Metal Matrix Composite Materials Research Articles

Studies on Selective Laser Quenching by High Repetition Frequency Lasers with Scanning Galvanometer

This study introduces a novel material processing methodology termed High Repetition Frequency Selective Laser Quenching (HRF-SLQ). This technique utilizes high-power lasers with a maximum power of 5 kilowatts in conjunction with a scanning galvanometer, operating at elevated repetition rates up to 200 hertz, to specifically treat surfaces of high and medium carbon steels. The application of this method leads to the creation of allotropic metal matrix composite materials (A-MMCs). In general, the scanning speed of a galvanometer can range from hundreds to thousands of times per second. Based on the high acceleration and rapid jumping characteristics of the scanning galvanometer, this technology transforms the high-power laser heating of metal plates from continuous heating mode to parallel pulse heating mode, which repeats heating 30 to 200 times per second. This transformation ensures the quenched layer avoids melting even under prolonged irradiation times by high-power lasers. Consequently, it can significantly enhance processing efficiency by selective laser quenching (SLQ), ensuring that the depth of the hardened layer reaches 0.88 to 0.94 millimeters and keeping the surface smooth without melting. This paper systematically investigates the influence of various processing parameters, such as laser power (P), single heating time (t1), and the number of processing units (N), on the depth of the SLQ and the quenching efficiency. It also examines the impact of HRF-SLQ technology on the properties of A-MMCs and analyzes temperature field variations from room temperature to melting point through simulation methods combined with laser quenching experiments.

Tribological and microstructure studies of LM26/SiC metal matrix composite materials and structures for high temperature applications

This study aimed to investigate the tribological and microstructural characteristics of LM26 composites reinforced with silicon carbide to evaluate their suitability for high-temperature applications. For the sample fabrication, the modified stir-casting method was optimized using a Taguchi L16 orthogonal array. The wear rate and friction behavior were evaluated using the Taguchi’s S/N ratio analysis. When SiC was incorporated into the composite, the wear resistance increased by up to 15 wt%. The wear resistance of the LM26/SiC composite was improved compared to that of the pure LM26 aluminum alloy. The results of this study provide useful information to improve the wettability of metal matrix composites made from commercial-grade LM26 aluminum alloy by adjusting the SiC weight percentage. This type of composite has the potential as a replacement material for traditional applications such as heat sinks, heat exchanger fins, and electronic packaging.

Melting and solidification dynamics during laser melting of reaction-based metal matrix composites uncovered by in-situ synchrotron X-ray diffraction

Laser additive manufacturing (AM) of reaction-based metal matrix composites (MMCs) involves highly complex and non-equilibrium material transformation behavior, including melting, dissolution, precipitation, and solidification. Yet, the dynamics and interplay of these phase transformation processes remain poorly understood, posing substantial challenges in identifying the microstructure formation mechanism, and predicting and controlling the microstructure in the printed parts. Here we performed the in-situ X-ray diffraction experiment to characterize the phase evolution dynamics of the 316L + 10 vol.%TiC system during laser melting, which provides direct and quantitative insights of the complex phase reaction and evolution dynamics under rapid heating and cooling conditions relevant to additive manufacturing of reaction-based MMCs. Further in-depth thermodynamic and kinetic calculations revealed that most of the phase evolution behavior observed in the in-situ X-ray diffraction experiment cannot be solely explained by widely used equilibrium thermodynamic models, and diffusion-controlled nonequilibrium dissolution and precipitation kinetics must be considered to elucidate the complex phase evolution behavior, including incomplete TiC dissolution, and three-step TiC precipitation. The three distinct types of precipitates generate unique hierarchical TiC micro- and nanostructures, which enhances the yield strength from 513 MPa to 877 MPa by 71 %, tensile strength from 628 MPa to 1054 MPa by 68 %, and Young's modulus from 193 GPa to 221 GPa by 14 %. The findings of our research provide the knowledge foundation for the design of unique microstructures and advanced MMC materials through laser AM.

New Processing Route for the Production of Functionally Graded 7075 Al/SiCp Composites via a Combination of Semisolid Stirring and Sequential Squeeze Casting

Advanced processing techniques are required to produce functionally graded metal matrix composites due to the metallurgical conditions required during production. In this study, we developed a novel approach for this task by using a combination of two different methods to produce functionally graded 7075 Al/SiCp (5–20 wt.%) composites. The first process was direct semisolid stirring, which was used to prevent particle agglomeration, brittle reaction products, floating or settling of the reinforcements, and poor wettability. The second process was sequential squeeze casting, which enabled liquid diffusion between the two composite layers that were used to produce a functionally graded aluminum matrix composite. Thus, a method was developed to eliminate the problems encountered in the production of particle-reinforced metal matrix composite materials using liquid stirring methods and to produce composite materials with the desired functionally graded structure. The resulting functionally graded material was subjected to spectrometer analyses, density measurements, and metallographic examinations to determine the characteristics of its layers and interfacial zones, as well as to assess the formation of the graded structure. The results indicate the potential of using this new combined manufacturing method, which is efficient and controllable, to produce functionally graded metal matrix composites.

Improving the Load Carrying Capacity through Asymmetric Spur Gear using WC-Fe Metal Matrix Composite for Automobile Applications

Gears are the components that have been used for a century to transmit power from one place to another place. Symmetric spur gears are commonly used in the gearbox to transmit power between two parallel shafts. In order to increase the load carrying capacity of the spur gear with reduced noise and vibration, its profile can be modified. This can be achieved by changing the gear tooth design into asymmetric form. Asymmetrically toothed gears are used in power transmission for transmitting the power in one direction. These teeth help to improve the load carrying and power transmitting capacity of the gear. The strength can be further increased by changing the material used in gears. This can be made possible by using Metal Matrix Composite as a gear material. The metal matrix composites have high stiffness and strength to weight ratio compared to the Alloy Steel. The main objective of this project is to increase the load carrying capacity of the spur gear by using WC-Fe metal matrix composite material. The symmetric and asymmetric gear modeling has been done for existing car gear (Maruthi 800) using Ansys parametric design language software. The contact stress, bending stress and von Mises stress of the composite, as well as conventional gear material, is analyzed and the results are compared to find the percentage increase in strength of the gear.

Slurry erosive wear behaviour of metal matrix composites – A review

Slurry erosion has become a problem in the components that handle particle-entrained slurry. The limitation of the metallic materials to inhibit the slurry erosive wear has led to the development of metal matrix composite (MMC) materials to suit applications in severe erosive environments. Compared to ductile and brittle materials, metal matrix composite materials behave differently when subjected to slurry erosion. However, due to the ductile matrix and hard reinforcement phases, the metal matrix composites exhibited semi-ductile and semi-brittle erosion behaviour under slurry erosion conditions. This work presents the material removal mechanisms of MMCs, erosion models, and types of equipment for slurry erosion testing. In addition, the various factors that influence slurry erosion, such as the properties of MMC, properties of flow, erodent particles, and slurry, have also been reviewed.

Effect of SiC addition in fabrication of Al/SiC metal matrix composite by stir casting

Aluminum alloys find extensive application in aerospace and automobile industries due to their advantageous attributes: low density, commendable mechanical properties, superior corrosion resistance, wear resistance, and a lower thermal coefficient of expansion compared to traditional metals and alloys. These materials boast excellent mechanical properties while maintaining a relatively cost-effective production, rendering them highly desirable across various scientific and technological applications. The objective of developing metal matrix composite materials is to combine the favorable characteristics of both metals and ceramics. This study focuses on investigating the behavior of Aluminum alloy 6063 combined with SiC composite produced through the stir casting method. A different percentage (3% & 5%) of SiC is added with Al6063, and the specimens were fabricated by a stir-casting process. Tensile tests, Hardness Tests, and impact test were conducted on the specimens obtained from the stir-casting process. The result showed that there is an increase in hardness and decrease in tensile and impact strength upon the addition of SiC with Al6063 to fabricate metal matrix composite.

A Finite-Element-Analysis-Based Feasibility Study for Optimizing Pantograph Performance Using Aluminum Metal Matrix Composites

A pantograph is a key component on the tops of trains that allows them to efficiently tap electricity from power lines and propel them. This study investigates the possibility of using metal matrix composites (MMCs), specifically aluminum MMCs, as a material for making pantograph parts regarding the dynamics of the train’s movement and external meteorological conditions. In this study, a computer-aided design (CAD) model is created using PTC Creo design software and moves to detailed finite element analysis (FEA) simulations executed by the ANSYS software suite. These simulations are important in examining how the dynamic performance of pantographs can vary. The incorporation of Al MMC materials into the structure of the pantograph resulted in significant improvements in structural robustness, with equal stress reduced by up to 0.18%. Similarly, aluminum MMC materials reduced the strain energy by 0.063 millijoules. The outcomes not only give a new perspective to the implementation of modern materials but also provide a breakthrough concept to improve efficiency and increase the service life of pantographs. This study marks a significant milestone in the theoretical development of essential train systems, furnishing eminent perspectives toward the tactical development of transportation infrastructure by suggesting new avenues for the smooth incorporation of smart materials in railway transportation, which would contribute to a more sustainable and reliable future.

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.

Enhancing mechanical properties of selective-laser-melting TiN/AISI 420 composites through Taguchi GRA and PCA multi-response optimization

The enhancement of mechanical properties in martensitic AISI 420 stainless steel is realized through the incorporation of TiN ceramic particles using the selective laser melting (SLM) method. This study introduces an innovative hybrid mixing method designed to uniformly disperse TiN within the AISI 420 matrix, ensuring the absence of agglomerations and contaminations in the feedstock for the SLM process. Employing a combined approach involving the Taguchi method, Grey Relational Analysis, and Principle Component Analysis, optimal processing parameters and TiN content are identified, encompassing a laser power of 350 W, laser speed of 370 mm/s, hatch distance of 0.07 mm, layer thickness of 0.05 mm, and one percent by weight of TiN particles. The optimized SLM sample showcases exceptional characteristics with a hardness of 743 ± 20 HV, tensile strength of 1822 ± 21 MPa, and a modulus of toughness of 99.7 ± 3.0 J/m3, surpassing existing results. Introducing TiN particles into the AISI 420 matrix with suitable SLM processing parameters induces significant microstructural alterations, reinforcing the matrix and elevating the mechanical properties. These results mark a substantial advancement in metal matrix composite materials by applying cutting-edge manufacturing techniques.

Microstructure, Phase Composition, and Mechanical Properties of Intermetallic Ni-Al-Cr Material Produced by Dual-Wire Electron-Beam Additive Manufacturing

Electron-beam additive manufacturing is one of the most promising methods for creating complex metal parts and structures. Additive manufacturing has already gained wide acceptance in the creation of various constructions from aluminum, copper, titanium, and their alloys as well as different classes of steels and other metallic materials. However, there are still many challenges associated with the additive manufacturing and post-production processing of intermetallic alloys. Thus, it is currently an urgent task for research. In this work, heat-resistant intermetallic alloys based on nickel, aluminum, and chromium were produced by dual-wire electron-beam additive manufacturing using commercial NiCr and Al wires. The microstructure, phase composition, and microhardness of the intermetallic billets are strongly dependent on the ratio of NiCr and Al wires, which have been fed during the additive growth of the material (NiCr:Al = 3:1 and NiCr:Al = 1:3). A metal-matrix composite material (Al3Ni-based intermetallide in Al-based matrix) was fabricated using the NiCr:Al = 1:3 ratio of the wires during the deposition. In tension, it fractures in a brittle manner before the plastic deformation starts, and it possesses a high microhardness of 6–10 GPa with a high dispersion of the value (the mean value is 8.7 GPa). This is associated with the complex phase composition of the material and the high fraction of a brittle Al3Ni intermetallic phase. In the material, obtained with the ratio NiCr:Al = 3:1, the ordered Ni3Al(Cr) and disordered Ni3Cr(Al) intermetallides are the dominating phases. Its microhardness turned out to be lower (4.1 GPa) than that in Al + Al3Ni-based composite, but intermetallic Ni3Al-based alloy demonstrates good mechanical properties in a high-temperature deformation regime (650 MPa, more than 10% elongation at 873 K). Microstructural studies, analysis of phase composition, and tensile mechanical properties of additively produced intermetallic materials show the perspective of dual-wire electron-beam additive manufacturing for producing intermetallic compounds for high-temperature applications.

Experimental tribological and mechanical behavior of aluminium alloy 6061 composites incorporated ceramic particulates using Taguchi analysis

Aluminium metal-matrix composites are broadly employed in industries like aerospace, marine, automobile-sector, and many others, generating a broad research interest. They are preferred for their high strength and low wear rate. This research work is mainly directed towards the fabrication of two types of metal-matrix composite materials using aluminium-alloy 6061(AA6061) as the matrix material and incorporating aluminium oxide (Al2O3), aluminium nitride (AlN), and silicon carbide (SiC) as a reinforcement material. AA6061 has been reinforced with Al2O3 and SiC particulates in AS series composites, while AA series composites, AA6061 has been reinforced with Al2O3 and AlN particulates. This hybrid metal composite was constructed using the stir-casting method. These hybrid composites have been investigated for their physical and mechanical characteristics, viz. density, hardness, impact strength, void content, flexural strength, and tensile strength following the ASTM standards. Tribological characteristics of these hybrid composites were performed by Pin-on-disc (POD) tribometer. Taguchi’s design of experimental technique was applied taking four factors viz. composition, sliding-velocity (SV), sliding-distance (SD), and load, and each having 4 levels. ANOVA was employed to find out meaningful parameters. SEM analysis of worn-surface was executed to find out the dominant wear mechanism. Experimental density was highest for AS42, and AA42 composites and void content were lowest for the same. Mechanical properties viz. density, hardness, impact strength, void content, flexural strength, and tensile strength were higher than the base alloy. From the response table of Taguchi analysis of AS and AA composite, the load factor significantly impacted the specific wear rate (SWR) to follow filler content (FC). It can be followed from the ANOVA table for AS composite that the load factor had a magnificent impact on the SWR. The SV and SD show no significant effect on SWR.

Determinant of Dynamics and Interfacial Forces in Ultraprecision Machining of Optical Freeform Surface through Simulation-Based Analysis.

This study delves into the intricacies of ultraprecision machining, particularly in the context of machining optical freeform surfaces using Diamond Turning Machines (DTMs). It underscores the dynamic relationship between toolpath generation, hydrostatic bearing in DTMs, and the machining process. Central to this research is the innovative introduction of Metal Matrix Composites (MMCs) to replace the traditional materials used in designing linear bearings. This strategic substitution aims to dynamically enhance both the accuracy and the quality of the machined optical freeform surfaces. The study employs simulation-based analysis using ADAMS to investigate the interfacial cutting forces at the tooltip and workpiece surface and their impacts on the machining process. Through simulations of STS mode ultraprecision machining, the interfacial cutting forces and their relationship with changes in surface curvatures are examined. The results demonstrate that the use of MMC material leads to a significant reduction in toolpath pressure, highlighting the potential benefits of employing lightweight materials in improving the dynamic performance of the system. Additionally, the analysis of slideway joints reveals the direct influence of interfacial cutting forces on the linear slideways, emphasising the importance of understanding and controlling these forces for achieving higher-precision positioning and motion control. The comparative analysis between steel and MMC materials provides valuable insights into the effects of material properties on the system's dynamic performance. These findings contribute to the existing body of knowledge and suggest a potential shift towards more advanced precision forms, possibly extending to pico-engineering in future systems. Ultimately, this research establishes a new standard in the field, emphasising the importance of system dynamics and interfacial forces in the evolution of precision manufacturing technologies.

INVESTIGATION OF ELECTROEROSION MACHINING PERFORMANCE OF METAL MATRIX COMPOSITE MATERIALS PRODUCED USING STIR AND INDIRECT SQUEEZE METHOD

In this study, metal matrix composite (MMC) materials were made with an aluminum matrix (AA7075 alloy) and reinforcement silicon carbide (SiC) elements using molten metal stir and indirect squeeze casting. SiC was used as a reinforcing element in the making of MMC material in different amounts (10%, 14%, and 18%) by mass. Electro Discharge Machining (EDM), cut depth (0.5 mm), three different pulse-on times, three different discharge current values, and a fixed pulse-off time (20 s) were used to machine MMC materials. The effects of machining parameters on machining time, average surface roughness, hole diameter, and material wear difference after machining were studied. As a result of the study, the composite material with 75 [Formula: see text]s pulse-on time, 6A current value, and 10% reinforcement element had the lowest machining time, the largest hole diameter, and the smoothest average surface. These machining parameters and materials also had the shortest machining time (5 min). Based on the signal-to-noise ratios, the best parameters for average surface roughness, hole diameter, Processing time, and material wear amount (MMC, discharge current value, and impact time) were found to be [Formula: see text], [Formula: see text], [Formula: see text], and [Formula: see text], respectively. Based on the ANOVA results, the [Formula: see text]2 values for the average surface roughness, hole diameter, machining time, and material wear loss value were 99.3%, 98.7%, 77.8%, and 97.3%, respectively.

The application of metal matrix composite materials in propulsion system valves

The application of metal matrix composite materials in propulsion system valves

Influence of cryogenic treatment duration of drills on drilling performance and hole quality of metal matrix composite materials

Influence of cryogenic treatment duration of drills on drilling performance and hole quality of metal matrix composite materials

Exploring the mechanical, metallurgical, and fracture characteristics of hybrid-reinforced magnesium metal matrix composite synthesized via friction stir processing route

Low-cost hybrid-reinforced magnesium metal matrix composite (HMMC) materials present a revolutionary category of materials achieved by combining two or more distinct reinforcing elements within the magnesium (Mg) matrix. The main focus of this research is to fabricate Mg-based HMMCs with exceptional mechanical and other characteristics by utilizing Mg substrate AZ61A as the base material. To achieve this, nano-titanium carbide (TiC), nano-silicon carbide (SiC), and fly ash (FA) were selected as hybrid reinforcements, and the friction stir processing technique was employed for their incorporation. The microstructural, thermal, mechanical, wear, and fracture properties of synthesized HMMCs were carefully examined using a conventional testing approach. The findings demonstrate that the grain size of the base AZ61A alloy was measured at 32 µm, whereas the AZ61A/FA/TiC/SiC composite exhibited a remarkable reduction to 3.5 µm. Notably, this reduction in grain size leads to simultaneous enhancement in mechanical properties. The microhardness, ultimate tensile strength, and ultimate compressive strength of the developed HMMC showed an impressive increase, measuring 2.09 times, 2.75 times, and 2.10 times higher, respectively, compared to their initial values of the base material. Moreover, a significant enhancement in wear resistance was also observed, attributed to the increased hardness and homogenous hybrid reinforcement dispersion into the HMMCs. In addition, it was evident that the synergistic combination of different reinforcement particulates in Mg-based alloy improves overall fracture resistance and catastrophic failure and mitigates crack propagation.

Multi-Body Dynamic Analysis of Hydrostatic Bearing with the MMC Material in Micro-Nano Machining.

This study focuses on the analysis of a linear hydrostatic bearing using harmonic frequency response and harmonic response simulations. The aim is to evaluate the feasibility of replacing the existing alloy steel material with a metal matrix composite (MMC) in terms of its performance and dynamic characteristics for both the base and carriage parts. The simulation results indicate that the MMC material exhibits higher resonant frequencies and improved damping capabilities compared to the structural steel material. The higher resonant frequencies observed in the MMC material are attributed to its stiffness and structural properties. These properties contribute to increased natural frequencies and improved vibration damping characteristics. This suggests that incorporating the MMC material in the bearing design could enhance motion control, improving the ability to precisely control and manipulate the movement of components or systems. In the context of ultraprecision machining applications, incorporating the MMC material in the hydrostatic bearing design can also lead to a more accurate and controlled motion, resulting in improved precision and finer machining outcomes. The displacement analysis confirms that both materials meet the specifications provided by the manufacturer, supporting the viability of using MMC as an alternative. However, further experimental validation and considerations of material feasibility, manufacturing factors, and cost-effectiveness are necessary before implementing the MMC material in practical applications. Overall, this research highlights the potential benefits of MMC in the design of linear hydrostatic bearings, paving the way for enhanced performance in ultraprecision machining processes.

Optimization of piston material with aluminium alloy based metal matrix composites

Piston failure is caused by a combination of mechanical and thermal loads is a frequent occurrence that can be expensive to repair or replace. In this paper, analysis is carried out to evaluate and improve the performance of a piston intended for deployment in a four-stroke SI engine with a single cylinder. To determine the most suitable material for the piston, different materials, alloys and aluminium based metal matrix composite are examined. Piston is designed using CAD software and static structural analysis and thermal transient analysis is done using finite element analysis. Based on the analysis, Al 6061–1.5% B4C- 1.5% SiC metal matrix composite material is found to be the most desirable choice among the five materials considered due to lower value of deformation (31% to 76% less in comparison) and mechanical stresses (0.38% to 0.83% less in comparison).

Numerical analysis of the influence of particle population characteristics in a metal matrix composite material

Numerical analysis of the influence of particle population characteristics in a metal matrix composite material