Metal Matrix Research Articles

Comprehensive glass/banana fiber characterization with zirconium carbide filler-reinforced hybrid composites for lightweight structural applications

Comprehensive glass/banana fiber characterization with zirconium carbide filler-reinforced hybrid composites for lightweight structural applications

Production and Characterization of Hybrid Al6061 Nanocomposites

Aluminum-based hybrid nanocomposites, namely the Al6061 alloy, have gained prominence in the scientific community due to their unique properties, such as high strength, low density, and good corrosion resistance. The production of these nanocomposites involves incorporating reinforcing nanoparticles into the matrix to improve its mechanical and thermal properties. The Al6061 hybrid nanocomposites were manufactured by conventional powder metallurgy (cold pressing and sintering). Ceramic silicon carbide (SiC) nanoparticles and carbon nanotubes (CNTs) were used as reinforcements. The nanocomposites were produced using different reinforcement amounts (0.50, 0.75, 1.00, and 1.50 wt.%) and sintered from 540 to 620 °C for 120 min. The characterization of the Al6061 hybrid nanocomposites involved the analysis of their mechanical properties, such as hardness and tensile strength, as well as their micro- and nanometric structures. Techniques such as optical microscopy (OM) and scanning electron microscopy (SEM) with electron backscatter diffraction (EBSD) were used to study the distribution of nanoparticles, the grain size of the microstructure, and the presence of defects in the matrix. The microstructural evaluation revealed significant grain refinement and greater homogeneity in the hybrid nanocomposites reinforced with 0.75 wt.% of SiC and CNTs, resulting in better mechanical performance. Tensile tests showed that the Al6061/CNT/SiC hybrid composite had the highest tensile strength of 104 MPa, compared to 63 MPa for the unreinforced Al6061 matrix. The results showed that adding 0.75% SiC nanoparticles and CNTs can significantly improve the properties of Al6061 (65% in the tensile strength). However, some nanoparticle agglomeration remains one of the challenges in manufacturing these nanocomposites; therefore, the expected increase in mechanical properties is not observed.

Dielectric, low‐frequency noise and mechanical properties of hybrid carbon nanotubes/graphene nanoplatelets epoxy composites

AbstractThis study analyzes the electrical, microwave (26–37 GHz), low‐frequency (20 Hz–10 kHz) noise, and mechanical properties of epoxy hybrid composites filled with multi‐walled carbon nanotubes (MWCNT) and graphene nanoplatelets (GNP). The system's percolation threshold was around 0.25 vol.% MWCNT, while the electromagnetic properties were almost independent of GNP concentration. The composites are shown to be suitable for electromagnetic shielding in the 26–37 GHz range, with microwave absorption increasing as the total nanocarbon concentration rises. The electrical transport in these composites is governed by one‐dimensional Mott hopping at low temperatures (below 245 K) and redistribution effects above room temperature. The low‐frequency voltage noise spectra of the composites are predominant of the 1/f component, with noise spectral density proportional to Ub, where the exponent b is close to 2, indicating noise caused by resistance fluctuations. The optimal electromagnetic properties are near 0.5 vol.% MWCNT and 0.25 vol.% GNP concentrations. The tensile elastic modulus and yield strength showed the highest increases at 0.25/0.25 loading, with gains of 40.43% and 16.77%, respectively, compared to neat epoxy. Fracture toughness and energy release rate increased with adding 0.25 vol.% GNP, while Charpy impact strength improved with higher MWCNT loading.Highlights Percolation threshold in hybrid MWCNT/GNP composites is close to 0.25 vol.% MWCNT Low‐frequency voltage noise spectra of the composites are 1/f type

An insight into the quasi-static indentation and specific energy absorption performance of glass fiber-aluminum wire mesh hybrid laminates

This study investigates the quasi-static indentation (QSI), three points bending and Izod impact performance alongside with the damage evaluation of pure glass-fiber laminates (GG) and hybrid laminates with aluminum mesh of two configurations (A1 with Al-mesh at the surface layers and A2 with Al-mesh in the middle layers). The energy absorption capacity, bending performance, and impact strength of the hybrid laminates were found to be enhanced in terms of weight ratio. Hybrid laminates exhibited better energy absorption (17.95%) and impact resistance (up to 63.7%). A1 possessed increased ductility and less damage, whereas A2 offered superior bending strength and toughness. The proposed hybrid composites proved to be an effective choice for fields requiring lightweight, energy-absorbing structures.

Effect of Nano Particle Size on Mechanical and Fatigue Behavior of TiO2 Particular—Reinforced Aluminum Alloy Composites

Aluminum alloys are among the most widely used materials in the parts and vehicle sectors due to their high strength-to-weight ratio and qualities such as higher corrosion and wear resistance, as well as minimal thermal growth when compared to other metals. This research involved matrix alloy AA7075 aluminum reinforced with constant 7 wt. % TiO2 (with different particle sizes 30, 70, and 100 nm). The goal of this study is to improve the mechanical (impact strength and young modulus) and fatigue properties of AA7075 alloy-based metal matrix composites, and fatigue. AA7075 composites with a constant weight percentage of 7wt.% of TiO2 and variable particle size have been successfully synthesized by the stir casting route. Microstructural examinations revealed that nanocomposites with (30nm) particle size have better distribution and less porosity compared to the other particles size. The nanocomposite having 30 nm particle size was found to have maximum improvement UTS and YS in comparison with the other nanocomposites, 20.45%, and 12.87% respectively, and minimum elongation. An increase in particle size and fatigue results indicates the decreasing trend of fatigue life and strength. The higher endurance fatigue limit was recorded to be (23.875 MPa) for (30 nm) nanocomposite.

Studies on fatigue, creep, and tribological performance of coconut shell, seashell, and eggshell filler-based bio-fiber-reinforced epoxy hybrid composites

Studies on fatigue, creep, and tribological performance of coconut shell, seashell, and eggshell filler-based bio-fiber-reinforced epoxy hybrid composites

Development of sustainable aluminum alloy‑tungsten carbide hybrid composites using industrial waste - An experimental analysis

The research article focuses on the development of aluminum alloy 6061 sustainable composites with the utilization of industrial waste through the use of the stir casting process. Recycling industrial waste is essential for reducing environmental impact. Thus, the red mud waste came from the aluminum production process, which was considered for producing sustainable metal matrix composites (MMCs). Also, tungsten carbide (WC) microparticles have been used to develop hybrid aluminum composite materials. The concentrations of red mud and tungsten carbide were 2 wt%, 4 wt%, and 6 wt%, respectively, and were used to achieve the desired strength performance of aluminum metal matrix composites. The elemental and bonding analyses of hybrid composites were analyzed using X-ray Diffraction (XRD) and Fourier Transform Infrared Spectroscopy (FTIR) analysis. Mechanical characterizations of aluminum hybrid sustainable composites were also investigated, including tensile, compression, and microhardness testing. The results show that increasing reinforcement by up to 4 wt% increases the mechanical strength of aluminum alloy composites. The tensile, compression, and microhardness of metal matrix composites are increased by 25.24 %, 40.2 %, and 20.6 %, respectively, as compared to the aluminum alloy 6061 alloy. The surface morphology of metal matrix composites was analyzed by utilizing Field emission scanning electron microscopy. The proposed sustainable aluminum composites have the potential to develop structural and automotive components due to their higher strength-to-weight ratio.

Fabrication and comprehensive evaluation of Zr-based bulk metallic glass matrix composites for biomedical applications

AbstractThe aim of this study is to fabricate Zr-based bulk metallic glass matrix composites (BMG-MCs) for biomedical usage and subject them to a comprehensive and farreaching analysis with respect to their mechanical properties, biocorrosion resistance, biocompatibility, and interactions with biofilms that all may arise from their chemical compositions and unusual disordered internal structure. In this study, we fabricate Zr40Ti15Cu10Ni10Be25, Zr50Ti15Cu10Ni10Be25, and Zr40Ti15Cu10Ni5Si5Be25 alloys and confirm their glassy matrix nature through differential scanning calorimetry (DSC) and scanning electron microscopy (SEM) analyses. The mechanical properties, assessed via nanoindentation, demonstrate the high hardness, strength, and elasticity of the produced materials. Corrosion resistance is investigated in simulated body fluid, with Zr-based BMG-MCs exhibiting superior performance compared to conventional biomedical materials, including 316L stainless steel and Ti6Al4V alloy. Biocompatibility is assessed using human fetal osteoblastic cell line hFOB 1.19, revealing low levels of cytotoxicity. The study also examines the potential for biofilm formation, a critical factor in the success of biomedical implantation, where bacterial infection is a major concern. Our findings suggest, as never reported before, that Zr-based BMG-MCs, with their unique composite glassy structure and excellent physicochemical properties, are promising candidates for various biomedical applications, potentially offering improved performance over traditional metallic biomaterials.

Phonon-charge carrier dynamics via grain-boundary phase in equilibrium reaction of higher manganese silicide/CNF hybrid composites

Higher manganese (TE) silicide (HMS), an eco-friendly, low-cost, and earth-abundant p-type thermoelectric material, exposes a Nowotny chimney-ladder crystal structure, obeying the 14th-electron rule. Here, a hybrid composite of a carbon nanofiber (CNF) and HMS was synthesized by vacuum melting followed by spark plasma sintering, and its thermoelectric performance were demonstrated. The incorporation of CNF with HMS notably enhances the Seebeck coefficient and decline the thermal conductivity without significantly affecting the carrier concentration and electrical conductivity due to the interfacial energy filtering effect. A maximum Seebeck coefficient of 307 μV/K was recorded for the 0.5% CNF composite with HMS, leading to accomplish a high-power factor of 1755.63 μW/mK2 at 803 K. Also, interfaces, grain boundaries, and dislocations leading to the high magnitude of strain, confirmed from HR-TEM and strain analysis, leads to decrease in lattice thermal conductivity to 1.95 W/mK. As a result, HMS attains the peak zT value of 0.64, suggesting that carbon-based composites are a promising way to boost the thermoelectric performance of HMS-based compounds.

An Analysis Comparing the Taguchi Method for Optimizing the Process Parameters of AA5083/Silicon Carbide and AA5083/Coal Composites that Are Fabricated via Friction Stir Processing

Aluminium metal matrix composites are widely used in automotive, aerospace, marine, and structural engineering due to their high strength-to-weight ratio and superior mechanical properties. Optimizing friction stir process parameters is critical to enhancing the performance of these materials. This study investigates the effects of FSP parameters such as rotational speed, tilt angle, and traverse speed, on the mechanical properties of AA5083/Silicon carbide and AA5083/Coal composites. Using a Taguchi L9 design of experiments, signal-to-noise ratio, and analysis of variance, this study identifies the optimal process settings for maximizing ultimate tensile strength, microhardness, and elongation. From the results, the study revealed that for AA5083/Silicon carbide composites, rotational speed was the most significant factor affecting tensile strength, while for AA5083/Coal composites, tilt angle played a more critical role. Rotational speed consistently influenced microhardness and elongation for both materials. The signal-to-noise ratio analysis indicates that optimal FSP parameters vary depending on the reinforcement material used. This study highlights the importance of tailoring FSP settings to specific reinforcements to achieve optimal mechanical properties. These findings contribute to the advancement of friction stir processing techniques for fabricating high-performance aluminium metal matrix composites, particularly for applications in industries requiring strong, lightweight, and corrosion-resistant materials.

Investigation on Water Erosion Behavior of Ti-based Metal Matrix Composite: Experimental Approach

Wet steam flow produces big water droplets in the low-pressure zone of a steam turbine blade. These droplets clash with subsequent blades, resulting in a strong impact that is evident as erosion. Titanium and its alloys are valuable for technical applications such as turbine blades because of their low density, high strength, and exceptional corrosion resistance. The boron carbide(B4C) has a high hardness but a low strength; therefore, it's exciting to investigate water erosion of Ti/ B4C and SiC combination. The effect of 1 wt% B4C and 1, 3, 5, and 7 wt% SiC particles on water droplet erosion of Ti composite was studied using the SPS method for 5 minutes at 1200 oC temperature and 50 MPa pressure. The L9 orthogonal array with four levels of parameters of the Taguchi method is used to conduct the experiments. By measuring the weight of the specimen at interval time, the erosion behavior with time is obtained with different nozzle diameters. The effect of material and experimental parameters on erosion resistance is studied, and an empirical relation is developed.

Graphene reinforced magnesium metal matrix composites by infiltrating coated-graphene preform with melt

Graphene’s exceptional mechanical, electrical, and thermal conductivity capabilities make it an ideal reinforcement for metal matrix composites. However, graphene is hard to be dispersed in the melt metal due to its high surface energy, non-wetting nature, and strong van der Waals interactions between graphene sheets, which weaken the reinforcing efficiency of composites. A novel process by infiltrating the coated-graphene preform with melt magnesium was proposed to improve the dispersion of graphene in the magnesium matrix. Graphene preforms with oriented pores were prepared by a directional freeze-drying method. Magnesium oxide coatings were deposited on the surface of graphene inside the graphene preform using the evaporation of magnesium atoms to enhance the strength as well as the wettability between the preform and magnesium matrix. Magnesium matrix composites were fabricated by liquid-solid pressure infiltrating coated-graphene preform with molten magnesium. The microstructure of graphene preforms and composites and mechanical properties of the composites were characterized. The results show that graphene is uniformly dispersed in the matrix and presents a reticular structure, and the hardness, elastic modulus, and compressive strength of the composite were improved apparently compared to the matrix. This study suggests that the method of preparing composites by infiltration provides a novel strategy for fabricating nano-material reinforced magnesium matrix composites.

Comparative Analysis of Boron-Al Metal Matix Composite and Aluminum Alloy in Enhancing Dynamic Performance of Vertical-Axis Wind Turbine

This study aims to assess the dynamic performance of the vertical-axis wind turbine (VAWT) with the help of conventional aluminum (Al) and the boron Al metal matrix composite (MMC). The simulations were conducted using ANSYS software and involved natural frequencies, mode shapes, a mass participation factor, and Campbell plots. The results of static structural analysis show that the boron Al MMC is vastly superior to the aluminum alloy because there is a 65% reduction of equivalent stress with a 70% reduction of deformation compared to the aluminum alloy. These results show that boron Al MMC can withstand higher loads with lesser stress; the structure remains compact and rigid in its working conditions. From the findings, it can be ascertained that employing boron Al MMC improves VAWT power, efficiency, and robustness. However, the critical speed that was established in the dynamic analysis of boron Al MMC requires extraordinary control and the use of dampening systems, thereby avoiding resonance. Overall, boron Al MMC contributes to significant enhancements in the VAWTs’ mechanical and operational characteristics; however, the material’s complete potential can be achieved only with proper maintenance and employing the correct damping techniques. Information about these two materials will allow for a better understanding of their comparative efficacy and their potential application in the further development of VAWTs.

Aluminum droplets on Ni substrates: Evaluating high-temperature oxidation at the liquid/gas interface

In reactive wetting aluminum (Al)/nickel (Ni) systems, oxides at liquid/gas (L/G) interfaces received less attention compared to intermetallic compounds forming at liquid Al/solid Ni interfaces yet potentially significantly influencing wetting properties. Between 900 and 1250 °C, we observed that the shape of sessile Al droplets with dense oxides at the L/G interface and intense interactions at liquid Al/solid Ni interfaces deviates from a spherical cap and can be used as a way to characterize the oxide evolution. This approach reveals a critical temperature of 1100 °C under a PO2 level of 3.9 × 10−9 atm and a vacuum level of ∼2 × 10−2 mbar. Above it, Al2O3 oxides at the L/G interface are eliminated as Al2O gas, while at lower temperatures, they develop as a mixture of Al2O3 oxides and Al-Ni intermetallic compounds with Ni being dissolved from the substrate. At high temperatures (above 1200 °C), despite oxide-free L/G interfaces, non-spherical cap shapes were also obtained due to the formation of sharp edges at the contact line triggered by the growth of intermetallic compounds. The coupling between the droplet shapes and the interfacial interactions is further confirmed by in-situ observation of oxides, analysis of quenched samples and thermodynamic calculations. The proposed method can be potentially applied to multiple reactive wetting systems (e.g. Sn/Cu, Al/Fe, Mg/Ni systems), which are crucial for high-temperature processes such as soldering, coating, and processing of metal matrix composites.

Solidification Processing of Aluminum Alloy Metal Matrix Composites for Use in Transportation Applications

Solidification Processing of Aluminum Alloy Metal Matrix Composites for Use in Transportation Applications

Optimized Mechanical and Thermal Performance of Glass and Caustic Soda-Treated Banana Fibre Hybrid Composites

Optimized Mechanical and Thermal Performance of Glass and Caustic Soda-Treated Banana Fibre Hybrid Composites

Impact of Boron Nitride(H) reinforcement on the properties of 5.8% copper-based aluminium alloy surface composite done by friction stir processing

ABSTRACT Numerous experiments and research is underway within the realm of aluminium metal matrix surface composites (MMSCs). This material has been applied in various marine, and aerospace industries, on account of its remarkable mechanical properties and desirable weight to strength ratio. The current study is focused on the synthesis of surface composites comprising of BN(H) reinforced 5.8% Cu aluminium alloy matrix composites. Boron Nitride(H) was reinforced on the surface of the Aluminum Alloy by FSP. Grooves were machined on the surface of the matriux and compacted with reinforcement particles. The wear rate, tensile behaviour, and microhardness were evaluated for the fabricated surface composites. The microstructural analysis was done via EDAX and FE-SEM to establish the presence of the reinforced particles. The tensile strength increased marginally with an increase in microhardness and reduction in elongation percenatge. The wear morphology aided in identifying the various wear mechanisms observed.

Hybrid composite beads of chitosan/graphene oxide for dye adsorption: characterizations, kinetic modeling and toxicity study

The current study aimed to the preparation of graphene oxide impregnated chitosan– polyvinyl alcohol hybrid beads (GO/CS-PVA) for the removal of Reactive Black 5 (RB5) dye from wastewater solutions, presenting them as a cost-effective alternative for wastewater treatment. These hybrid beads were fabricated using a dripping technique in an aqueous solution. The surface and structure of the material before and after adsorption process were studied by analyzing FTIR spectroscopy and Scanning electron microscope (SEM) as well as adsorption capacity was also evaluated. The results proved the successful synthesis of GO/CS-PVA beads and elucidated the physical adsorption mechanism of RB5. SEM images revealed uniform spherical beads with a rough surface, approximately 752 μm in diameter. Additionally, the evaluation of adsorption capacity showed that the optimum condition for RB5 adsorption is at pH = 3 while the kinetic investigations revealed that the adsorption process adhered to the pseudo-second-order model, indicating a chemisorption reaction. Furthermore, an increase in temperature from 25 to 65 °C enhanced the maximum adsorption capacity of GO/CS-PVA beads by 34%. The cytotoxic effect of the hybrid as measured on adipose derived stem cells via the MTT assay was negligible. In conclusion, it was proved that the eco-friendly GO/CS-PVA beads adsorbents can efficiently remove RB5 from wastewater in practical applications.

Mechanical properties and fractography of SiC and fly ash particulates reinforced Al2024 alloy aerospace metal composites

An effort has been made to study the effect of 15-micron sized fly ash and 70 microns sized SiC particles reinforced Al2024 alloy composites in the present work. By squeeze casting method the hybrid composites with constant 3 wt.% of fly ash and 5 and 7 varying wt. percentages of SiC particulates were fabricated. The hybrid composites were analyzed for Microstructure hardness and UTS. Using SEM microstructure characteristics were carried out to find the distribution of the reinforcements in the base matrix. The hardness and UTS were enhanced with the increase in percentage of reinforcements. It is found to be slight decrease in the impact strength of hybrid composites as compared to the base alloy. Various types of fracture mechanisms were analyzed in the Al2024 alloy with SiC and fly ash particulates reinforced composites using SEM.

Binder Jetting Additive Manufacturing of Inconel 718/TiC Metal Matrix Composites: Influence of TiC Content on Processing, Microstructure, Mechanical and Tribological Properties.

This paper investigated the influence of titanium carbide (TiC) content on the processing, microstructure, mechanical and tribological properties of Inconel 718/TiC composites produced by binder jetting additive manufacturing. It was found that increasing the amount of TiC required an increase of the drying intensity during printing due to a decrease in the thermal conductivity of the powder mixture. The sintering process also depended on the TiC content. The most optimal modes were 1270 °C for 10 h for samples with 0 and 3% TiC and 1280 °C for 5 h for samples with 5 and 10% TiC. The hardness of the materials increased as the proportion of reinforcement increased. The best tensile properties, also at high temperatures, were possessed by samples with 3% TiC, showing high strength and, in addition, satisfactory plasticity. The maximum wear resistance was achieved by the composite material containing 5% TiC.