Hybrid Metal Matrix Composites Research Articles

Investigation on mechanical, tribological and microstructural properties of Al–Mg–Si–T6/SiC/muscovite-hybrid metal-matrix composites for high strength applications

The wide range of aluminium variants (alloys and composites) has made it an important material for aviation, automotive components, auto-transmission locomotive section units, S.C.U.B.A. tanks, ship, vessels, submarines fabrication and design etc. regardless of the fact that the aluminium alloys were being utilized in myriads of sectors owing to its exceptional superior and versatile functional characteristics, the property such as wear-resistant ought to be enhanced in order to further prolong diverse spectrum of applications. An aluminium alloy having lower hardness and tensile strength has been incorporated with silicon carbide that drastically strengthens the properties. This study involves fabrication of aluminium silicon carbide with muscovite/hydrated aluminium potassium silicate/aluminosilicate in stir casting method to obtain a hybrid metal matrix composite. Maintaining a constant amount of aluminium and silicon carbide, muscovite or hydrated aluminium potassium silicate is varied to obtain three distinctive compositions of (Al/SiC/muscovite) composites. The mechanical characteristics like tensile-strength, flexural-strength, toughness, hardness, scratch adhesion, percent-porosity and density were studied. The dispersion of muscovite and silicon carbide particles were observed by viewing the microstructure photographs obtained using optical microscopy and Scanning Electron Microscope (SEM). EDAX analysis affirms the presence of reinforcing constituents in Al–Mg–Si–T6 alloy matrix. A drum type wear apparatus was utilized to evaluate the percentage of wear-loss in different compositions using different loads and it was found that the wear-loss decreases linearly as the muscovite percentage was increased.

Experimental and numerical investigations on thermal expansion and thermal conductivity properties of Al 6061-SIC-GR hybrid metal matrix composites

In this research paper, the determination of thermal expansivity and thermal conductivity has been accomplished for Al 6061, Silicon Carbide and Graphite hybrid metal matrix composites from room temperature to [Formula: see text]C. Aluminium-based composites reinforced with Silicon Carbide and Graphite particles have been prepared by stir casting technique. The thermal expansion and thermal conductivity properties of hybrid composites with different percentage compositions of reinforcements have been investigated. The results have indicated that the thermal expansivity and thermal conductivity of the different compositions of hybrid MMCs decrease by the addition of Graphite with Silicon Carbide and Al 6061. Few empirical models have been validated for the evaluation of thermal expansivity and thermal conductivity of hybrid composites. Using the experimental values, namely modulus of elasticity, Poisson ratio and thermal expansivity, computational investigation has been carried out to evaluate the thermal parameters, namely thermal displacement, thermal strain and thermal stress. Similarly, using the experimental values, namely density, thermal conductivity, specific heat capacity and enthalpy at varying temperature ranges, computational investigation has been carried out to evaluate thermal gradient and thermal flux.

Studies on Egg Shell and SiC Reinforced Hybrid Metal Matrix Composite for Tribological Applications

The hybrid metal matrix composite is developed through stir casting process. In theAl7075 aluminium matrix material, two different combination of reinforcements are used to make hybrid composite and they are as (i) Al7075 + Al2O3 + SiC and (ii) Al7075 + Al2O3 + egg shell powder. The weight proportion of SiC and egg shell powder varied to study the influence of reinforcement. To validate the hybrid composite developed, electron microscopic imaging, density and hardness measured. Maximum surface hardness of 197 Hv is observed in the composite with 6% egg shell powder. The presence organic egg shell is in the form of calcium oxide which is harder than carbide particle reinforced in the hybrid composite material. It has posse’s natural strength compared to synthetic material and with less in density.The density of egg shell is less compared to SiC and alumina particle reinforcement. Electron images and the corresponding spectroscopic results infer that the reinforcements are equal distributed in the volume of composite. While casting the egg shell has been found in the form of calcium oxide along with aluminium and oxide elements. Since, the composite has less density which is light in weight compared to alumina or silicon carbide. With respect to sliding wear behaviour, the hybrid composite with Sample 1 (3% SiC) and Sample 4 (6% egg shell) has good wear resistance. With increase in hard particle the wear mechanism is abrasion and metal loss trend found increasing. The minimum of 0.25 mm3/min found with less load (10 N) and 0.42 mm3/min for 20 N load. On prolonged exposure more than 40 μm reached for maximum load. Increase in hard particle reinforcement (6% Al2O3 + 6% SiC) has induced severe surface damage due to abrasion on worn surface. Adhesive morphology and minimum wear are noticed with 6% Al2O3 + 6% SiC in hybrid composite. Therefore, it is confirmed that the reduced in hard particle or increase in egg shell may produce expected results on sliding wear behaviour.

Experimental investigation on characterization of microwave welded Al6061-Gr-SiC hybrid metal matrix composites

In the present work, experimental microwave welding of Al6061-6%Gr-SiC hybrid metal matrix composites (MMC) in bulk form has been carried out. The principle of microwave hybrid heating was applied with domestic microwave having the frequency of 2.45GHz and 900W power. The interface powder Al6061 and susceptor as charcoal powder were used for the welding process. The stir casting process was used to prepare Al6061-6%Gr-SiC hybrid MMCs by varying SiC content by 3%, 6% and 9% and keeping 6% graphite constant by wt%. The composite weld joints were characterized by scanning electron microscope (SEM) equipped with energy dispersive spectrum (EDS) and mechanically through tensile test, Rockwell hardness test and impact test. The microstructure study showed the good metallurgical bonding between the interface and base composites without any visible cracks. The SEM-EDS study revealed the formation of various carbides and inter metallics at the weld interface. The average ultimate tensile strength of the joint was found to be 135MPa with 4.3% elongation. The average Rockwell hardness at the weld joint observed was 61.5HRB. The average impact strength of welded composite was 1.62J/mm2.

Aluminium metal matrix composites and effect of reinforcements – A Review

A composite is a fusion of two or more different material chemically and unsolvable phases; its properties and structural concert are greater the ingredients performing homogeneous phases. ceramics and Metals, as well, can be implanted with particles, to advances their property; these mixtures are known as MMCs. Aluminum alloy compose a significant engineering material generally engaged in the aerospace industries for the production of dissimilar parts and equipments. It is due to its more strength to density fraction that it a sought after MMCs. A variety of processing technique and mechanical properties testing’s available for manufacturing the Aluminium matrix composites. The mutual reinforcement’s effect on Aluminium Metal Matrix composites with individual and multiple particulate reinforcements like Hybrid Metal matrix composites are finding better applications in aerospace industries, automobile industries, underwater, and transportation. In the current situation, a bunch of research activities were on pipe line. This review particularly directs the engineers and researchers towards right reinforcement materials selection especially hybrid composites by their properties in the appropriate field and diverse technique involved in production of metal matrix composites.

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.

Dry sliding wear behavior of Mica, Fly Ash and Red Mud particles reinforced Al7075 alloy hybrid metal matrix composites

Objective: To synthesize and evaluation of wear behavior of mica. The effect of mica, fly ash and red mud particles reinforced Al7075 alloy composites. Method: The hybrid composites were prepared with constant 1 wt. % of red mud particles and varying weight percentages of mica (2, 4 and 6 wt. %) and fly ash (1, 3 and 5 wt. %) particles in Al7075 alloy by stir casting method. Findings: The synthesized multiple particles reinforced Al7075 alloy hybrid composites were subjected to microstructural studies and wear properties testing. Microstructural characterizations of obtained samples were carried out by scanning electron microscopy and XRD patterns. The mica, fly ash and red mud particles were evenly distributed and presences of these particles were confirmed by the XRD patterns. Novelty /Improvement: Al7075 alloy with red mud, fly ash and mica particles reinforced hybrid composites were exhibited the superior wear resistance. Various wear mechanisms were observed in the Al7075 alloy with mica, fly ash and red mud composites using SEM. Keywords: Al7075 Alloy; Mica; Fly Ash; Red Mud; Wear; Worn Morphology

Magnetic and mechanical characterization of Al-MWCNT-Fe-Ni hybrid metal matrix composites

This paper aimed to synthesize the aluminum (Al) based magnetic hybrid composites by using iron nanoparticles (Fe: 16–28 vol%), nickel nanoparticles (Ni: 2 vol%) and multi-wall carbon nanotubes (MWCNT: 2 vol%) as reinforcements. The magnetic, mechanical, electrical properties were investigated. The highest saturation magnetization of 79.21 emu/g was given by the composite with high volume fraction of iron nanoparticles. However, with an addition of nickel (2 vol%) in Al-MWCNT-Fe, the magnetic properties were decreased. A reduction of power losses up to 41.5% was achieved by using Ni 2 vol%. It was also found that the composites with greater aluminum content had better tensile strength with the highest strength of 68.5 MPa and better flexural strength. The greatest hardness of HV 74 was achieved by increasing the Fe content. The electrical resistivity varied between 1354 µΩ.cm and 2450 µΩ.cm, which is higher than that of commercial aluminum and some of its alloys.

Machinability analysis on wire electrical discharge machining of stir casted AA2024/Al2O3/BN hybrid composite for aerospace applications

ABSTRACT Metal Matrix Composite (MMC) materials are having enhanced characteristics and considered as an alternate material for various engineering applications. Due to reinforcement added, the materials become harder which results in poor machining performance by conventional machining techniques. Wire Electrical Discharge Machining (WEDM) is an effective method for making complex shapes in harder material that are electrically conductive. In this present exploration, an analysis has been performed on machinability of WEDM of Hybrid MMC (AA2024+Al2O3+BN) which is prepared by stir cast process and development of artificial intelligent decision-making tool for WEDM process. The ascendancy of variables namely duration of pulse on, pulse off and applied current in contrast to preferred performance parameters such as material removal rate, surface roughness, dimensional deviation, and orientation tolerance error were investigated. Grey theory has been engaged for attaining gray relational coefficient values and considered as an input information to develop the Grey-ANFIS model for predicting the desired performance measures. An analysis has been performed by comparing the experimentation outcomes and predicted values. Also the performance of developed Grey-ANFIS model is analyzed to disclose the competency and it is proved that the model is capable of predicting the desired performance measures in an effective manner.

Experimental investigations of material removal rate on Mg/SiCp-flyash hybrid metal matrix composites by electrical discharge machining

The widening growth of the mechanical industries largely associated with enormous requirement of composite materials due to their light weight and enhanced mechanical properties. Electrical Discharge Machining (EDM) is an imperative modernistic machining technology employed for cutting difficult-to-machine and new age-band of materials. In this research work, Mg/SiCP-Fly-ash hybrid metal matrix composites (MMCs) was fabricated by powder metallurgical route and machined by EDM machining. The pulse on time, pulse off time and the applied current were the parameters used to study the material removal rate in EDM process. EDM drilling operations were conducted on an ELEKTRA PLUS spark erosion electrical discharge machine. 10 mm diameter brass tool was chosen to drill the MMC specimens. A mathematical model was computed to show a relationship of EDM machining process variables such as applied current, pulse on time and pulse off time on the MRR. The ANOVA (analysis of variance) method was performed to analyze the various input data on the output responses.

Evaluation of the mechanical properties and microstructure analysis of heat treated LM-12 alloy with SiO2 and CNT hybrid metal matrix composites

The current study is meant for LM-12 aluminium alloy reinforced with different weight percentage of SiO2 and carbon nano tubes hybrid metal matrix composite development using stir casting method with sand mould technique. Further, heat treatment was carried out using ice quenching process for evaluating tests such as Microstructure analysis, Tensile strength and Hardness of Hybrid Metal Matrix Composite which were developed experimentally. Tests were performed on different specimens within the heat treated casting, according to ASTM standards. The microstructures of the composites were concentrated to know the scattering of the reinforcement particulates in Matrix. It has been observed that expansion of particulates essentially enhances tensile strength and hardness..

Modelling and combined effect analysis of electric discharge Machining process using response surface methodology

Electrical discharge machining (EDM) is a contactless machining process based on the erosive impact of the electrical discharges. It has shown considerable usage in the machining of composites of extreme hardness and strength. The hybrid metal matrix composite (HMMC) is one such type of hard material. HMMCs have a parent metal with reinforcement materials added in varying weight percentages (% wt.) to improve the chemical and physical properties of the base metal. The electrode consumption increases with the increase in workpiece material hardness. The Industries are facing problems relating to high electrode consumption. This study provides the modeling and investigation of EDM of Aluminum-based HMMC, developed under strict environmental conditions by stir casting method. Current (Ip), pulse on time (Ton), pulse off time (Toff), voltage (V) and spark gap (Sg) were the selected machining parameters. Response surface method (RSM) utilised to evaluate the effect of selected parameters on electrode wear rate (EWR) using a pure copper (Cu) electrode. Second-order mathematical model for EWR developed using RSM and validated using analysis of variance (ANOVA). The ANOVA confirmed the model to be 95% significant. The combined effect of process variables on EWR studied through 3D surface plots. The current followed by pulse on time and spark gap adjudged to be the significant parameters on which EWR depends. The optimized setting of Input parameters noted out to be Ip = 3A, Ton = 50 µs, Toff = 6 µs, V = 40 V, and Sg = 5 mm.

A study on the effect of voltage on performance characteristics of electrochemical surface grinding of HMMC

Application of Hybrid Metal Matrix Composites (HMMCs) are restricted in the advanced manufacturing industries such as aerospace and automobile because of machining challenges due to its superior mechanical properties. Hybrid machining processes (HMP) have become more popular to fabricate complex shapes and intricate profiles of MMCs and other advanced materials. Electrochemical grinding is such an HMP that combines conventional electrochemical machining and mechanical grinding. The aim of the present research to shows the effect of voltage on quality characteristics during electrochemical grinding of Al-SiC-Gr HMMCs. Experiments performed on the indigenously developed experimental setup of electrochemical surface grinding. Results revealed that the material removal rate (MRR) increases by increasing applied voltage.

Fabrication and analysis of LM13/B4C/Gr hybrid metal matrix composites

Due to mechanical characteristics like light weight nature, enhanced wear resistance, greater strength to wear ratio, stiffness, and better electrical and thermal properties, Aluminium (Al) matrix composites are deployed in military, automotive and aerospace areas. Frequently utilized ceramic elements for reinforcing with Al are alumina and silicon carbide (SiC). Boron carbide (B4C) is an excellent reinforcement substance having a higher hardness than other substances. Because of its substantial hardness, B4C can be used as a substitute to alumina and SiC. In addition to its superior hardness, modest density, greater strength, better chemical stability, and wear resistance are diverse appealing characteristics of B4C. So, for boosting the properties of the LM13/Gr composite samples, B4C is added up to 9% by considering its clustering property. This article describes the production process of LM13/B4C/Gr composites and evaluation of their mechanical characteristics. Stir casting method is adopted to produce the Al composite samples and the mechanical properties of new hybrid composites are found improved. Selection and/or Peer-review under responsibility of International Conference on Sustainable materials, Manufacturing and Renewable Technologies (i-SMaRT 2021)

Study on effect of ceramics on dry sliding wear behaviour of Al-Cu-Mg based metal matrix composite at different temperature

The current global industrial scenario entails a heterogeneity of contemporary material, and its associated process increases product performance such as the capacity to withstand at elevated temperature, higher operating speed, and load. Due to which there has been increasing demand for the newly developed materials. Current study was carried out to explore the effects of ceramics on Al2219 versus un-reinforced Al2219 alloy. According to the current exploration, it clearly says that boron carbide (B4C) and graphite (Gr) content can be an appropriate alternative to Al2219. Stir casting technique was used to fabricate Al2219 and reinforced with Aluminium oxide (Al2O3), B4C & Gr. Scanning electon microscop (SEM) reveals the developed microstructure of Al2219, HMMC (hybrid metal matrix composite), and worn surface morphology. Chosen alloy predominantly consist of Al and Cu-Mg phase. Al having an incoherent interface with a matrix. In high-temperature wear results, the contemporary HMMCs shows significant increases (30%) in wear resistance at (150 °C). Due to the existence of the B4C & Gr reinforcement particulate improves the strengthening kinetics in the matrix phase at 150 °C when compared to Al2219. IBM SPSS Statistics.22 was used to predict the wear properties of the composite. Artificial neural network (ANN) predictive outcomes fit to actual measured data & absolute relative error is < 1%.

Optimization of wear properties on AA7075/Sic/Mos2 hybrid metal matrix composite by response surface methodology

Nowadays, composites are profoundly thriving as the replacement of ferrous alloys. The Aluminum manifested into a great substitute due to its properties like lightweight, low density, high strength, and corrosion resistance. The process of fusing the non-ceramics reinforcement like Silicon carbide, Boron carbide, Aluminum oxide, Titanium diboride with a non-metal like Graphite, Molybdenum disulfide or with other non-ceramic to form a hybrid metal matrix composite. In the present paper, an investigation carried out on Aluminum 7075 material by the process of stir casting where the Silicon Carbide (SiC) with three different weight % (i.e., 3%, 6%, 9%) and Molybdenum Disulphide (MoS2) with 1% constant weight % added to the base material. The tensile test and hardness test were then done on a UTM and Rockwell Hardness testing machine, respectively, for all three prepared materials. As the percentage of SiC increases in the material, the hardness value and tensile strength are increasing. The Al7075 + 9%SiC + 1%MoS2 is the highest of all.

Investigating the Material Removal Rate Parameters in ECM for Al 5086 Alloy‐Reinforced Silicon Carbide/Flyash Hybrid Composites by Using Minitab‐18

This study explained about machining parameters of Al5086/Flyash/Sic hybrid metal matrix composites by the Taguchi technique. Al5086 reinforced in SiC (5–10 wt %) and 8% weight of flyash are retained as constants. The specimens are prepared with the help of the stir casting method. The material removal rate was examined by electrochemical machining under various parameters such as feed rate (0.15–0.30 mm/min), voltage (10–20 V), and electrolyte concentration (20–35 g/litre). Taguchi’s L16 orthogonal array was selected for design of experiments (DOEs), and 16 experimental tests were conducted to examine the effect of the selected machining parameters employed to identify the best optimal levels and also to investigate the effect of electrochemical machining parameters on MRR determined by Minitab‐18.

Statistical analysis of Wear behaviour of AA6351/BN hybrid metal matrix composites by using Taguchi Method

Statistical analysis of Wear behaviour of AA6351/BN hybrid metal matrix composites by using Taguchi Method

WITHDRAWN: Corrosion resistance of Al6061-basalt natural filler and zircon hybrid composite material in acid media

The present investigation is an attempt made to develop Al6061/Basalt/Zirconium oxide Hybrid Metal Matrix Composites (MMCs) by liquid metallurgy technique (stir casting) and to study the wear properties of Al6061/Basalt/Zirconium oxide reinforced hybrid metal matrix composites. The composite is prepared by using Liquid Metallurgy Route (Stir Casting Technique), although other processing technique such as powder metallurgy delivers better mechanical properties in MMCs, Liquid state has some significant focal points, for example, better matrix molecule holding, simpler control of matrix structure, ease of handling, closer to net shape and wide choice of material. Al6061 is taken as a base material (matrix) and Basalt (1–10%) and Zirconium oxides (2%) are used as reinforcements. Corrosion analysis for Aluminum Metal Matrix Composites (MMCs) was done in acid (HCl) media at room temperature & different time intervals. The results were tabulated & it was found that the MMC containing 4% basalt underwent maximum corrosion at room temperature. SEM is done for all the samples the results are tabulated.

Microstructural and tensile behaviour of hybrid MMC Al7075/ SiC/B4C produced by mechanical stir casting

Aluminium-based metal matrix composites (MMCs) are one of the preferable choices of engineering material for automobile and aircraft parts. The low density with improved properties makes it suitable for most of the engineering application. The present work consists of the fabrication of Al7075/SiC/B4C hybrid MMCs by mechanical stir casting route. The percentage of each reinforcement are varies from 1 to 10% by weight with the total percentage of reinforced material kept at 10% by weight. The results reveled the homogeneous mixing of both the reinforcement SiC and B4C into the matrix material and it is validated by light microscopy images. As an outcome, the tensile behaviour of the specimen was investigated. The results of tensile characterization of composite indicate that the range of Ultimate tensile strength varies from 47 MPa to 59 MPa for all selected combination of reinforcement. The maximum UTS of 58.9 MPa and Yield strength of 49.46 MPa was obtained for the specimen developed by adding 1% SiC and 9% B4C at 1.36% of elongation.