Hybrid Metal Matrix Composites Research Articles

Analysis of Wear Behaviour of AA5052 Alloy Composites by Addition Alumina with Zirconium Dioxide Using the Taguchi-Grey Relational Method

The present study deals with preparation of Al hybrid metal matrix composites by the stir casting technique. In this work, Al5052 alloy was selected as the main metal which reinforces with zirconium dioxide and aluminium oxide. The wear test has been conducted on the POD apparatus. 9 specimens are produced by varying reinforcements’ percentage for conduction of tests. The amount of ZrO2 reinforcement is fixed to 8wt%, while the concentration of Al2O3 varied from 5wt% to 10wt%. The parametric optimization of wear behaviour is done through the Taguchi method with L9 orthogonal array. Minitab statistical software helped to find SN ratio and ANOVA reading for each parameter: load (N), sliding speed (rpm), and wt% of reinforcements. From the ANOVA outcome, the load parameter is the highest influencing element that improves wear resistance of made samples around 46%, followed by weight% of reinforcement 29% and sliding speed 26% as second and third influenced parameters, respectively.

Fabrication and mechanical characterization of Al7075-T6/SiC/Gr/S-glass fiber particulate reinforced hybrid metal matrix composite using vacuum sealed stir casting technique

Fabrication and mechanical characterization of Al7075-T6/SiC/Gr/S-glass fiber particulate reinforced hybrid metal matrix composite using vacuum sealed stir casting technique

Experimental study on surface characteristics in μED milling of Al6063%-5%B4C-5%ZrSiO4 composite using TOPSIS method

Al6063 composites are widely used in automobile, aerospace and biomedical industries due to their excellent mechanical properties. Machining of micro channels in composites is difficult for conventional machining process due to presence of hard reinforcement. Materials with base metal. Micro Electrical discharge (μED) milling is popular micromachining technique for machining simple, intricate shapes and microchannels on any conductive material. However, it a slow machining process, the identification of optimum condition has become wide research area in μEDM. The present work aims to study the influence of process variables namely voltage, spindle speed and threshold on machining characteristics of μED milling of Hybrid Metal Matrix Composites (HMMCs). Experimental trials are carried out with copper electrode at different parametric condition. Al6063%-5%B4C-5%ZrSiO4 composite was fabricated using stir casting method and experimental runs were designed using general full factorial method. The significant parameters are identified using Analysis of Variance (ANOVA) and the ideal machining conditions for multi-response are determined using Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) method. The morphology of machined surface with best and worst conditions is examined using SEM. Results indicated that the voltage and threshold are the influencing parameters for considered response indicators. Recast layer thickness seems to be low with best machining conditions as compared to worst conditions. Increase in voltage and threshold increases the Material Removal Rate (MRR) and decreases the Electrode Wear Rate (EWR). Surface finish is better when the lower order of capacitance and voltage is used. MRR is increased by 48% with best machining conditions compared to worst machining condition.

Comparative study of machining quality for the Al–SiC–Gr hybrid metal matrix composite using ECM and ECSG

Hybrid metal matrix composites have superior strength to weight ratio as compared with conventional composites or superalloys. This characteristic makes them suitable for different advanced industries such as aerospace, automobile, and biomedical. Mechanical and thermal energy based processes have their own limitations to machine these composites due to superior mechanical properties and melting of reinforcement particles, respectively. Researchers are trying to machine metal matrix composites by the electrochemical process with the aim to achieve better machining quality, but low material removal rate and oxide layer formation on the machined surface has emerged as the main limitation. A hybrid variant of electro-chemical machining (ECM) and conventional grinding has capability to overcome these limitations. Keeping this in view, the experimental set-up of electro-chemical surface grinding (ECSG) has been developed with the aim to compare the machining characteristics of the hard-to-cut hybrid metal matrix composite Al–SiC–Gr with the ECM process. The machining performances have been compared on the basis of material removal rate, surface roughness, and microcrack width in the machined component. The influence of some important input process parameters on these performance characteristics have been analyzed scientifically. Experimental results show that the ECSG process improves the machining performance by reducing or eliminating the oxide layer from the machining zone due to suitable grinding effects. Material removal rate, surface roughness, and microcrack width were improved by 68%, 24%, and 40%, respectively, by using the ECSG process. The formation of the large size oxide layer with high crack width on the machined surface was observed at high voltage, high electrolyte concentration, and at low table speed.

Mechanical and Tribological Behavior of AA 6082 with Hybrid Metal Matrix Composites

Abstract: Among automobile manufacturers, in recent times, a paramount importance has been given to less fuel consumption of the vehicles by utilizing lightweight and high strength materials. Metal matrix composites (MMCs) have been used commercially in the automotive market for nearly twenty years. Metal Matrix Composites (MMCs) have very light weight, high strength, stiffness and exhibit greater resistance to corrosion, oxidation, and wear. Tensile and compressive strength is an especially important property of Aluminium matrix composites which is essential for automotive application. In this study hybrid Aluminium matrix composite was fabricated through crucible casting route. Zirconium di Oxide (ZrO2) and Egg shell particles were used as reinforcement phases for the present study. The hybrid MMCwas prepared with varying the ZrO2 particles weight ratio ranging from 2% to 4% and Es were varied 3% to 5% fixed quantity 1% of magnesium. The various mechanical properties were investigated and compared with non-metal matrix alloy of Al6082. Finally mediumlevel of reinforcement enhanced the tensile and compressive strength moderately. Keywords: AA6082, MMC, Pin on Disc, Stir Casting, Tensile Strength

Synthesis and Characterization of Hybrid Metal Matrix Composites (MMCs) Reinforced With Silicon Carbide (SiC) and Aluminium Oxide (Al2O3)

Synthesis and Characterization of Hybrid Metal Matrix Composites (MMCs) Reinforced With Silicon Carbide (SiC) and Aluminium Oxide (Al2O3)

Experimental Investigation of Friction and Wear Behavior of AL7075-TiO2-B4C using RSM, ANN and Desirability Function

Metal Matrix Composites (MMC) are widely used in high strength and light weight applications. AL7075 featuring high fatigue strength, good corrosion and wear resistance makes it to employ as a good vehicle building material and also finds it usage in some important engine components which are subjected to constant wear. In this study, dry sliding wear behaviour of hybrid MMC formed by reinforcement of aluminium 7075 with B4C and TiO2 at 3% and 3% weight fraction respectively is investigated. Reinforced particles are powdered using ball mill, reduced to nano size and uniformly dispersed in aluminium matrix using stir casting method. Specimen was prepared according to ASTM standards and wear tests were conducted. Experiments were conducted with keeping force, speed and distance as input parameters while Coefficient of Friction (CoF) and average wear rate as the output parameters. RSM and ANN models were developed to simulate the experiments. The surface which was subjected to test evidenced that presence of TiO2 and B4C particles protected the material to a certain extent. The tests revealed that wear rate and CoF were greatly influenced by force and distance followed by the speed of the rotating disc. The predictions from RSM and ANN models are also correlated well with the experimental data. ANN model also showed better accuracy and capability for predicting the wear rate and CoF. By desirability function, it was found that the material performed well at a keeping force of 38.9 N, speed of 300rpm and distance of 1000 rpm.

Preparation and investigation of mechanical properties of 1350-h19 Al-Zn-Al2O3 hybrid metal matrix composites by stir casting process

Presently, lighter and stronger material is gaining popularity, especially in the automotive and aerospace industries, to lessen weight and boost fuel economy. This forced the industries towards developing metal matrix composites to improve the overall performance of vehicles and spacecraft. Among various combinations of composites utilized so far, Aluminum Matrix Composites (AMC) are frequently employed to meet industrial requirements. In this article, an attempt is made to synthesize and investigate the mechanical properties of 1350-H19 Al-Zn-Al2O3 hybrid metal matrix composite (HMMC). Al2O3 powder and Zn powder are reinforced in 1350-H19 Al using stir casting process, where the percentage of Al2O3 is varied 0 wt%, 6 wt%, and 12 wt% in Al-5 wt% Zn. Further, Taguchi's parameter design is used to establish the optimal parameter settings of the stir casting process for the hardness of the developed HMMC. Finally, the effect of various stir casting process parameters is analyzed using analysis of variance (ANOVA). The results indicated that a significant amount enhances the hardness of the HMMC compared to the base metal matrix.

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

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

Effect of sliding speed on tribological behaviour of heat treated hypoeutectic Al-7Si alloy and hybrid metal matrix composites

In the present paper, effect of sliding speed on wear behaviour of as-cast and heat treated hypoeutectic Al-7Si alloy and hybrid metal matrix composites have been investigated. Aluminium is used as matrix and Silicon Carbide (SiC) and graphite (Gr) particles are used as reinforcements. The proposed Aluminium Metal Matrix Composites (AMMCs) was fabricated by stir-cast method. Aluminium A356 matrix and reinforcements of SiCp was varied from 0 to 9% by weights in steps of 3%, and addition of fixed quantity of 3% by weight of Gr particles. The castings were machined as per ASTM standard and T6-heat-treatment was carried out. Specimens were aged at different durations from 3 to 12 hrs in steps of 3 hrs at a temperature of 155 ºC. The pin-on-disc wear testing machine was employed to evaluate the wear rate of the composites. As per the results, addition of reinforcement and aged at T6-9 hrs shows most wear resistance in all sliding tests. The increase in sliding speed with increase of wear rate was observed. The wear tested samples were examined using scanning electron microscope (SEM) and energy dispersive spectrum (EDS) and analysed.

Comparative analysis of thrust force, roughness and roundness error in drilling of aluminium composites using RSM, ANN and fuzzy logic

Making holes without any defect in a solid product made of hybrid Aluminium composite material, is a difficult job in assembly industries. Hybrid composite of Aluminium 7075 reinforced with ceramic materials like silicon carbide, boron carbide, graphite and mica are used in automobile and structural industries due to their excellent mechanical properties. Thrust force developed during drilling, Error in the circularity and poor surface finish of the drilled holes are some of the common problems faced in the drilling process. Hence, to optimise the quality of drilling, analysing these responses under various conditions of drilling by varying the drilling factor become essential. This study discusses the development of various models to predict the thrust force developed, roughness and circularity error in the holes drilled on a hybrid metal matrix composite. Testing of drilling is conducted in CNC vertical machining centre using Titanium aluminium nitride (TiAlN) coated carbide drill tool of 5 mm diameter. Various drilling factors considered in our study are point angle of the drill tool, drilling speed and feed rate. Multiple regression equations using RSM, Artificial neural network (ANN) and Fuzzy Logic algorithms are used to develop the prediction models. The predicted values of thrust force, surface roughness and circularity error from these models are found to be matching with the observed experimental values.

Mechanical characterization of aluminium 6061 hybrid metal matrix composites

Bigger interest in utilizing Metal Matrix Composites (MMCs) research on MMCs has provided not only new types of hybrid metal matrix composites, but also characterizations of their physical, thermo-mechanical, and tribological properties over the past 30 years. The main objective of this research is to produce MMCs with enhanced strength and wear resistance, that to replace the traditional heavy weight metals and alloys. In this research the parent material chosen was AA6061 aluminium alloy which has a wide commercial application and the reinforcements (SiCp/Fly ash/Glass Fibre) which can increase the wear tendency and in addition to that glass fibre is used to improve the biaxial strength of the prepared MMC. The work presented here uses Silicon carbide as the material, fly ash and glass fibre reinforced aluminium alloy (Al6061) composites, processed by stir casting route was used. The required quantities of silicon carbide (10 g and 15 g) and fly ash (10 g and 15 g) were taken in a powder container and the composites were prepared by using the stir casting process. This new material is evaluated through a limited mechanical test that Tensile, Hardness and Wear and to strengthen the experimental process SEM images are taken before and after the tests. The addition of reinforcement in Aluminium 6061 hybrid metal matrix composites, the tensile strength increases in the specimen 1 10 g of reinforcement mixed with A6061 and as well as in the specimen-2 15 g of reinforcement mixed with A6061 and wear resistance increases gradually and also wear and hardness in specimen 2 gives moderate result but the tribological behaviour is good.

Mechanical, microstructural and tribological behavior of stir cast Al8011/TiB2/SiC hybrid metal matrix composites

Modern technology requires enriched mechanical and thermal characteristics. In the present scenario, the decent mechanical and thermal properties of hybrid Metal matrix composites (MMCs) make them more demanding in various fields such as automotive, aviation, and structural applications. In this paper, an attempt has been made to fabricate the composite Al8011 + TiB2 + SiC with 9 different weight fractions follows as reinforcement 1(TiB2) by 2%,4%, and 6% with varying reinforcement 2(SiC) percentage by 1%,3%, and 5%. Fabrication is made through the stir casting technique by considering ideal process parameters such as stirring temperature, stirring speed, stirring time, preheating temperature, grain size, and wt.% of particulate reinforcements. With the help of Electron discharge machining (EDM), the specimens for the tests performed were cut according to the ASTM standards. The test results in the present investigation revealed that an increase in mechanical properties has been detected with the addition of reinforcements when compared with individual matrix and reinforcement materials. Wear test analysis illustrates that increase in resistance to wear of composite with the increase in TiB2 percentage of reinforcement. According to the microstructural analysis, an increase in stirring speed and stirring time reduces porosity. X-ray diffraction was used to identify crystalline phases of various MMCs. A unit cell dimensions can also be calculated based on the diffraction peak positions obtained from the X-ray diffractometer (XRD) test. The process of determining the unit cell dimensions from peak positions is known as indexing. Miller indices, hkl, must be assigned to each peak in a powder diffraction pattern to index it. The process of indexing electron diffraction patterns of a single crystal is to label the individual diffraction spots with their proper values and sign (+or -) of h, k, and l. When x-rays are scattered from a crystal lattice, peaks of scattered intensity are observed which correspond to the condition, the Angle of incidence = Angle of scattering and the path length integer is equal to an integer number of wavelengths. The condition for maximum intensity contained in Bragg's law above allows us to calculate details about the crystal structure, or if the crystal structure is known, to determine the wavelength of the x-rays incident upon the crystal. Indexing of diffraction patterns was done for all the metal matrix composites and in which the miller indices and interplanar d- spacing were calculated.

Microstructural and mechanical characterization of stir cast Al-SiC/Flyash/Graphite hybrid metal matrix composite

Aluminium is one of the most commonly used material in manufacturing industries. Hybrid aluminium matrix composite have recently received a lot of attention recently in the aviation, aerospace, and automotive industries to meet the advance engineering challenges. The present study focus on fabricating aluminium metal matrix hybrid composites using AA6061 as a matrix material and a novel combination of Silicon Carbide (SiC), Flyash and Graphite (Gr) as reinforcing materials by employing stir casting process. Mechanical properties like yield strength, ultimate tensile strength, percentage elongation and hardness were evaluated for the developed composite specimens in accordance with ASTM standards. The metallography of the developed composite was assessed by using optical microscope and scanning electron microscope (SEM). The fabricated composite disclosed fine grain structure as compared to the as cast aluminium alloy. The hardness of developed composite increased due to the presence of brittle and hard reinforcement particles into the matrix material. The developed composite has a higher tensile strength which may be attributed to the load transmission from the matrix material to the reinforcing particles.

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

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

Evaluation of mechanical properties of aluminium alloy (AA 6082) reinforced with Rice husk ash (RHA) and Boron carbide (B4C) hybrid metal matrix composites using stir casting method

Aluminum alloys are commonly employed in shipbuilding and automotive manufacturing units. The mechanical properties of alloys, such as strength and hardness, can be improved by adding reinforcement to the matrix material. Stir casting is an improved method for uniform dispersion of particles over conventional casting methods. Therefore, an effort is made to fabricate aluminium alloy (AA 6082) composites with different ratios of hybrid reinforcement of Rice Husk Ash (RHA) and Boron Carbide (B4C) reinforcements.The mechanical properties of composites such as tensile strength, hardness, flexural strength, and impact strength were evaluated. The microstructural properties of composites were evaluated using a scanning electron microscope to determine the dispersion of particles in the matrix material. It is found that tensile strength, hardness were improved by 20% as well as the uniform distribution of reinforcement particles in composites.

Effect of addition of titanium carbide and graphite reinforcement on Al7075 hybrid metal matrix composites by gravity stir casting method

In recent years composite materials play vital role on automobile and aerospace industries and the maximum researcher developed the composite, they are used maximum addition of reinforcement particle to the base aluminium matrix is less than 10 % of weight fraction. An attempt is made to increase the addition of reinforcement to the aluminium base material more than 10 % weight fraction. In this research work is to evaluate the mechanical properties of Al7075-Titanium carbide (TiC)-Graphite (Gr) composites developed by gravity stir casting method with increasing the addition of weight percentage of ceramic reinforcement of titanium carbide from 10%,12% and 14% weight fraction with fixed 2% weight percentage of graphite to the composite. The developed Al7075-TiC-Graphite composites were exposed to tensile hardness, and impact studies. The tensile strength, Hardness and impact strength of the composite were decreased while increasing the addition of ceramic reinforcement. Scanning electron microscope confirms the presence of reinforcement of titanium carbide and graphite in the hybrid metal matrix composite. The average tensile strength of the composite increased from 80.87 MPa to 139.87 MPa for the addition of titanium carbide of 10% and 12% weight fraction addition of TiC, beyond that the average tensile strength were decreased when further increasing the addition of reinforcement to base alloy matrix material. The hardness of the Al7075-TiC-Graphite composites increased to 41.31% while increasing the addition of weight percentage of TiC to base matrix where as impact strength of composites decreased while increasing the addition of reinforcement due to higher brittle nature of reinforcement than the base aluminium matrix material. The scanning electron microscope (SEM) confirms the presence of Aluminum, TiC and Graphite particle in the cast composite.

On the Selection of a Composite Material for Two-Wheeler Foot Bracket Failure Prevention through Simulation and Mathematical Modeling

A foot bracket is a metal panel bracket used to mount and support the footrest in two-wheeler systems. It holds the footrest in place while rigidly supporting it. In working conditions, this element has often been observed to fail when specific load-fluctuation conditions are established at its rear end. Appropriate materials therefore need to be identified to overcome such a recurring failure. To address these issues, the present study has been implemented with the specific objective to determine the response of selected Al6061-T6 and Al7075-T6 Hybrid Metal Matrix Composites (HMMC). The results, obtained using the ANSYS Software, show that the selected composites can withstand 636,962 N/m² of maximum stress and 8.88 × 10−6 m of minimum displacement. These results are also compared with relevant mathematical models and it is concluded that the identified material combination provides the required improvement of structural stability that can withstand the load fluctuation on the foot bracket.

Fabrication of hybrid metal matrix composites (HMMCs) – A review of comprehensive research studies

The metal matrix composites have drawn focus from the many of industries owing to their exciting mechanical, structural properties and micro-structures. The performance advantage of MMCs is their tailored thermo- physical and mechanical properties. These properties are ideally suited for application in automotive, aviation, space and electronic sectors. MMCs can be fabricated through wide range of manufacturing methods including liquid metallurgy and powder metallurgy, deposition of matrix. Among these techniques, stir casting can produce near-net shape and has been proven to be economical and flexible method to fabricate MMCs. Achieving optimal range of mechanical properties of hybrid MMCS have ever been a challenge for researchers. This research paper discusses about research studies on fabrication of hybrid MMCS via different fabrication techniques.

Prediction of mechanical properties of aluminium metal matrix hybrid composites synthesized using Stir casting process by Machine learning

In recent days, aluminium based hybrid metal matrix composites (Al-HMMC) is heavily demanding in aerospace and marine industry due to its enriched mechanical properties. Al7075 and Al6061 aluminium alloy are most widely used as a base matrix in Al-HMMC and stir casting method is an efficient process to manufacture them. The mechanical properties of Al-HMMC depend on material parameters and fabrication process parameters. Effecting parameters were identified based on a thorough literature review, and they include material parameters such as different types of matrix, reinforcements, and their weight percentages and sizes, as well as fabrication process (Stir Casting) parameters such as stirring speed, stirring time, and reinforcement mixing temperature. To achieve desirable results of hybrid composite materials from stir casting method, it requires high experimental cost and time. To overcome these limitations, machine learning and artificial intelligence are emerging tools, which utilize probabilistic and statistical methods to learn from the past experience based upon the experimental data to predict more accurate outcomes. In this work an attempt has been made to develop a machine learning model that can predict mechanical properties accurately. Experimental data of mechanical properties of aluminium HMMC has been collected and then used for training and testing of different machine learning models. Decision tree regression model showed maximum accuracy of 92.029 % on dataset for prediction of Ultimate Tensile strength (UTS) of Al-HMMC. The UTS of two samples of Al-HMMC with Al7075 and Al6061 as base matrix were predicted from decision tree model and compared with actual experimental values with an error < 10%.