Metal Matrix Research Articles

Investigating the influence of rubber reinforcement on mechanical and vibration properties in glass and jute epoxy hybrid composite

Investigating the influence of rubber reinforcement on mechanical and vibration properties in glass and jute epoxy hybrid composite

Exploring synergies between GnP and fiber orientation in enhancing mechanical, thermomechanical, and shape memory properties of carbon fiber polymer composites

Abstract This research investigates the mechanical, thermomechanical, and shape memory properties across 12 configurations of shape memory hybrid composites, varying in carbon fiber orientation: uni-directional (UD), bi-directional-Twill (BDT), and bi-directional-Plain (BDP), and multi-walled carbon nanotube weight percentages of 0.4%, 0.6%, and 0.8% elucidate the synergistic effects of fiber architecture and nanomaterial reinforcement. The fabrication process involves initially preparing GnP-modified epoxy nanocomposites through ultrasonication followed by hand layup techniques to fabricate three-phase shape memory hybrid composites. Optimal tensile performance is observed in GnP-modified UD composites at a 0.6 wt% concentration, achieving a tensile strength of 728.32 MPa and a modulus of 71.29 GPa. Furthermore, enhancements in thermomechanical and shape memory properties are noted in GnP-modified BDT composites and are further improved in GnP-modified BDP composites configurations. These improvements are attributed to enhanced interfacial bonding between the polymer and fiber, with the maximum effect observed at the 0.6 wt% BDP composite, validated by morphological analysis using FESEM. The study demonstrates that despite polymer modification, all configurations maintain high shape recovery ratios, particularly notable at 97.54% for 0.6 wt% GnP modified BDP composite, exceeding 90% across all configurations, indicating robust performance in shape memory capabilities.

Graphene-reinforced metal matrix composites produced by high-pressure torsion: a review

Graphene-reinforced metal matrix composites produced by high-pressure torsion: a review

Enhancing predictive modeling of nano metal matrix composites with LEO-HDNN approach

Enhancing predictive modeling of nano metal matrix composites with LEO-HDNN approach

Estimation of Tensile and Flexure Strength of Hybrid Composites along with Epoxy as Matrix and Jute & E-Glass as Reinforcements

The natural fibers have the good properties such as mechanical and physical than artificial fibers in a many cases during the fabrication of composite materials that are used in many engineering applications. Also hybridization of fibers leads to impotent of mechanical properties these composites used in interior of aerospace vehicles, automobiles bumpers, decorative items, window panels, interior paneling, etc. where application pf load is very less. This research work is concentrated on the evolution of hybrid composite of Jute/E-glass reinforced with matrix epoxy using Hand layup method. Laminated composites specimens are prepared by calculating the required number of fiber layers and quantity of matrix based on the different volume fraction. The testing specimens are prepared for Tensile and Bending test as per standard of ASTM. The Universal Testing Machine is used to conducted Tensile and Bending test and results are plotted the graphs.

Recent developments in the mechanical properties and recycling of fiber‐reinforced polymer composites

AbstractFiber‐reinforced polymer composites (FRPCs) have become integral to various industries due to their exceptional strength‐to‐weight ratio, corrosion resistance, and versatility. Recent advancements in the properties and recycling of FRPCs reflect significant progress in performance and sustainability. This paper reviews the latest developments in FRPC technology, highlighting innovations in material formulation, including advancements in fiber types, matrix materials, and hybrid composites that enhance mechanical properties. Furthermore, this review emphasizes the modification of matrices by incorporating graphene, which aims to improve the chemical bonding and mechanical interlocking between fiber and matrix. Additionally, it addresses recent breakthroughs in recycling technologies, focusing on methods such as chemical recycling, mechanical recycling, and developing eco‐friendly matrices. Integrating these advancements aims to improve the lifecycle management of FRPCs, reduce environmental impact, and support the transition towards a circular economy. This review underscores the balance between enhancing composite performance and promoting sustainable practices, paving the way for more environmentally responsible applications of FRPCs.Highlights The different types of fiber‐reinforced polymer composites have been thoroughly reviewed. How does graphene affect the mechanical behavior of fiber composite laminates? Provide a systematic correlation and comparison between fabrication methods, materials, and properties. The recycling methods for fiber‐reinforced polymer composites have been deliberated.

Machine learning potential for the Cu-W system

Combining the excellent thermal and electrical properties of Cu with the high abrasion resistance and thermal stability of W, Cu-W nanoparticle-reinforced metal matrix composites and nano-multilayers are finding applications as brazing fillers and shielding material for plasma and radiation. Due to the large lattice mismatch between fcc Cu and bcc W, these systems have complex interfaces that are beyond the scales suitable for methods, thus motivating the development of chemically accurate interatomic potentials. Here, a neural network potential (NNP) for Cu-W is developed within the Behler-Parrinello framework using a curated training dataset that captures metallurgically relevant local atomic environments. The Cu-W NNP accurately predicts (i) the metallurgical properties (elasticity, stacking faults, dislocations, thermodynamic behavior) in elemental Cu and W, (ii) energies and structures of Cu-W intermetallics and solid solutions, and (iii) a range of fcc Cu/bcc W interfaces, and exhibits physically reasonable behavior for solid W/liquid Cu systems. As will be demonstrated in forthcoming work, this near accurate NNP can be applied to understand complex phenomena involving interface-driven processes and properties in Cu-W composites. Published by the American Physical Society 2024

A FEM-based model for failure initiation in the microstructure of gray cast iron under uniaxial compression

PurposeThe purpose of this study was to validate the feasibility of the proposed microstructure-based model by comparing the simulation results with experimental data. The study also aimed to investigate the relationship between the orientation of graphite flakes and the failure behavior of the material under compressive loads as well as the effect of image size on the accuracy of stress–strain behavior predictions.Design/methodology/approachThis paper presents a microstructure-based model that utilizes the finite element method (FEM) combined with representative volume elements (RVE) to simulate the hardening and failure behavior of ferrite-pearlite matrix gray cast iron under uniaxial loading conditions. The material was first analyzed using optical microscopy, scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS) and X-ray diffraction (XRD) to identify the different phases and their characteristics. High-resolution SEM images of the undeformed material microstructure were then converted into finite element meshes using OOF2 software. The Johnson–Cook (J–C) model, along with a damage model, was employed in Abaqus FEA software to estimate the elastic and elastoplastic behavior under assumed plane stress conditions.FindingsThe findings indicate that crack initiation and propagation in gray cast iron begin at the interface between graphite particles and the pearlitic matrix, with microcrack networks extending into the metal matrix, eventually coalescing to cause material failure. The ferritic phase within the material contributes some ductility, thereby delaying crack initiation.Originality/valueThis study introduces a novel approach by integrating microstructural analysis with FEM and RVE techniques to accurately model the hardening and failure behavior of gray cast iron under uniaxial loading. The incorporation of high-resolution SEM images into finite element meshes, combined with the J–C model and damage assessment in Abaqus, provides a comprehensive method for predicting material performance. This approach enhances the understanding of the microstructural influences on crack initiation and propagation, offering valuable insights for improving the design and durability of gray cast iron components.

Effect of Thermal Expansion Mismatch on Thermomechanical Behaviour of Compacted Graphite Iron

Compacted graphite iron (CGI) attracts significant attention in the automotive industry thanks to its suitable thermomechanical properties and cost-effectiveness. A primary fracture mechanism at the microscale for CGI involves interfacial damage and debonding between graphite inclusions and its metallic matrix, which can occur under high-temperature service conditions due to a mismatch in the coefficients of thermal expansion between these two phases. Such microscopic interfacial damage can initiate macroscopic fractures in cast-iron components subjected to thermal loading. While this phenomenon was studied in various composites, there remains a lack of detailed information for CGI, especially related to the complex morphology of its graphite inclusions. This study investigates the influence of graphite morphology and type of matrix on the thermomechanical performance of CGI at high temperatures. A set of three-dimensional finite-element models were developed in the form of unit cells with a single graphite inclusion embedded within a cubic domain of the metallic matrix. Elastoplastic behaviour was assumed for both phases in the numerical simulations. The study is focused on the response of the constituents in CGI to pure thermal loading in order to explore the relationship between graphite morphology and fracture mechanisms. The findings aim to enhance understanding of how graphite morphology affects the behaviours of CGI under high-temperature conditions.

Progress in MOFs and MOFs-Integrated MXenes as Electrode Modifiers for Energy Storage and Electrochemical Sensing Applications

The global energy demand and environmental pollution are the two major challenges of the present scenario. Recently, researchers focused on the preparation and investigation of catalysts for their capacitive properties for energy storage devices. Thus, supercapacitors have received extensive interest from researchers due to their promising energy storage features and decent cyclic stability/performance. The performance of the supercapacitors are significantly influenced by the physicochemical properties of the electrocatalyst. In this review article, we have compiled the previous reports on the fabrication of MOFs-based composite materials with MXenes for energy storage and electrochemical sensing applications. The metallic and bimetallic MOFs and MOFs/MXenes materials for supercapacitor applications are reviewed. In addition, MOFs/MXenes-based hybrid composites are also compiled towards the determination of various toxic/hazardous materials, such as metal ions like copper ions, mercury ions, and picric acid. We believe that present review article may benefit the researchers working on the preparation of MOFs-based catalysts for supercapacitor and electrochemical sensing applications.

Moisture-induced mechanical property changes in natural hybrid composites with mwcnt fillers

ABSTRACT This study investigates the moisture absorption behaviour and its effects on the mechanical properties of polyester composites reinforced with jute and hemp fibres. The differences in moisture absorption between distilled water and saltwater are examined. Tensile and flexural tests are conducted on pure jute fibre-reinforced polyester composite, pure hemp fibre-reinforced polyester composite, and jute (J-P) and hemp (H-P) fibre-reinforced polyester composite. Changes in mechanical properties due to varying moisture conditions are analysed. Furthermore, the impact of a synthetic nano filler, multiwall carbon nanotubes (MWCNTs), on these composites is assessed. The study reveals that MWCNTs enhance mechanical properties, particularly in moist conditions. Fracture behaviour analysis aids in understanding the interaction between natural fibres, the matrix, and nano-reinforcement. At maximum natural fibre weight fractions (40%), moisture absorption reaches 8.17% for the J-P composite in distilled water and 9.61% in saltwater, while the H-P composite shows maximum absorptions of 6.61% and 8.27%, respectively. The hybrid composite records 4.18% and 7.17% under similar conditions. Compared to the plain jute fibre-reinforced composite, the addition of multiwall carbon tubes into the polymer matrix significantly reduces the moisture absorption capacity of the jute composite to 34.89% and 31.30% for distilled water and saltwater, respectively.

Mechanical and dynamic characteristics for the CFRP, GFRP, and hybrid composites exposed to HCl environment

In the current study, the low-velocity impact (LVI) characteristics of carbon fiber-reinforced polymer (CFRP), glass fiber-reinforced polymer (GFRP), and hybrid composites before and after the corrosive environment exposure were investigated. In this regard, CFRP, GFRP, and hybrid composites were subjected to LVI and tensile loadings after being kept in a 10% diluted HCl environment for 1 week and 1 month, and the impacts of the corrosive environment on the composites’ dynamic and mechanical responses were determined by comparing the outcomes of the control and aged specimens. LVI tests for CFRP, GFRP, and hybrid composites were carried out by transferring 25.2 and 11.2 J impact energy to the specimens with two impact velocities of 3 and 2 m/s, respectively, and thus, the effects of impact energy and hybridization were investigated. Moreover, tensile tests were conducted for the control and aged specimens with 2 mm/min crosshead speed, and thus, the effects of fiber material, hybridization, and corrosive environment on the mechanical properties were determined. The study found that CFRP composites had higher stiffness than GFRPs, whereas hybrid composites exhibited dynamic responses between CFRP and GFRP, as expected. On the other hand, it turned out that the composites absorbed most of the impact energy, which was interpreted as being absorbed by the damage of fiber-reinforced composites, which stand out with their brittle characteristics. Furthermore, it was discovered that the damage severity elevated as expected with a longer aging time, which was attributed to the corrosive liquid attacking the fibers, matrix, and fiber/matrix interfaces and reducing strength. It was also observed that, as predicted, the corrosive effects generally resulted in a reduction in tensile responses, including ultimate strain and tensile strength.

Experimental Investigation on Bending Properties of DP780 Dual-Phase Steel Strengthened by Hybrid Polymer Composite with Aramid and Carbon Fibers

Lowering passenger vehicle weight is a major contributor to improving fuel consumption and reducing greenhouse gas emissions. One fundamental method to achieving lighter cars is to replace heavy materials with lighter ones while still ensuring the required strength, durability, and ride comfort. Currently, there is increasing interest in hybrid structures obtained through adhesive bonding of high-performance fiber-reinforced polymers (FRPs) to high-strength steel sheets. The high weight reduction potential of steel/FRP hybrid structures is obtained by the thickness reduction of the steel sheet with the use of a lightweight FRP. The result is a lighter structure, but it is challenging to retain the stiffness and load-carrying capacity of an unreduced-thickness steel sheet. This work investigates the bending properties of a non-reinforced DP780 steel sheet that has a thickness of 1.45 mm (S1.45) and a hybrid structure (S1.15/ACFRP), and its mechanical properties are examined. The proposed hybrid structure is composed of a DP780 steel sheet with a thickness of 1.15 mm (S1.15) and a hybrid composite (ACFRP) made from two plies of woven hybrid fabric of aramid and carbon fibers and an epoxy resin matrix. The hybridization effect of S1.15 with ACFRP is investigated, and the results are compared with those available in the literature. S1.15/ACFRP is only 5.71% heavier than S1.15, but its bending properties, including bending stiffness, maximum bending load capacity, and absorbed energy, are higher by 29.7, 49.8, and 41.2%, respectively. The results show that debonding at the interface between S1.15 and ACFRP is the primary mode of fracture in S1.15/ACFRP. Importantly, S1.15 is permanently deformed because it reaches its peak plastic strain. It is found that the reinforcement layers of ACFRP remain undamaged during the entire loading process. In the case of S1.45, typical ductile behavior and a two-stage bending response are observed. S1.15/ACFRP and S1.45 are also compared in terms of their weight and bending properties. It is observed that S1.15/ACFRP is 16.47% lighter than S1.45. However, the bending stiffness, maximum bending load capacity, and absorbed energy of S1.15/ACFRP remain 34.4, 11.5, and 21.1% lower compared to S1.45, respectively. Therefore, several modifications to the hybrid structure are suggested to improve its mechanical properties. The results of this study provide valuable conclusions and useful data to continue further research on the application of S1.15/ACFRP in the design of lightweight and durable thin-walled structures.

Investigation of the Thermophysical Simulation and Material Removal Mechanism of the High-Volume-Fraction SiCp/Al Composite in Wire Electrical Discharge Machining

SiC particle reinforced aluminum matrix composites (SiCp/Al) are widely used in aviation, weaponry, and automobiles because of their excellent service performance. Wire electrical discharge machining (WEDM) regardless of workpiece hardness has become an alternative method for processing SiCp/Al composites. In this paper, the temperature distribution and the discharge crater size of the SiCp/Al composite are simulated by a thermophysical model during a single-pulse discharge process (SPDP) based on the random distribution of SiC particles. The material removal mechanism of the SiCp/Al composite during the multi-pulse discharge process (MPDP) is revealed, and the surface roughness (Ra) of the SiCp/Al composite is predicted during the MPDP. The thermophysical model simulation results during the MPDP and experimental characterization data indicate that the removal mechanism of SiCp/Al composite material consists of the melting and vaporization of the aluminum matrix, as well as the heat decomposition and shedding of silicon carbide particles. Pulse-on time (Ton), pulse-off time (Toff), and servo voltage (SV) have a great influence on surface roughness. The Ra increases with an increase in Ton and SV, but decreases slightly with an increase in Toff. Moreover, compared with experimental data, the relative error of Ra calculated from the thermophysical model is 0.47–7.54%. This means that the developed thermophysical model has a good application and promotion value for the WEDM of metal matrix composite material.

Fatigue Crack Growth Behavior of Additively Manufactured Ti Metal Matrix Composite with TiB Particles

Fatigue crack growth behavior of additively manufactured Ti metal matrix composite with TiB particles at room temperature was studied using a compact tension specimen and at the stress ratio of 0.1 (R = 0.1). The composite studied in this work was manufactured with a unique additive technique called plasma transferred arc solid free-form fabrication, which was designed to manufacture low-cost near-net-shaped components for aerospace and automotive industries. The fatigue crack growth rate experiments were carried perpendicular and parallel to the additive material build, aiming to find any fatigue anisotropies at room temperature. The findings reveal that additively manufactured Ti-TiB composite shows isotropic fatigue properties with respect to fatigue crack growth. Furthermore, the fatigue crack growth mechanisms in this additive composite material were identified as void nucleation/coalescence and the bypassing of particles and matrix, depending on the interparticle distance.

Investigation on novel ultralight weight thermally insulated fireproof composite

Abstract This study highlights the performance of ultra-lightweight fireproof composite. Polyacrylonitrile based carbon fiber (CF) has been reinforced in Polyetherimide (PEI) polymer to develop the composite. The Surfac2e of CF and PEI film was modified by low-pressure plasma to improve the bonding strength between matrix and reinforcement. The polymeric composite was fabricated by compression molding with a pressure of 2 bar, temperature of 380 °C and holding time of 30 min. CF/PEI composite was used to make a hybrid composite by layering of silicone foam in between the layers. The hybrid composite was exposed to a Bunsen burner under sustained flame for a duration of 10 min. The composite panel’s flame-facing side reached 676.2 °C after 10 min of fire exposure, while the temperature on the other side only reached 58.2 °C. The fabricated hybrid composite was exposed to very low temperature in order to test its ability of thermal insulation under extreme cold temperature. Over the specific period of testing, the temperature of the dry ice decreased from 25 °C to −3.1 °C. After exposure to fire, only minimal loss of material was observed. The hybrid composite of carbon fiber and PEK film, sandwiched between silicone foam, exhibits excellent fire resistance due to its high limiting oxygen index. This composite is considered to be among the best thermally insulating and fire-resistant materials. Thermogravimetric analysis of carbon fiber and PEI-Carbon fiber composite was performed to determine the optimal processing temperature of compression molding for the composite, upon heating, it showed a modest weight decrease of 6.053%. The composite shows a significant improvement of impact resistance, compressive strength and thermal stability. A simulation model was developed under Ansys fluent software for both heating and cooling. The analysis of developed model also shows similar results.

Improvement of mechanical performance via interfacial strengthening of carbon fiber‐epoxy reinforced hybrid laminate by incorporation of functionalized graphene nanoplatelet interphase

AbstractThis study is an attempt to develop high‐quality hybrid composites via functionalization (for homogeneous distribution) of the graphene nanoplatelets (FGNP) and then doping to carbon fiber reinforced especial aviation epoxy matrix (Araldite LY5052) via vacuum bagging molding (VBM). The utilized materials were characterized by UV–Vis spectroscopy, tensile, impact, hardness tests, and fracture mode analysis using a scanning electron microscope (SEM). The results revealed a 92% (502.5 MPa) and 85% (490 MPa) improvement in tensile strength values by doping the 1 and 1.5 wt% FGNPs, respectively. There was an improvement in impact strength with the addition of FGNP; a 28% (3.23 J/mm2) increase was achieved in the nanocomposite with 1 wt% FGNP added, and there was a decrease again in the nanocomposite with 1.5 wt% FGNP added. However, it was still 12% (2.83 J/mm2) better than the neat composite. In addition, the results of examining the fractured surface structures of the impact and tensile test specimens were compatible with these results. It reveals a significant separation of fiber‐matrix bonds with 1.5 wt% FGNP contribution. While tensile and impact strengths peak at 1 wt% FGNP value and decrease afterward, hardness values increase in parallel with the increase in FGNPs.Highlights Composites were developed by functionalized graphene nanoplatelets (FGNP). The fiber‐matrix interface was strengthened with FGNP interphase. A 92% tensile strength increase was achieved with 1 wt% FGNP additives. 28% in impact strength and 55% in hardness increase by 1 wt% FGNP. The morphology confirmed that the FGNP interphase filled the interface.

Delamination assessment and prediction in ultrasonic-assisted drilling of laminated hybrid composites

This study presents a novel application of the Random Forest (RF) algorithm to predict delamination in ultrasonic-assisted drilling (UAD) of carbon fiber reinforced polymers (CFRPs). It performs a multi-dimensional analysis of factors including graphene nanoplatelet (GNP) addition, ultrasonic vibration, cutting tool type, and feed rate on delamination damage. The RF algorithm was chosen for its ability to handle both regression and categorical tasks. The model demonstrated strong predictive performance, achieving an R² value of 0.9445 on test data, with a root mean squared error (RMSE) of 0.32% and a mean absolute error (MAE) of 0.29% relative to the average values. Analysis of variance (ANOVA), Sobol sensitivity, and Shapley additive explanations (SHAP) analysis were used to assess the impact of input parameters. Sobol identified the cutting tool type and feed rate as the most influential factors, contributing 37.7% and 34.3% to delamination variance, aligning with ANOVA findings. SHAP further confirmed the tooling type and feed rate as key factors, with contributions of 48.75% and 32.61%. The analyses revealed that GNPs increased delamination due to higher thrust forces, while ultrasonic vibration and high-cobalt tools reduced delamination. Optimal conditions were a feed rate of 0.08 mm/rev with an 8% cobalt tool and ultrasonic vibration, excluding GNPs.

Exploring the synergistic effects of graphene on the mechanical and vibrational response of kenaf/pineapple fiber‐reinforced hybrid composites

AbstractThe automotive, aerospace, and sports industries are increasingly utilizing hybrid composites made from natural fiber reinforcements. This study evaluated the performance of a composite made from kenaf and pineapple fibers, manufactured using the compression molding process, with graphene nanoparticles added at varying weight concentrations of 0.5, 1.0, 1.5, and 2.0 wt%. Results showed that adding 0.5 wt% graphene increased the tensile, flexural, and impact strength of hybrid composite by 133.75%, 90.24%, and 25.67%, respectively. Microstructural analysis revealed that graphene integration has enhanced the interfacial bond between the fiber and the matrix, creating resin‐rich areas. Furthermore, the free vibrational analysis indicated that graphene‐infused composites exhibited higher natural frequencies, improving their energy‐absorbing capabilities. Water absorption tests demonstrated that the inclusion of graphene reduced water penetration by improving interfacial bonding, minimizing voids, and decreasing surface energy, which limited water pathways in the composite. Furthermore, the composites with 0.5 wt% graphene showed a contact angle of 80.8°, indicating lower hydrophilicity compared to neat composites, which had a contact angle of 70.7°. This research emphasizes the advantages of hybrid composite materials derived from kenaf and pineapple fibers, specifically for applications in vehicle interiors and construction, including wall panels and separators.Highlights Hybrid composite was prepared using the compression molding process. Adding 0.5 wt% graphene improved the mechanical properties of composites. Hybrid composites with lower wt% graphene had higher natural frequencies. The composites with 0.5 wt% graphene had better water absorption properties.

FRICTION STIR PROCESSED MAGNESIUM MATRIX SURFACE COMPOSITES: A COMPREHENSIVE REVIEW

Abstract Nowadays modern materials are tailored using different manufacturing techniques. Usually, material surface is modified by even distribution of reinforcement particles/ fibres up to a certain depth. The developed surface metal matrix composites (MMCs) exhibit superior metallurgical, mechanical and electrochemical properties in contrast to base materials. These surface MMCs have potential applications in biomedical, automotive, aerospace and power industries. Many techniques have been used to develop these surface MMCs, however, the friction stir processing (FSP) has gained wide popularity. This review paper summarizes the effects of different FSP parameters on the metallurgical, mechanical and electrochemical properties of developed surface composites. Furthermore, the effects of secondary phase particles on the Magnesium-matrix surface composites are also comprehensively discussed.