Metal Matrix Composite Materials Research Articles

Recycling of Aluminum-Based Composites Reinforced with Boron-Tungsten Fibres.

High strength fibres of carbon, boron, silicon carbide, tungsten, and other materials are widely used to reinforce metal matrix composite materials. Carbon and boron fibers are usually used to reinforce light alloys based on aluminum and magnesium. Products made from these materials are characterized by high strength and rigidity and can be used for a long time. Technological waste containing such fibres are hazardous to the environment because they are durable and have needle-like and other sharp shapes. Therefore, they must be disposed of with extreme care. A significant incentive for the processing and reuse of waste composites of this type is the relatively high cost of production of the primary fibre and the material as a whole. With the increase in the production of such materials in recent years, the need to recycle composite waste is becoming increasingly important. Three main options for primary processing are used to prepare composites for their subsequent use. They are mechanical, thermal, and chemical grinding technologies. One of the actual and practical areas of processing technology is the method of powder metallurgy. This paper presents the main stages of processing composite materials based on an aluminium matrix and B-W fibres to obtain powder compositions. The results of the studies showing the possibility of the effective use of the obtained crushed waste to manufacture concrete products and the production of cutting and grinding tools are presented.

Impact behavior of long glass fibre reinforced aluminum metal matrix composite prepared by friction stir processing technique for automotive

This work dealt with the fabrication of novel long glass fibre reinforced aluminum metal matrix composite (LGFRAMMC) material for automotive applications. The composite specimens were prepared by incorporating long glass fibre with different fibre volume percentage (50, 66, 80, and 100 vol.%) as reinforcement in aluminium alloy (Al6061) using the friction stir processing (FSP) method. The mechanical behaviour of the composite materials was investigated for their primary loading conditions such as tensile and Izod impact stress. Microstructural characterization and fractured mechanism of the fabricated composites were carried out by scanning electron microscope (SEM) analysis. The tensile strength and elongation of the developed composite specimens decreased with the incorporation of long glass fibre, whereas the Izod impact strength of the developed composite specimens was significantly improved as compared to the conventional base metal (Al6061) body panels used in automobiles. The low tensile strength of LGFRAMMC specimens compared to base metal was because of tunnel defect, brittle fracture and extreme plastic deformation (EPD) as characterized by fibre pull-out, pits, and micro cracks. The synergetic effects of EPD and reinforcing by long glass fibres lead to a remarkable improvement in the impact strength.

Physical methods of processing melts of metal matrix composites: Сurrent state and prospects

This review focuses on the known theoretical and experimental results in the field of obtaining metal matrix composite materials by processing the melts using physical methods in the conditions of casting and metallurgical processes. The possibilities, advantages and disadvantages of various physical impact methods are considered from the standpoint of their effect on the structural and morphological characteristics, physicomechanical and operational properties of cast composite materials based on aluminum and its alloys. The paper provides a classification and a detailed description of physical methods used for melt processing when obtaining metal matrix composites depending on the melt state during processing (melting, pouring and crystallization) and according to the physical principle of the effects applied (thermal, electromagnetic, cavitation, mechanical, etc). The paper describes a contemporary view of the laws and mechanisms of the effect exerted by melt processing using physical methods on the structure and phase formation processes of as-cast metal matrix composites. The currently known effects of the impact on their structure are described from a qualitative and quantitative point of view, in particular, effects associated with a change in the wettability of particles, their distribution, dispersion and morphology, as well as with a change in the structural state of the matrix material. The paper systematizes the data on the properties of metal matrix composites obtained using physical impacts on the melt during melting and crystallization. The research shows the prospects for the development and practical application of physical impact methods for melts in the production of metal matrix composites based on various matrix materials and reinforcement systems including endogenously, exogenously and integrally reinforced composite materials. Priority areas of theoretical research and experimental development are discussed highlighting discussion areas and issues in the field of obtaining metal matrix composites using physical impacts on melts during melting and crystallization. Areas for future research in this field are proposed based on the systematic analysis of key problems limiting the widespread industrial use of physical methods for melt processing.

Production and characterization of AA2014-B4C surface-modificated composite via the squeeze casting technique

Metal matrix composite (MMCs) materials provide superiority to monolithic materials in various mechanical properties such as tensile, yield, abrasion resistance, impact resistance by adding reinforcements such as B4C, SiC, Al2O3. While liquid metal processes offer an important advantage, such as low-cost production in high volumes, the heterogeneous clustering of reinforcements in the matrix and the formation of porosity in the area between the reinforcement and matrix pose a problem for composite production. The squeeze casting method stands out in composite production due to its low cost, suitability for mass production, allowing high reinforcement ratio, and ease of homogeneous distribution of reinforcements. In this study, a composite layer reinforced with B4C was produced with a thickness of 1 and 2 mm on a substrate of aluminum 2014 wrought alloy using the squeeze casting method. The mechanical properties of the composite materials produced were characterized via tensile, wear, impact, and hardness tests, and were examined with the help of Scanning Electron Microscopy (SEM). It has been observed that the composite region contains 50 vol.% of B4C reinforcement and the particles of reinforcement were homogeneously distributed into the matrix. All results of the tests mentioned above are better than those obtained in the monolithic 2014 aluminum alloy.

In-situ metal matrix composites development for additive manufacturing: a perspective

This paper presents an overview on some ceramic materials capable of achieving in-situ reinforcements in Al/Al-alloy metal matrix composites (MMCs) during laser processing. It also presents perspective on further exploitation of the in-situ reinforcement capabilities for high quality MMCs feedstock material development. The approach utilized in writing this paper encompasses the review of relevant literature on additive manufacturing (AM) of MMCs. It is widely accepted that the in-situ reinforcement approach has proven to be more advantageous than the ex-situ approach. Though there are still some challenges like the formation of detremental phases and the evaporation of low melting temperature elements, the in-situ reinforcement approach can be used to tailor design composite powder feedstock materials for the AM of MMCs. The preprocessing or tailor-designing in-situ metal matrix composite powder before laser melting into desired components holds more promises for metal additive manufacturing. The need for the development of MMCs powder feedstock that can be directly fabricated using suitable AM technique without prior powder processing like blending or mechanical alloying has not yet been addressed Therefore, having a pre-processed in-situ reinforced MMC feedstock powder can encourage easy fabrication of MMC and other advantages of AM technologies powder recycling. The idea explained in this article is relevant to materials development for AM processing of metal matrix composite. This paper has pointed out future trends for MMCs materials feedstock powder development and new ideas for further exploitation of MMCs and AM technologies. The advantages of tailor-designing composite powders other than merely mixing them has been emphasized.

Structure and Properties of Metal-Matrix Composites Based on an Inconel 625–TiB2 System Fabricated by Additive Manufacturing

This research work studies the structural phase parameters and physicomechanical properties of metal-matrix composite materials based on a Ni–TiB2 system obtained by additive manufacturing (specifically, direct laser deposition). The properties of the composites obtained were investigated at high temperatures (up to 1000 °C). The feasibility of the fabrication of a composite nanostructure of alloy with advanced physicomechanical properties was shown. The introduction of reinforcing TiB2 particles into an Inconel 625 matrix was confirmed to increase the microhardness and tensile strength of the material obtained. Apparently, the composite structure of the samples facilitates the realisation of several strengthening mechanisms: (1) a grain boundary mechanism that causes strengthening and dislocation movement; (2) a mechanism based on the grain structure breakdown and Hall–Petch relationship realisation.

RESEARCH PAPER ON ELECTRICAL DISCHARGE MACHINING

By means of the improvement and growths in new machineries, low weight- high strength, high hardness and temperature resistant materials have been advanced for distinctive applications which include aerospace, medical, automobile and more. In the machining of hard and metal matrix composite materials, outdated manufacturing processes are being more and more changed by more nontraditional machining processes which include Electrical Discharge Machining (EDM). The work piece material designated in this experiment is Inconel 925 taking into interpretation its wide usage in industrial applications. In today’s world stainless steel provides to nearly half of the world’s production and consumption for industrial determinations. In this experiment the input variable factors are voltage, current and pulse on time. As we know that Taguchi method is functional to produce an L9 orthogonal array of input variables by means of the Design of Experiments (DOE). So, Taguchi method is used to analysis the output data. The consequence of the compliant parameters stated overhead upon machining characteristics such as Material Removal Rate (MRR) and Tool Wear Rate (TWR) is considered and examined. In this we are focused on to analysis minimum TWR and maximum MRR based on control factors and response parameters.

Research on the shielding performance and optimization of new type foam metal matrix composite shielding materials

The research and development of new composite shielding materials is of great practical significance for radiation shielding of reactors. Foam metal is light in weight, and has the characteristics of high specific strength and high specific area. From the structural characteristics of the foam metal, a new type of foam metal matrix composite shielding material can be prepared. The foam metal matrix composite shielding material consists of two parts: metal matrix and filling material. In this paper, there are three kinds of foam metal matrix (RAFM, tungsten and nickel) and eight kinds of filling materials (B4C, three kinds of lead-boron polyethylene compounds, two kinds of borated polyethylene compounds, polyimide resin, air). The shielding effect of the above-mentioned foam metal matrix composite shielding material on neutrons and gamma at different porosities is explored through MCNP simulation, and several high-performing shielding combination schemes are obtained. The neutron transmittance less than 50% and the gamma ray transmittance less than 30% are used as shielding targets. The shielding combination schemes obtained above are applied to the shielding model, and then the minimum thickness of the shielding target can be achieved by simulation. The results show that when the foam metal matrix is tungsten, the filling material is B4C and the porosity is 80%, its thickness of 8.5CM can reach the shielding target, which is the best shielding scheme. Compared with the traditional iron/water mixed shielding, the thickness reduction rate of this solution is 84.45% and the mass reduction rate is 47.53% when the above-mentioned shielding target is reached. In addition, the above optimal scheme is compared with the experimental data of nickel-based foam metal to further illustrate the reliability of the new foam metal matrix composite shielding material.

Estimation, optimization and analysis based investigation of the energy consumption in machinability of ceramic-based metal matrix composite materials

The current study aims to determine the influence of machining and production parameters during the milling of Cu/B–CrC composites. The relationship between energy consumption and cutting speed, feed rate and reinforcement ratio were investigated. For this purpose, 2d and 3d graphs for comparison of the effects of input parameters were demonstrated and analyzed. The predictability of the energy consumption during milling was measured by a fuzzy inference system (FIS). According to the graphical and optimization results, the optimum conditions to obtain the minimum energy consumption were 5% reinforcement ratio, 125 m/min cutting speed and 0.2 mm/rev feed rate. A reinforcement ratio of 52.71% was the most effective factor on energy demand followed by the feed rate (24.26%) and cutting speed (12.85%). According to the obtained results, there was a minor margin of error between the actual and predicted findings ranging from 1.6 to 2.4%. Considering the energy consumption is one of the key factors among machinability criteria, the study proposes a comprehensive approach for industrial and academic works.

Thermal Conductance of Graphene-Titanium Interface: A Molecular Simulation.

Titanium is a commonly used material in aviation, aerospace, and military applications, due to the outstanding mechanical properties of titanium and its alloys. However, its relatively low thermal conductivity restricts its extended usage. The use of graphene as a filler shows great potential for the enhancement of thermal conductivity in titanium-based metal-matrix composites (MMCs). We used classical molecular dynamics (MD) simulation methods to explore the thermal conductance at the titanium–graphene (Ti/Gr) interface for its thermal boundary conductance, which plays an important role in the thermal properties of Ti-based MMCs. The effects of system size, layer number, temperature, and strain were considered. The results show that the thermal boundary conductance (TBC) decreases with an increasing layer number and reaches a plateau at n = 5. TBC falls under tensile strain and, in turn, it grows with compressive strain. The variation of TBC is explained qualitatively by the interfacial atomic vibration coupling factor. Our findings also provide insights into ways to optimize future thermal management based on Ti-based MMCs materials.

Thermal conductivity of Aluminum/Graphene metal-matrix composites: From the thermal boundary conductance to thermal regulation

Aluminum is a commonly used heat dissipation material, and further improvement of its cooling performance is usually by adding an appropriate reinforcement phase into its composites. Graphene holds great promise for thermal enhancement in composites due to its outstanding thermal properties. However, the systematic study of the thermal conductance of the Aluminum/Graphene (Al/Gr) interface and thermal conductivity of Al/Gr metal-matrix composites (MMCs) are still lacking. The thermal properties of Al/Gr MMCs are explored using molecular dynamics simulation methods. Thermal boundary conductance of the Al/Gr interface plays a crucial role in the whole thermal properties of the Al/Gr composite. The parameters of model size, layer number, temperature, and strain are considered. The results show that the thermal boundary conductance (TBC) decreases with increasing layer number, and reaches a plateau at n = 5. TBC falls under tensile strain and, in turn, it grows with compressive strain. The variation of TBC is explained qualitatively by the phonon coupling factor and surface potential energy barrier. The thermal conductivity of Al/Gr MMCs is computed taking into account TBC effects at Al/Gr interfaces, and its thermal conductivity increases with graphene volume content. Our findings also provide insights into ways to optimize future thermal management based on MMCs materials.

Characterization and Comparison of Areca Sheath Ash (ASA) and Rice Husk Ash (RHA) for Silica Potential

Utilization of agricultural by products as a reinforcement which offers a effective consequences on composite materials in the present days. Also a number of the agro waste substances as an ash are secondary filler material for Metal matrix composite materials. In this paper observe changed into achieved on characterization of agriculture waste ashes like Rice husk ash (RHA) and ASA (Areca sheath ash), burned at Controlled temperatures at 650°C in a metallurgical furnace at 3 exceptional durations of instances like 1hr, 2hr, and 3hr. Also each ashes were chemically and physically characterized, consequently decide the proportion of composition. The ensuing ashes have been analyzed the use of chemical evaluation via XRF and volumetric, gravimetric and instrumental test, SEM and EDS to determine their chemical composition which may be similarly used as reinforcement with metal matrix composites. Results acquired that impact of burning temperature and time on Chemical composition, Physical property, Loss of ignition (LOI) and Density. The ashes have been discovered to include excessive percent of silica content of 90% to 92% in Rice husk ash and 74% to 78% in Areca palm leaf sheath ash, after which accompanied through alumina content of 0.89% to 0.98% in each substances at 650oc temperatures respectively, additionally density of 0.98gm/cc for RHA and 1.12gm/cc Areca palm leaf sheath ash. Loss on ignition (LOI) of 4.5% to5.5% acquired on the equal temperature. These consequences suggests that rice husk ash and Areca sheath ash include excessive percent silica and a few alumina and may be utilized in chemical formulations requiring silica which include in metal matrix composites.

Design and fabrication of an adjustable stirring and degassing system for synthesis of metal matrix composite material

Stir Casting is an economical and easy liquid state manufacturing process for Metal Matrix Composite (MMC) material. For the stir casting process, the stirring mechanism plays an important role. Uniform mixing of reinforcement and metal matrix material is possible due to proper stirring during stir casting. This stirring improves the Mechanical, Tribological, and Morphological Properties of MMC. This research paper includes the design and fabrication of an Adjustable Stirring System for a coal furnace. Complete Setup is portable. Design of rotor, shaft, Frame, the motor with a driver, control panel, sliding mechanism was carried out in detail for an Adjustable Stirring System. Finally, Metal matrix composite material was fabricated using this Adjustable Stirring System. Specimen prepared for tensile testing and hardness test as per the ASTM standard. Results were compared for Aluminium alloy, Aluminium Alloy with SiC Reinforcement using manual stirring, Aluminium Alloy with SiC Reinforcement using an adjustable stirring system. Improvement in Hardness and tensile strength for Aluminium Alloy with SiC Reinforcement using an adjustable stirring system was observed.

ИЗГОТОВЛЕНИЕ МЕТАЛЛОМАТРИЧНЫХ КОМПОЗИЦИОННЫХ МАТЕРИАЛОВ С ПРИМЕНЕНИЕМ АДДИТИВНЫХ ТЕХНОЛОГИЙ (обзор)

A review of scientific and technical literature in the field of obtaining metal-matrix composite materials (MMCM) reinforced with ceramic particles using additive technologies is presented. The structure, basic physical and mechanical properties and morphology of MMCM are briefly described. The structure and properties of MMCM reinforced with micro- and nano-sized ceramic particles are briefly described. The use of additive technologies for the manufacture of MMKM will make it possible to manufacture parts of a more complex shape, providing high adhesion between powder layers.

Investigating the influence of composite spur - worm gear model used in thermal press application

In the modern world, composites have dominated most industries over the forecast period and are an excellent replacement for the currently used metallic steel as a gear material. Hence, the main objective of the research work is to focus on designing an efficient composite spur–worm gear system, implementing analytical calculations with comparing different simulation studies to determine the overall strength and safety of the gears used in thermal hot press application. Here, both gears of Aluminium Silicon Carbide (Al-SiC) metal matrix composite material have been selected. The composite used in the study is cost-efficient compared to the remaining composite materials and proved to be of greater use in industrial applications. Different analysis was conducted on the spur–worm gear system to compare its performance for safer strength design and optimization of the gears. Total deformation and von-Mises equivalent stress were the results obtained through the investigation, which played a crucial role in determining the safety and strength of the gear system used in the thermal press application by satisfying the mesh convergence test.

Optimization on Powder Metallurgy Process Parameters on Nano Boron Carbide and Micron Titanium Carbide Particles Reinforced AA 4015 Composites by Taguchi Technique

Aluminium metal matrix composite is developed using powder metallurgy, with number of different operational factors considered. The three most important operational factors are sintering time, sintering temperature, and compaction pressure. Investigations are conducted using L9 orthogonal array as the experimental design. Density, Vickers hardness, and compressive strength are determined through experiments. The S/N ratio based on Taguchi’s law and a number of anomalies accomplished were used to determine the effect of individual input parameters (ANOVA). The main effect plots identified the optimal parameter settings for obtaining a less density, a higher hardness, and a higher compressive strength. In addition, the ANOVA analysis confirmed that the best metal matrix composite material is produced at the optimal sintering time and average temperature and compaction pressure for generally classified levels.

Combining effect of annealing and reinforcement content on mechanical behavior of multi-walled CNT reinforced AA5052 composites

The large requirement of materials to enhance the overall performance of aerospace and automobile components focused the researchers on developing aluminum metal matrix composite (MMC) materials. This work deals with the fabrication of aluminum MMCs reinforcing with multi-walled carbon nanotubes (MWCNT) produced by a low-cost stir casting process. The tensile strength and micro-hardness tests were carried out to study the mechanical behavior of the composites. Moreover, the microstructural observation was also analysed with the help of FESEM and XRD analysis. The composites were subjected to annealing heat treatment process to investigate the mechanical strength. It was observed that with the reinforcement of CNT, the aluminum alloy composites exhibited superior mechanical properties as compared with the base alloy whereas annealing reduced the mechanical properties of the composites as compared to the as-casted condition for each composition of CNT content. Moreover, the tensile fractography was also characterized in terms of equiaxed dimples, CNT pull-out, matrix cracking on the fracture surfaces.

Исследование структуры и свойств металломатричных композиционных материалов, полученных методом прямого лазерного выращивания

Due to mechanical properties, Inconel family alloys are proven to be functional materials that are used at elevated temperatures in chemically aggressive environments and under high loads. Development of additive technologies has revealed a potential of these alloys as an initial powder raw material for additive manufacturing machines. In this work, the application of metal matrix composite materials in a direct laser growing technology is studied. The technology of self-propagating high-temperature synthesis is used to manufacture the composite material. The study results show that the application of metal matrix materials in the technology of direct laser growing allows one to increase wettability of ceramic particles by a matrix metal. As a result, the quality of particle-matrix borders is improved, the porosity is decreased, and the uniformity of the distribution of particles in the matrix is increased. The structure of the obtained materials is represented by Inconel 625 matrix alloy and inclusions of TiB2 ceramics. The average size of the ceramic particles is less than 300 nm. It is shown that adding to Inconel 625 powder of a composite metal matrix SHS powder of NiTi-TiB2 in an amount of 5 wt% leads to an increase in the microhardness of the material by 1.5 times relative to the materials obtained from pure Inconel 625. At the same time, there is an increase in the ultimate strength of the materials up to 920 MPa and a decrease in the ductility by 15% relative to the samples made of pure Inconel 625 alloy.

Nano reinforcement technique as a tool for enhancement the mechanical and fatigue properties

Abstract For the past three decades, AA7075 based metal matrix composite materials showed more attraction due to their enhanced mechanical and fatigue properties. The mechanical and fatigue behaviour of nano composites needs more investigation for their applications. In the present study, stir casting route based AA7075 reinforced with nano – sized, Al2O3 particles (average size 35 nm). The evaluation of mechanical and fatigue properties in the nano cast composites and matrix were carried out at room temperature (RT). The composites and base metalwere subjected to high and low cycle fatigue. Scanning Electron Microscope was used to estimate fatigue behaviour of nano composites samples. The mechanical and fatigue properties was enhanced by the nano Al2O3, when compared to the matrix. The microsite evaluation showed uniform distribution of Al2O3 particles into the matrix and few porosity was recorded. The improvement of the properties above is attributed to the grain refinement and to the distribution of the Al2O3.

Mechanical and microstructural characterization of high reinforcement content aluminum metal matrix composites in extreme conditions

The final motivation of the research in which is framed this work is to optimize the friction-stir welding, FSW, process and its implementation in conventional machining centers. The FSW process occurs in the solid state at high temperature and by severe plastic deformation (high deformation at high rate) of the material. In this work we have studied the behavior at high temperature and high deformation rates of metal matrix composite materials 2124Al-25%SiC and 6061Al-40%SiC. The plastic deformation capacity in the high temperature regime has been studied by tensile, compressive and torsion tests at temperatures in the interval 300-475ºC and high strain rates, at 1s-1 and above. Large plastic deformations have been obtained without the appearance of serious defects despite the high reinforcement content. The good behavior in the conditions studied presumes the good weldability by means of the FSW technique. On the other hand, the data of the microstructure have allowed determining some of the constants that appear in the creep equation. Finally, we have succeeded in explaining the creep behavior through models developed for this technique from the experimental results.