Metal Matrix Composite Materials Research Articles

The influence of particle population geometry and slenderness on the mechanical behaviour of a metal-matrix composite material

The influence of particle population geometry and slenderness on the mechanical behaviour of a metal-matrix composite material

Physical and mechanical behavior of aluminum-magnesium alloy matrix hybrid composite fabricated through friction stir consolidation process

Nowadays metal matrix composite materials are preferable in automotive and aerospace industries due to their mechanical properties and essentially attractive strength to weight ratios. However, their availability in use is limited because of their manufacturing method difficulty and process extravagancy. The aim of this research was to fabricate metal matrix hybrid composite through a novel approach thermo-mechanical method called friction stir consolidation (FSC) process. XRD result witnessed the presence of SiC, ZrO2, and AZ61 alloy phases. Different compositions of AZ61, SiC, and ZrO2 powder were taken into consideration and the progression of the FSC process were examined through properties of compressive strength, hardness, density, and porosity. For instance, the compressive yield strength of composition 85%Vol. of AZ61, 10%Vol. of ZrO2, and 5%Vol. of SiC accounts 164.2 MPa with an acceptable 2.2451 g/cm3 and 0.593% density and porosity respectively. However, when the strength to weight ratio was taken into consideration, 95%Vol. of AZ61, 2.5%Vol. of ZrO2, and 2.5%Vol. of SiC composition attained highest strength to weight ratio value. Additionally, the compressive yield strength value increased directly proportional with the ZrO2 volumetric composition. Likewise, the fractured surface of sample acquired highest strength to weight ratio was examined through SEM Fractography analysis.

Experimental and Numerical Analysis of the Progressive Damage and Failure of SiCf/TC4 Composite Shafts

Long fibre-reinforced metal matrix composite materials, which are widely used in industry, have complex and diverse damage modes due to their structural characteristics. In this study, the progressive damage process and failure mode analysis of the SiCf/TC4 composite shafts were thoroughly investigated under single torsional loads. A bearing performance test was carried out, the damage process was monitored using acoustic emissions, and the fracture specimens were analysed using a scanning electron microscope (SME). More specifically, under reverse torque loading, the damage process was slow-varying, the interface was subjected to tensile force, and fracture occurred mostly in the form of interface cracking; further, the breaking load of the specimen was 11,812 Nm. Under forward loading, the damage process was fast-varying. The fibres were subjected to tensile forces, and the fracture form was mostly fibre fracture; the breaking load of the specimen was 10,418 Nm. Under torque loading, the first damage to the specimens appeared in the outermost layer of the composite material’s reinforced section, and the initial cracking position was at the interface, expanding from the outside to the inside. Based on the principles of macro-mechanics and micro-mechanics theory, the cross-scale models were proposed, which contain the shaft with the same dimensions as the specimen and a micro-mechanics representative volume element (RVE) model. The initial interface damage load was 6552 Nm under reverse torque loading. Under forward loading, the initial interface damage load was 9108 Nm. In comparison to the acoustic emission test results, the main goal was to calculate the progressive damage process under the same conditions as the experiment, verifying the effectiveness of the cross-scale models.

Growth mechanisms of interfacial carbides in solid-state reaction between single-crystal diamond and chromium

Interfacial bonding is one of the most challenging issues in the fabrication, and hence comprehensively influences the properties of diamond-based metal matrix composites (MMCs) materials. In this work, solid-state (S/S) interface reaction between single-crystal synthetic diamond and chromium (Cr) metal was critically examined with special attention given to unveil the role of crystal orientation in the formation and growth of interfacial products. It has been revealed that catalytically converted carbon (CCC) was formed prior to chromium carbides, which is counterintuitive to previous studies. Cr7C3 was the first carbide formed in the S/S interface reaction, aided by the relaxation of diamond lattices that reduces the interfacial mismatch. Interfacial Cr7C3 and Cr3C2 carbides were formed at 600 and 800 °C, respectively, with the growth preferred on diamond (100) plane, because of its higher density of surface defects than (111) plane. Interfacial strain distribution was quasi-quantitively measured using windowed Fourier Transform-Geometric Phase Analysis (WFT-GPA) analysis and an ameliorated strain concentration was found after the ripening of interfacial carbides. Textured morphologies of Cr3C2 grown on diamond (100) and (111) planes were perceived after S/S interface reaction at 1000 °C, which is reported for the first time. The underlying mechanisms of Cr-induced phase transformation on diamond surface, as well as the crystal orientation dependent growth of interfacial carbides were unveiled using the first-principles calculation. The formation and growth mechanisms of Cr3C2 were elucidated using TEM and XRD analyses. Finally, an approach for tailoring the interfacial microstructure between synthetic diamond and bonding metals was proposed.

Tribological characteristics of aluminium alloy composites manufactured by liquid state casting process – A review

The global requirement for good quality and superior performing composites has led to research in hybrid metal matrix composite materials. In metal matrix composites, Al alloy composite has been chosen widely because of its high strength-to-weight ratio and superior wear resistance. Reinforcements like particulate Al2O3, SiC, fly-ash and graphite, etc. can easily be included in the melt using a liquid state casting process. In order to fulfil the essential need for elaborating their application, conventional stir casting method is employed which is economical for fabricating composite material when compared to other solid-state and liquid-state processes. This paper mainly focuses on the tribological properties and problems incorporated at the time of stir casting process of aluminium alloy composites containing one or more reinforcements. It provides inputs on the reinforcement incorporated, the matrix composition and the interface overlap and distribution each of which is critical in determining the performance of the composite. Processing AMMCs is straight forward using stir casting process, which is the most inexpensive and robust process that can be used on a wide scale, while other methods are confined to laboratories alone.

Preparation and characterization of Al8011 TiO2 and nano Graphene hybrid composite mechanical and wear behavior

Aluminum Metal Matrix Composite (AMMC) materials are advantageous in a wide range of engineering applications, most notably due to their lightweight strength, among other factors. The present research focuses on determining the mechanical and wear behavior of Aluminum 8011 (Al8011) reinforced with (30 µm particle size) Graphite (Gr) by 3% by weight fraction and titanium oxide (TiO2) 5%, 10% and 15% weight. Stir casting was chosen as the cheapest approach in this investigation because it was readily available and cost-effective. Distinct samples of the newly developed composites were used in conjunction with a control sample of the aluminum alloy base material. Al8011 reinforced with (Gr) and TiO2 is being investigated in order to better understand how these materials interact with one another when heat treated and without treatment. With increasing TiO2 and Gr content, the hardness improved as well as the hardness up to specific limitations; the microstructure shows the compounds distribution uniformity for Al8011 with 10% TiO2 and 2% wt Gr. The hardness also improved with the same compositions, according to the test findings (10% TiO2 and it was identified that the heat treatment created a strong bond between the compound reinforcement. The wear resistance also increaseswith the hardness.

Closed-form asymptotic micromechanics model of fiber reinforced polymer and metal matrix composites

This work presents an analytical asymptotically-correct micromechanics model that helps to predict the effective material properties of a unidirectional composite material. The conventional and numerical approaches estimate the homogenized material properties of composites for their defined component volume fractions, their constituent properties and configurational geometry. Presently these approaches are based on kinematic assumptions such as having displacement or stress components vary through the cross section for beam like structures or through the thickness for plate like structures according to certain predefined functions that doesn’t always logically follow the 3D analysis. In the present formulation, the micromechanics model is developed by accommodating all possible deformations without assuming the displacement function or stress components. These are derived by minimizing the potential energy in terms of generalized strain measures. In the present formulation, Berdichevsky’s Variational Asymptotic Method (VAM) is employed as a mathematical tool to accomplish the homogenization procedure. The Hashin-Rosen model popularly referred to as the Concentric Cylinder Model (CCM) serves as the framework to estimate all the relevant homogenized elastic moduli and coupling coefficients. The derived quantities of interest are obtained as closed form expressions which are functions of the properties of the reinforcement material, the matrix material, their volumes fraction and the geometry of their relative arrangement. These expressions are arrived following the 3D elasticity governing rules by satisfying the interfacial displacement continuity and transverse stress equilibria conditions at the reinforcement and matrix materials interface. The developed expressions for the elastic moduli, shear moduli and Poisson’s ratios of few typical polymer and metal matrix composite materials are validated with some of the relevant results available in the literature.

Graphene Reinforced Aluminium Metal Matrix Composite Materials an Alternate Novel Material for Super Lightweight Fuel Tank (SLWT) Structural Application – A State of Art

Graphene Reinforced Aluminium Metal Matrix Composite Materials an Alternate Novel Material for Super Lightweight Fuel Tank (SLWT) Structural Application – A State of Art

A review of electrical discharge machining (EDM) and its optimization techniques

Non-traditional machining processes replace outdated manufacturing processes for machining hard metal matrix composite materials. Electrical Discharge Machining (EDM) is a non-conventional process that carries out machining depending on the materials’ thermal conductivity, melting point and electric resistivity. Stainless steel is used to produce nearly half of the world’s production units, and this process ensures the machining of stainless steel effectively. Various EDM processes are used to carry out various machining processes, which otherwise would not have been possible by any other machining operation. This paper provides an insightful review of existing literature, focusing on the techniques and associated parameters. In particular, input parameters, such as peak current, pulse on time, and pulse off time, are studied, along with the effect of dielectrics against the output parameters, such as metal removal rate and surface rudeness. Researchers in the past intensely focus on tool wear ratio. From this review, it is evident that researchers emphasized the material removal rate, surface finish and marching efficiency of the process under consideration.Besides, it is concluded that researchers did not seem to emphasize on study of different optimization techniques in this regard.

Evaluating the dynamic characteristics of microwave-casted metal matrix composite material by using experimental modal analysis

This paper proposes an experimental modal analysis technique to measure the dynamic characteristics of microwave-casted metal matrix composite (MMC). To fabricate MMC, silicon carbide (SiC) is reinforced into the SS202 matrix. The damping capacities of MMC at different reinforcements of SiC powder such as 0.05%, 0.1% and 0.2% are measured through experimental modal analysis. The main objective is to study the effect of reinforcement on the damping capacity of SS202. The domestic microwave oven with the specification of 2.45 GHz and 900 W power is used to cast the MMC material. The graphite split mold is used for in-situ microwave casting. The mechanical characterization in terms of micro-hardness and scanning electron microscopy (SEM) of MMC is also examined. From SEM imagining, complete diffusion of the SiC in SS matrix is observed for 0.05% of SiC reinforcement; however, incomplete diffusion is observed for 0.1% and 0.2% of SiC reinforcement. It is observed that the hardness of the SS202 is increasing with the decrease in the percentage of SiC powder. The experimental modal analysis is carried out by using SO Analyzer. The response model in terms of the frequency response function (FRF) curve is measured when the specimen is excited at impact excitations. The half power bandwidth method is used to calculate the damping factor of the material from the measured FRFs. It is observed that the damping capacity increases with the increase in percentage of SiC in SS202. SS202 with 0.05%, 0.1% and 0.2% SiC have the hardness value of 155.33 HV, 107.33 HV and 58.33 HV, respectively.

Design and fabrication by selective laser melting of a LIDAR reflective unit using metal matrix composite material

The selective laser melting is an additive manufacturing technology able to directly fabricate full dense metal part from a virtual model. The geometrical complexity degree of freedom allows the implementation to several industrial applications such as the laser imaging detection and ranging systems. A key component of this system is the reflective unit produced with traditional technology (surface with ribs) with optimized geometry for lightweight, which must be further lightened while continuing to meet functional requirements. Aim of this work is to reach these goals by using an integrated product/process methodology which considers all the fabrication steps. A complete redesign allowed to exploit the additive manufacturing advantages of a metal matrix composite based on AA 2000 series combined with a high content of ceramic. The increased mechanical properties, such as the tensile strength of 484 MPa and Young modulus of 96GPa, combined with a lattice structure empowered the SLM capability. The component was validated via finite element method simulation focused on the most critical polishing operation. Results on static and dynamic analysis showed the 25% lightened mirror satisfies the requirements. The testing on the physical prototype confirmed the enhanced mechanical properties and the interferometric measurement proved the mirror functionality with a surface front error less than the required wavelength of 1550 nm. The work evidenced that polishing and the assembly configurations must be selected with particular care; otherwise, the final outcome is compromised for this SLMed component.

Influence of Thermal Residual Stresses on the Behaviour of Metal Matrix Composite Materials

Influence of Thermal Residual Stresses on the Behaviour of Metal Matrix Composite Materials

Properties and Mechanism of Al<sub>2</sub>O<sub>3</sub>- Al Composite Powder Prepared by Hydrothermal Method

In order to improve the wear resistance of aluminum matrix composites and reduce the cost at the same time, the Al2O3/Al composite powder was prepared by hydrothermal method in this experiment, and the material properties of the Al2O3/Al metal matrix composite powder material were studied. It can be seen from the results that the encapsulation degree of Al2O3/Al-based composite powder material first increases and then decreases with the increase of ammonia concentration, and first increases and then decreases with the increase of PH value. The optimal molar ratio of salt and alkali is 1:1. Through the optimization of process parameters, the ratio of aluminum nitrate and ammonia water is obtained as: 1:1, the slurry stirring speed is 1500r/min, the stirring time is 10min, and the heating temperature is 200°C, the obtained composite powder is relatively uniform, has a larger specific surface area, and has better powder properties.

Structure and Properties of Composite Materials Sintered at High Pressure and Reinforced with Amorphous Boron Particles

Metal matrix composite materials (CMs) reinforced with boron particles are synthesized from powders of amorphous boron and metal (Ni, Ti) at a pressure of 8 GPa and temperatures of 500–1000°C. It is established that amorphous boron crystallizes during synthesis at temperatures above 800°С. Amorphous boron particles are characterized by a hardness of ~30 GPa, an indentation modulus of elasticity of up to 270 GPa, and an elastic recovery of more than 60%. The patterns of boride formation during high-pressure synthesis are studied. It is shown that the wear resistance of a Ni–B CM synthesized at 600°С grows by more than 30 times, relative to the wear resistance of pure nickel. Reinforcing titanium with 30% amorphous boron increases wear resistance by more than two orders of magnitude, but the coefficient of friction of CMs is reduced slightly.

Engineering of the surface of the dispersed phase and bulk metal composite to create promising materials

The main technological problems in the synthesis of metallic composites containing carbon nanotubes or carbide particles are the distribution of the hardening phase in the bulk composite, the strength of its adhesion to the matrix, as well as the chemical and structural stability of the dispersed phase within the composite. These tasks are solved in various ways, primarily at the stage of preparation of the dispersed phase and the monolithic composite matrix. In our work, to ensure good wettability of the dispersed phase and uniformity of its distribution in the bulk aluminum, carbon nanotubes and carbide were metallized with a thin layer of metallic nickel. In the course of work on the creation of aluminum matrix materials reinforced with carbon nanotubes, the necessary conditions were selected for the formation of a metal matrix composite material with improved mechanical properties.As a result, a technique for obtaining an aluminum matrix composite was developed, which makes it possible to prevent the carbon nanotubes agglomeration and suppress the chemical reactions between the dispersed reinforcing phase and the matrix. The method of obtaining composite aluminum matrix material includes multiple cold pressing, as well as alternating pressing and temperature treatment.As it has been shown, the reinforcing phases of different structures have different effects on the mechanical properties of the aluminum matrix composite.

An accuracy control strategy for micro-milling process of folded waveguide slow wave structure

The slow-wave structure (SWS) working in the terahertz frequency band features large aspect ratio and long span with characteristic dimensions of tens of microns. The development of micro-manufacturing technology for the high-quality fabrication of terahertz SWS is technically essential to promote the advancement of terahertz radiation source devices. In this work, micro-milling approaches were devised to process the 0.34 THz folded waveguide SWS with particle-reinforced metal matrix composite material. The causes of shape error and position error, especially within the arc-shape region, were analyzed in detail, considering the influence from the following error of machine tool and the unfavorable rigidity of milling tools. The optimization of regionalized cutting parameters was achieved, and two productive tool-path-planning schemes were conceived according to the structural features within the processing areas, attempting to minimize the external impact on the shape accuracy of SWS. A practical tool replacement scheme with the orthometric setting slots as a reference for resetting after tool replacement was determined, in order to avoid misalignment at the junction of adjacent units. In consideration of the structural complexity of SWS and the position specificity of burrs, the tool path in the horizontal plane was designed in the way of alternately milling of S-shape slot and straight slot, with cutting parameters adaptable to the depth of the processing subregion, which shows excellent suppression effect of burrs. The proposed micro-milling process strategy offers promises to improve the fabrication quality of high-aspect-ratio SWSs with the minimum structure size of ~50μm.

The electrochemical degradation, wear behavior and machining of metal matrix composites based on 6xxx aluminum alloy with ceramic particulate reinforcements; a brief review

6xxx series aluminum alloy-based metal matrix composite materials are finding greater applicability in various fields like marine, aerospace and automobile industries. In fact, the diverse nature of the availability of ceramic particles and the hybrid combinations of the reinforcements make them versatile in superior properties as well as applications. More over these composites are latest additions to the novel materials developed in recent decades and hence the end products of these composites are reaching the markets in recent times after several years of optimization studies. There is a need to compose the material properties as a review document so that the research on the same domain will get accelerated. Hence it is appropriate to make a comprehensive study about 6xxx aluminum alloy-based metal matric composites in terms of its corrosion behavior in aggressive environments, wear behavior in engineering applications and feasibility of manufacturing the end products using the composite.

Review paper on thermal expansion and tribological behavior of composite materials

Composite materials are cutting-edge materials with uncontrollable opportunities for modern development and material research. The designer will get help from these materials to accomplish objectives and desired conceptions. The reinforcement of metals serves as a tool to satisfy the various objectives of different metals. The use of light metals for reinforcement opens up a world of possibilities for weight reduction. Traditional materials become motivating for usage as constructional and functional materials if their property contours either do not satisfy the higher standards of explicit expectations or are the solution to the difficulty. Traditional materials, on the other hand, become motivating for usage as constructional and functional materials if their property contours either do not reach the growing standard of explicit expectations or are the solution to the problem. The appreciating knowledge of composite materials, on the other hand, competes with other contemporary material technologies. Researchers and scientists are now interested in and active in breakthroughs relevant to metal matrix composite materials. A large number of scientists and researchers have conducted considerable research. Light alloys are attractive as a basic matrix, according to literature, due to affordability, availability, and recycling. As basic matrixes, aluminium, copper, magnesium, iron metals, and titanium including their alloys, are commonly employed. The choice of a certain base matrix is influenced by the industrial uses of composites. Other alloys can be employed, but only for a limited number of applications.

A preliminary study on the manufacturing aluminum–potassium feldspar metal matrix composite materials

AbstractThis study reports the results of a preliminary study of manufacturing aluminum–potassium feldspar metal matrix composites including its castability and mechanical properties. The material was composed considering 0.25 %, 0.5 %, and 0.75 % additive ratios to examine the impact of the amount of potassium feldspar on the material and mechanical properties of the manufactured aluminum metal matrix composite material. Aluminum alloy (A356) was utilized as the matrix of the composition. The composite material was manufactured by the stir casting technique. The modulus of elasticity, yield strength, tensile strength, elongation, density, and quality index of the material parameters was taken into account to determine the materials′ practicality. The preliminary results indicated that potassium feldspar is a promising mineral to be utilized as an additive for aluminum metal matrix composites since it has a positive impact on mechanical properties. By optimizing the casting parameters, the positive aspects of the potassium feldspar may make the material more practical to be utilized in vast engineering applications.

Weight Optimization of Chassis of an Automotive Vehicle using ANSYS

The objective of this paper is to find out the most favourable material and immensely fitted cross-section for TATA 11O9 TRUCK ladder chassis. This research aims to optimize the weight of the chassis. For this we have taken three materials like structural steel, carbon fiber and Aluminium silicon carbide metal matrix composite. The automotive chassis is the vehicle's base, providing strength and support to the numerous body sections such as suspension, engine, power train, and so on. Recent advancements in the realm of automobiles have expanded rapidly, particularly in the current context. Problem faced by modern days vehicle is the heavy weight. So here we try to decrease the weight of chassis frame by using various method and increase the strength, efficiency of chassis. Reducing the weight of chassis results in increase in performance of vehicle, reduce fuel consumption, less wear and tear of tire. The designing of the chassis is done on software SOLIDWORKS and further analysis is done on ANSYS19.2. The current chassis mass with traditional material is 1560 Kg which is made up of structural steel, whereas the chassis mass with Aluminium carbide metal matrix composite material is 523.45 Kg. According to the analysis, the chassis mass has been reduced by 66.44%, which would eventually hinder the vehicle's performance.