potentio-dynamic test, which is accomplished utilizing a test arrangement comprising of five mouth jar with calomel electrode and a working cathode (comprising of the specimen held rigidly with a copper wire and secured with Teflon tape notwithstanding a region of one square centimeter exposed to the electrolyte). The anodic and cathodic potentio-dynamic polarization estimations are acquired as tafel plots in the PC that is interfaced with the test arrangement. The outcomes reveal that the corrosion current (Icorr) increases with the increase in the weight percentage of Silicon carbide in the metal matrix. The electrolyte considered for the potentio-dynamic test is and 1 M HCl (acidic) medium.

Optimization of machining parameters in CNC turning of AA6061-B4C-CNT hybrid composites using Grey-fuzzy method

Aluminium hybrid composites and its machining receives a great attention due to their superior properties like good strength to weight ratio, good castability, machinability, and low cost, suitable for various applications in automotive and aerospace industries. CNC turning is considered as an ideal method for machining of aluminium hybrid composites. Nevertheless, the parameters of turning of aluminium hybrid composites need to be optimized for better and precise machining. Also, the presence of solid lubricants such as Carbon nanotube, Graphite, hexagonal Boron Nitride etc. promotes the machinability of aluminium hybrid composites. In this study, CNC turning on AA6061 matrix based hybrid composites reinforced with Boron carbide (5-15 vol.%) and Carbon nanotube (15 vol.%) was performed. Cutting Speed (rpm):60-180, feed (mm/rev): 0.10-0.20, depth of cut (mm): 0.50-1.00 and percentage of B4C (vol.%) 5-15 were the controlling parameters and responses namely tangential force (N), cutting power (W) and tool wear (mm3/min) were considered for the optimization. Experimental design was made as per Taguchi’s L27 orthogonal array and Grey-fuzzy analytical tool was applied for the optimization. The optimal setting for turning operation on this hybrid composite using Grey-fuzzy analysis were 120 rpm, 0.20 mm/rev, 0.5 mm and 15 vo.% for cutting speed, feed, depth of cut and reinforcement respectively.

Effect of multiple reinforcements (CNT/Si3N4) on hardness, electrical conductivity and friction coefficient of aluminium hybrid composites

Present investigation reports on the development of aluminium hybrid composites using powder metallurgy technique. Two different reinforcements namely silicon nitride (Si3N4) and carbon nanotubes (CNT) were used to reinforce pure aluminium matrix. Ball milled powder morphology and microstructure of hybrid composites were studied using scanning electron microscope to study the dispersion of Si3N4 and CNT.Microstructure studies showed uniform dispersion of both the reinforcements in aluminium matrix. Microhardness was obtained by applying a load of 50 N for dwell period of 20 seconds. Electrical conductivity in terms of %IACS was obtained using Eddy current tester. Coefficient of friction was obtained by conducting scratch test by employing a load of 10 N for a stroke length of 10 mm and scratch velocity of 0.2 mm/sec. Microhardness was found to increase with increasing content CNT content while electrical conductivity was found to decrease. Finally coefficient of friction was found to decrease with increase in CNT content owing to its lubricating nature.

Optimization of Abrasive Water Jet Machining Parameters on AA6061/B4C/hBN Hybrid Composites using Grey-RSM

Aluminium Matrix Hybrid Composites (AMHCs) possess an excellent combination of physical and mechanical properties suitable for a variety of applications in automobile and aerospace industries. Addition of solid lubricant hexagonal Boron Nitride (hBN) reduces the complexity in machining of aluminium hybrid composites. Abrasive Water Jet Machining (AWJM) is a non-traditional technique applied for the machining of alloys and composites, due to its better cutting performances. In this work, AA6061 matrix hybrid composites reinforced with B4C (5, 10 and 15vol.%) and hBN (15vol.%) were developed through liquid metallurgy route. The composite were then machined using AWJM. Process parameters considered were abrasive flow rate, water pressure, traverse speed, percentage of reinforcement and mesh size over the responses Kerf Taper Angle (KTA) and Surface roughness (Ra). The experimental design was based on L27 orthogonal array and Grey-RSM analytical tool was applied for optimization. The optimal values of parameter setting for AWJM machining process using Grey RSM methodology were 340 g/min, 200 MPa, 60.06 mm/min, 5.01% and 80 for abrasive flow rate, water pressure, traverse speed, percentage of reinforcement and mesh size were respectively.

Investigation on Mechanical Properties and Microstructure of B4C/Graphene Binary Particles Reinforced Aluminum Hybrid Composites

In the present study, boron carbide and graphene-reinforced aluminum hybrid composites with various boron carbide (1, 3, 6, 9, 12, 15, 30 wt%) and graphene nanoplatelets (GNPs) content (0.15, 0.30, 0.45 wt%) were produced by the powder metallurgy method. The method consists of mixing, ultrasonic dispersing, mixing, filtering, drying, pressing, and sintering processes. The apparent density, compressive strength, and Vickers hardness of the fabricated composites were determined by density meter, universal test machine, and micro Vickers hardness measurement device, respectively. The phase and microstructural analysis of the fabricated composites were analyzed using an X-ray diffraction device and scanning electron microscope, respectively. The maximum apparent density (2.54 ± 0.005 g/cm3), the highest Vickers hardness (109.8 ± 1.5 HV), the best compressive strength (244 ± 5 MPa), and minimum porosity (4.0%) were obtained at Al-30%B4C-0.15%GNPs composite. The enhancement in Vickers hardness and compressive strength of Al-30%B4C-0.15%GNPs composite was detected as + 293% and + 190% compared with pure aluminum. In conclusion, it was detected that the mechanical strength of Al-30B4C-GNPs composites improved up to 0.15 wt%GNPs content. After 0.15 wt%graphene content, the mechanical strength of Al-30B4C-GNPs composites decreased due to the agglomerated graphene nanoparticles.

Machinability studies on aluminium matrix nanocomposite under the influence of MQL

Abstract The overwhelming rise in pollution led to the enforcement of stern measures to restrict certain techniques and served a path to the development of alternate methods. Although aluminium hybrid composites were significantly seen in automobile and aerospace industries due to their enhanced thermal and mechanical properties, its machining is proven to be challenging. In this study, squeeze cast cylindrical workpieces are made out of unreinforced aluminium alloy and aluminium alloy-based hybrid nanocomposite. They are machined by varying the cutting speed, feed rate and depth of cut under dry and minimum quantity lubrication environments. The impact on cutting forces, surface roughness and tool wear are observed and compared and presented in this study

Tribological characterization of hybrid aluminum composite under boundary lubricating sliding conditions

Tribological behaviour of hybrid aluminium composite is studied under lubricated sliding conditions. The scope of this study is to determine the fundamental tribological properties of grapheme as secondary reinforcement and to evaluate its performance under boundary lubricating conditions. The hybrid aluminium composite is fabricated by rapid spark plasma sintered processing route. Variable concentration of Graphene Nano platelets (GNP) [0.5, 1, 2, 3, 4, 5 wt%] is added to the Al-Si-6 wt% Al2O3 composite. The lubricant used is PAO base oil and SAE20W50 Engine oil. The effect of the load and sliding distance is studied on the ball-on-disc tribometer. It is reported that COF remain stable with the increasing sliding distance (90 m–450 m) and decrease with the increasing load (10 N −40 N) and then attain a steady stable value after 40 N to 80 N load. The possibility behind the low friction and wear is the exceptional lubricating effect of the GNP particles layer which mixes with the lubricating oil. The GNP particle layer are the 2D Nano particles that form a low shear stress junction protective layer at the sliding interface, which cause easy shear because of weak Vander wall force drastically reduce friction and wear of the hybrid composite.

Tribological Characterization of Ecodesigned Aluminium Hybrid Metal Matrix Composites

Aluminium alloys infused with various reinforcements establish themselves for numerous leading engineering applications. In present study, wear characteristics of Al 7075-T6/Eggshell/SiC/Al 2 O 3 hybrid composites (Al 7075-T6 as base metal with three reinforcements eggshell particles wt. % 0.5, 1and 1.5, particle size ~ 55 µm, SiC particles wt. % 1, 1.5 and 2, particle size ~ 70 µm and Al 2 O 3 particles wt. % 1.5, 2 and 2.5, particle size ~75 µm) synthesized through electromagnetic stir casting route were studied at various temperatures under dry and lubricated conditions. The wear investigations were conducted on pin-on-disk rotary tribometer Make: Ducom, Atlas; TR-20L-PHM 800-DHM 850 at a constant load of 20N for a sliding speed of 2m/s and sliding distance of 2000 meters. Tribological attributes of synthesized hybrid composites were evaluated as the function of reinforcement contents as per the design of experiment according to Taguchi L9 array. Experimental study showed that at room temperature under dry wear condition, the developed hybrid composites had a maximum decrease of 60% in wear loss while with lubrication the wear was decreased by 89% as compared to the base metal. At an elevated temperature of 70 0 C under dry wear condition, the composite specimens exhibited maximum reduction of 82% in wear whereas under lubricated condition the wear was reduced by 82% in comparison of their unreinforced counter parts. With exceedingly augmented tribological attributes, the current study strongly rationalizes high temperature wear resistant applications of synthesized aluminium hybrid composites with a total reinforcement weight percentage of 4.5% only.

A review on aluminium matrix composite with various reinforcement particles and their behaviour

Aluminium metal matrix composites have the potential to satisfy the recently developed demands of advanced engineering applications. The improved mechanical property reduced weight, increased strength, compliance to conventional processing technique and potentially reduces the production cost of aluminum composites helps to meet industrial and engineering demands. The behavior of these materials is heavily influenced by the composition of particulate-reinforcements in the metal matrix since some of the processing parameters are associated with the reinforcing particles. Many combinations of reinforcement particles have been experimented and conceptualized on the design of aluminum hybrid composites. This paper is an attempt to review the different particulate-reinforcement used and their combinations in the processing of aluminum matrix composites and how it affects the mechanical and wear behaviors of these materials. The methodology of various papers has been studied and their corresponding conclusions were included. The major reinforcement particles used in Synthesizing these materials are briefly discussed and scope for new research areas for the purpose of further improvement on aluminum composites are identified.