Particulate Reinforced Aluminum Composites Research Articles

Fabrication of wear resistant nanocomposite and its mechanical properties: A step towards sustainability

AbstractNowadays, particulate reinforced aluminium composites are appealing structural materials for numerous applications, such as automotive and aerospace, due to their low weight and high specific strength. Nanocomposite morphology and interfacial properties may alter when nano sized particles are reinforced with an aluminium matrix. The addition of nano reinforcement of aluminium oxide particle improve the mechanical strength of base alloy and a further improvement in mechanical properties may be enhanced by grain refinement processed under multi axial forging technique. The present study demonstrates the synthesis of wear resistant nanocomposite. It also investigates the effect of multi axial forging on microstructure, mechanical properties and wear behaviour of aluminium based nanocomposite. Optical microscopy and electron backscatter diffraction techniques were used for microstructural characterization. The fractography and worn surface analysis were examined by using scanning electron microscopy. Energy dispersive X‐ray spectroscopy is used to show the presence of nanoparticles in casting. After three multi axial forging passes, the average grain size was reduced up to 4.2 μm as cast and 1.15 μm in nanocomposite. The wear resistance, microhardness and tensile strength of multi axial forging processed nanocomposite were significantly improved. All improved mechanical and wear properties cause the material one step towards sustainability.

Effect of impingement angle and impact velocity on slurry erosive wear behaviour of particulate reinforced aluminium composites

Effect of impingement angle and impact velocity on slurry erosive wear behaviour of particulate reinforced aluminium composites

Tribological and corrosion characteristics of tetra hybrid particulate-reinforced aluminum composites for aerospace and automotive applications

This study investigates Hybrid Particulate-Reinforced Aluminum Matrix Composites (HPRAMCs), a material class known for exceptional physico-mechanical, tribological, and corrosion resistant properties. The research synthesizes HPRAMCs using SiC, Al2O3, graphite (Gr), and sugar cane bagasse ash (SCBA) reinforcements through a powder metallurgy process, followed by sintering at 550°C for 3 h. Comprehensive tests include X-ray diffraction (XRD) for phase analysis, physico-mechanical assessments, tribological evaluations, and corrosion resistance analyses. Notably, secondary reinforcements significantly reduce porosity, with AS4 HPRAMC exhibiting a 0.53% porosity, while AS1 HPRAMC has 1.446%. AS4 HPRAMC displays a remarkable 209.76% increase in compressive strength and a 446.40% boost in material hardness compared to pure aluminum. Secondary reinforcements also improve tribological performance, reducing wear loss by 60.27% and the coefficient of friction by 89.89%. Exceptional corrosion resistance, with an inhibition efficiency of 99.691%, is observed in the AS4 HPRAMC sample, confirmed by scanning electron microscopy (SEM). These findings underline the substantial potential of HPRAMC materials, positioning them as promising candidates for aerostructural components, aircraft systems, automobiles, spacecraft, and high-performance engineering applications.

Mechanical strengthening and micro-mechanical modelling of newly fabricated 7068-aluminium/lightweight-high-entropy-alloy as aero-material

On account of their lower densities and distinct properties, lightweight high entropy alloys (LHEA) are gaining prominence in the fabrication of particulate reinforced aluminum composites. In lieu of this, present report was conceived to achieve strength and ductility improvement in aluminum-7068 aerospace alloy by the inclusion of highly flexible Al30Li20Mg10Be20Ti10Cu10 LHEA (at 4, 10, and 16 wt%) as reinforcing phase. From the experimental outcome, the X-ray diffraction of the composites depicted BCC and FCC phases derived from LHEA addition. As the LHEA dosage increased, these phases became more prominent. Meanwhile, CuAl2, and MgBe13 intermetallic phases were equally identified in the composites. Based on the microstructure, the particles were sparsely dispersed at 4%, evenly dispersed at 10%, and exhibited both dispersed and clustered particles at 16%. The identified phases and the morphology played significant role in the mechanical characteristics of the fabricated composites ensuing strength improvement. Likewise, the plastic deformability of the composites was enhanced, resulting in a boost in strain hardening sensitivity and a decrease in necking susceptibility. The strengthening mechanism and the micro-models are herein discussed. According to the results, optimal efficacy was deduced at 10% LHEA.

Effect of impingement angle and impact velocity on slurry erosive wear behaviour of particulate reinforced aluminium composites

Effect of impingement angle and impact velocity on slurry erosive wear behaviour of particulate reinforced aluminium composites

Synthesis, processing and phase analysis of quasi crystal particle reinforced aluminium matrix composite

ABSTRACT The main goal of the present study involves synthesis of Al-Cu-Fe based icosahedral quasi-crystal (QC) particles reinforced Al matrix composite and analyze its microstructure, phase and hardness property. The icosahedral quasi-crystal phase nominal composition was taken to Al63Cu25Fe12 (%). Mechanical alloying as a viable powder metallurgy route was used to synthesize the quasi-crystal phase with various milling parameters. The X-Ray diffraction analysis immediately after milling revealed that there was no formation of quasi-crystal phase exclusively by milling. However, after annealing the 100 hours milled powders at 600°C for 4 hours, the quasi-crystal phase was observed to form. The quasi-crystal phase was identified to be the 1/1 cubic approximant (α-Al85.5Cu36.95Fe15.5) of the icosahedral phase. The quasi-crystal particles reinforced aluminum composites were prepared with different concentrations (10–50 weight %) of the quasi-crystal phase by cold compaction. The compacted samples were then sintered for 4 hours at different temperatures such as 400°C, 500°C, and 600°C. The icosahedral Al64.3Cu23.5Fe12.2 phase formation was observed in the 600°C sintered composite, whose composition is approximately similar to the nominal composition used. The results uncovered that, while increasing the concentration of the reinforcement quasi-crystal phase, the hardness of the composite increased.

Feasibility Study on Tribology and Surface Morphology Characterization of Hybrid Composites

Objectives: To investigate the tribological behaviour of aluminium hybrid composites. Aluminium alloy (LM 25) is utilised in the aerospace and defence industries. Its wear properties are further improved to increase the lifespan of the components used in these sectors. Due to their ability to resist wear, graphite and silicon carbide are often used to manufacture machine tools. The objective is to identify the wear parameters of the LM 25 alloy. It was examined after stir-cased and strengthened with silicon carbide and graphite in various weight ratios. Methods: The dry sliding wear behaviour for aluminium alloys containing 2, 4, and 6 wt.% silicon carbide and a fixed 2 wt.% graphite is investigated using stir-casting composites. These process parameters included loads of 15, 30, and 45 N, sliding speeds of 0.55, 1.10, and 1.65 m/s, and sliding distances of 333, 666, and 999 m. Findings: According to the test results, the overall wear loss of SiC-reinforced hybrid composites was less compared to both unreinforced alloys and Al/Gr composites. The tribological behaviour of a composite consisting of 4% SiC and 2% Gr was significantly improved compared to the base alloy. Novelty: The novelty of this study is to induce a brake disc made of an Al alloy with wear-resistant SiC/Gr particle-reinforced aluminium composites committed to its surface. The role of tribology in determining material behaviour is shown to be important in controlling material removal. Keywords: LM25Al Alloy; Silicon carbide; Graphite; Double stircasing; Wear resistance; Worn surface morphology

Corrosion behavior of particle reinforced aluminum composites

Abstract In the study, the corrosion behavior of aluminum matrix composites reinforced with boron carbide (B4C), silicon carbide (SiC) and alumina (Al2O3) were investigated in saltwater (3.5 % NaCl). Composite materials were produced by powder metallurgy. For composite materials production, various reinforcement and aluminum powders were mixed by mechanical alloying for 4 and 10 hours. After mechanical alloying, mixed powders were compacted under 700 MPa pressure and sintered at 600 °C. Electrochemical corrosion tests were applied on specimens in the saltwater solution using potentiodynamic methods. According to the results of the investigation, the best corrosion resistance was obtained by aluminum/B4C and the lowest by aluminum/Al2O3 composites.

Influence of aging and annealing processes on the properties of TiB2 particulate reinforced aluminum composites produced by powder metallurgy

Influence of aging and annealing processes on the properties of TiB2 particulate reinforced aluminum composites produced by powder metallurgy

Manufacturing, microstructural and mechanical characterization of powder metallurgy processed Al7075/SiC metal matrix composite

Abstract Al7075-SiC matrix is considered in the present study since it got potential applications in the field of aircraft and space industries because of its greater strength to weight ratio. This research describes the microstructure, and mechanical characteristics of SiCp reinforced Al7075 metal matrix composite (MMC). Particle reinforced aluminium composites are preferable because of its decreased cost, uniform properties and various fabrication techniques. Through Mixing, compacting, and sintering processes, Al/SiC composites are produced with varying SiC content (0, 5, 10, 15, 20, 25 and 30 wt%). The Scanning Electron Microscope images revealed a uniform dispersion of SiC particles with fewer pores. The composite with 15 wt% SiC has recorded higher mechanical properties, hardness, toughness and flexural strength compared to other specimens because of uniformity in distribution of reinforcement particles in matrix materials without pores.

Plastic deformation and fracture behaviors in particle-reinforced aluminum composites: A numerical approach using an enhanced finite element model

A microstructure-based comprehensive finite element model, which incorporated the deformation/fracture of the matrix alloy, fracture of the particle and decohesion of interface, was built to predict the effects of particle size and shape on the plastic deformation and fracture behaviors in particle-reinforced metal matrix composites. The effect of particle size on the yield strength and work hardening rate of the matrix alloy was demonstrated. When the particle diameter is <10 µm, the fracture of the matrix alloy near the interface dominates the failure mechanism of the composite, whereas changed to particle fracture with particle diameter >10 µm. A cohesive zone model was also included in order to predict interfacial failure behavior. It was noted that SiC/Al interface exhibits a high interfacial bonding strength and the interfacial decohesion was caused by crack propagation from the particle to the interface. The simulation results are in good agreement with the experiment tensile test results in the SiCp/6061Al composite.

Surface characterization of the ceramic coating process on aluminum matrix composite reinforced particulate

Particulate-reinforced aluminum matrix composite for automotive components are developed since they have light density, high strength, and hardness, wear-resistant properties also low heat expansion coefficient compared to ferrous metals. An important factor that influences the composite characteristics is the condition of the interface area between the particle and the aluminum matrix with optimal wettability and minimal cavity defects. This research aims to improve hardness on particulate-reinforced aluminum composite which produces by a squeeze casting manufacturing process and ceramic coating process. Steps of this research include the development of an aluminum matrix composite manufacturing processes, which is followed by a ceramic coating process. Matrix composite material made of Al-7Si-9Zn-6Mg matrix with strengthened of 10% alumina (Al2O3) and 10% silicon carbide (SiC) particles, while for coating materials using Chromium Oxide, Aluminum Oxide, and Ez Zirconium. The results of the hardness test without the ceramic coating process are an average of 71 HRB (127 HV). After the coating process, an obtained hardness value of 163 HV for coating material of Chromium Oxide, 373 HV for Aluminum Oxide, and 338 HV for Ez Zirconium. The wear resistance test results in abrasion values of 2.222 x10-6 mm2/kg for coating materials of Chromium Oxide, 1.633 x 10-6mm2/kg for Aluminum Oxide, and 7.021 x 10-6mm2/kg for Ez Zirconium.

Influence of materials and machining parameters on WEDM of Al/AlCoCrFeNiMo0.5 MMC

ABSTRACTThe current study intends to optimize the wire electric discharge machining (WEDM) parameters while machining the newer AlCoCrFeNiMo0.5 high entropy alloy (HEA) particles-reinforced aluminum composites. AlCoCrFeNiMo0.5 HEA particles produced through arc melting technique are reinforced here for different weight % (0%, 3%, 6%, 9%, 12%, and 15%) along with pure aluminum by the way of powder metallurgy. WEDM studies were conducted by varying the appropriate parameters, namely, pulse ON time, pulse OFF time, and wire feed. Based on the selected parameters, through Taguchi method L18 orthogonal array is designed; the optimal parameter combination for better surface finish, material removal rate (MRR), and reduced kerf width (KW) is identified. For better understanding, through ANOVA, also the effect of each input variables over these adopted response variables was analyzed. The yielded results reveal that addition of AlCoCrFeNiMo0.5 HEA as reinforcement has considerable effect over the response variablessuch that MRR and KW reduces; surface roughness increases with increase in HEA %. ANOVA results confirm that pulse ON time has higher effect over the response variables than any other parameters involved for the study. Multi-objective optimization done through Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) methodology answers that MRR and surface finish have improved, whereas KW gets reduced noticeably.

The Dry Sliding Wear Properties of Nano-Sized TiCp/Al-Cu Composites at Elevated Temperatures.

Nano-sized ceramic particle reinforced aluminum composites exhibit excellent room-temperature mechanical properties. However, there is limited research on the dry sliding wear behavior of those composites at elevated temperatures, which should be one of the major concerns on elevated temperature applications. Here the Al-Cu composites reinforced with nano-sized TiCp were fabricated. The dry sliding wear behaviors of the nano-sized TiCp/Al-Cu composites at various temperatures (140–220 °C) and loads (10–40 N) with different TiCp contents were studied, and the results showed that the nanocomposites exhibited superior wear resistance. For instance, the relative wear resistance of the 0.5 wt.% nano-sized TiCp/Al-Cu composite was 83.5% higher than that of the Al-Cu matrix alloy at 180 °C under 20 N, and was also 16.5% higher than that of the 5 wt.% micro-sized TiCp/Al-Cu composite, attributed to the pronounced Orowan strengthening effect of nanoparticles. The wear rates of the nanocomposites were always lower than those of the Al-Cu matrix alloy under the same test condition, which increased with the increase in temperature and load and with the decrease in TiCp content.

Characterization of material removal in ultrasonically assisted grinding of SiCp/Al with high volume fraction

Due to the significant difference between the reinforcement grains and matrix phase, the machining of SiC particle-reinforced aluminum composites (SiCp/Al) is difficult and costly, especially for SiCp/Al with volume fraction higher than 50%. Ultrasonically assisted grinding (UAG), which has unique advantages in the machining of both ductile and brittle materials, is a promising solution of the machining of SiCp/Al. This study conducts both UAG and conventional grinding (CG) process on SiCp/Al with an electroplated diamond wheel. The study explores material removal mechanisms involved in UAG in comparison to that in the CG. It also investigates grinding forces, surface integrity, subsurface damage, and wheel wear. The study finds that material removal in grinding of SiCp/Al is dominated by SiC particle fracture that is induced in the grinding process. The ground workpiece is smeared with an aluminum layer, making it difficult to evaluate surface integrity. Compared with CG, UAG of SiCp/Al results in similar surface integrity in terms of surface roughness and subsurface damage, but a much lower grinding force (35–50% lower).

An analysis of end milling performance on B4C particle reinforced aluminum composite

The present work investigates the influence of cutting parameters on the output responses such as temperature rise, chip formation, delamination, tool wear, and surface roughness during end milling of stir cast AA6351-B4C composite. The titanium nitride (TiN)-coated solid carbide tool with four flute end mill is used for the experiments. The thermography and scanning electron microscopy (SEM) images are used to analyze the effect of temperature rise on the chip formation and chip behavior. The increase in feed considerably increased the chip thickness from 0.7 to 1.2 mm at 2000 rpm. In addition to that, the formation of abrasive tool wear at minimum cutting speed has resulted with an increase in surface roughness. Further, the delamination of the slot entry surface is also assessed and achieved a lower delamination factor (<1.10) at 0.5 mm depth of cut condition. Finally, the desirability analysis is performed and found that the cutting speed at 2030 rpm, feed at 0.05 mm/tooth, and depth of cut at 0.5 mm are the suitable conditions to produce minimum temperature rise, lower delamination, and surface roughness simultaneously. The microscopic images revealed smooth surface with improved finish while machining at the optimum condition. The confirmation test results are also verified and found to be within 95% confidence and prediction intervals.

Multi-scale study of microstructure evolution in hot extruded nano-sized TiB2 particle reinforced aluminum composites

The microstructural evolution of in-situ TiB2 nano-particle reinforced AlZnMgCu composites during hot extrusion was investigated from micro to macro scales by a combination of various techniques, including neutron and synchrotron X-ray diffraction, optical microscopy, scanning and transmission electron microscopy and electron backscatter diffraction (EBSD). The development of microstructure has shown a bimodal grain structure with distinctive spatial distributions of TiB2 particles: the elongated coarse grain structure with smaller dispersed particles and the fine grains mixed with clusters of relatively larger particles. The particle stimulated nucleation occurs at large particle clusters, resulting in recystallized (sub)micron sized fine grains. The dispersed smaller particles are observed to promote dislocation generation and to prohibit recovery. They are shown to reduce the misorientation of low angle grain boundaries due to the pinning effects on independent dislocations, which also lead to the suppression of dynamic recovery and increase of driving force for dynamic recrystallization. Quantitative texture analysis combined with neutron diffraction and EBSD has exhibited the development of a strong 〈111〉 and 〈001〉 dual fiber texture, and both texture volume fractions are changing with the particle content. In addition, the synchrotron diffraction experiments have shown that dislocation density increases with the particle content in both texture components. The microstructure evolution is the result from a complex process of particles/matrix interaction during the deformation and dynamic recrystallization. In comparison with its particle-free alloy counterpart, the thermomechanical response of the composites at high temperature is discussed in terms of aluminum deformation and recrystallization mechanisms combined with nanosized particle effects.

Effects of ultrasonic vibration treatment on particles distribution of TiB2 particles reinforced aluminum composites

The ultrasonic vibration treatment is successfully applied to improve the particles distribution of in-situ 2.5vol% TiB2 particles reinforced Al-4.5Cu alloy matrix composites fabricated by salt-metal reaction process. Large particles aggregates are eliminated by effects of the cavitation and the acoustic streaming of ultrasonic vibration for 30s. All the particles aggregates are eliminated and the particles are uniformly distributed in the melt after treated by ultrasonic vibration for 120s. TiB2 particles are identified by X-ray diffraction and transmission electron microscope analysis. Some TiB2 particles are dispersively distributed in the matrix after solidification. The composite treated by ultrasonic vibration for 120s has the optimal improvements of yield strength and ultimate tensile strength, which increased by are 84% and 39% respectively. The strengthening mechanisms are discussed, the improved particles distribution brings enhancements on Orowan strengthening, Thermal expansion mismatch strengthening, grain refinement, etc., which are responsible for the improvements of mechanical properties.

Effect of particle size on the thermal and mechanical properties of aluminum composites reinforced with SiC and diamond

The effect of particle size on thermal conductivity (TC) and bending strength was investigated in the SiC/Al and diamond/Al (Dia/Al) composites for thermal management applications. The results showed that with the particle size of SiC increasing from 7 to 250μm, the TC of the 40vol.% SiC/Al composite was improved by 50%, from 182 to 272W/mK, while the bending strength decreased by 100% from 352 to 175MPa. Comparatively, with diamond particles increasing from 30 to 200μm, the TC of the 40vol.% Dia/Al composite increased by around 52% from 313 to 475W/mK, and the bending strength declined by 32% from 327 to 223MPa. Characterization of fracture surface indicated that large SiC particles featured by an irregular shape tended to fracture prior to the Al matrix during loading, while large diamond particles with a regular shape did not have such a tendency. Moreover, diamond particles with a high intrinsic TC contributed to global TC much more than SiC ones with a relatively low TC. Thus, in order to balance thermal and mechanical properties of particulate reinforced aluminum composites, particle size of reinforcements should be well compromised according to their intrinsic properties.

Effect of Metal Matrix Alloying on Mechanical Strength of Diamond Particle-Reinforced Aluminum Composites

Diamond particle-reinforced Al matrix (Al/diamond) composites were produced by a gas pressure infiltration method, where 0.5-4.0 wt.% Ti was added to Al matrix. An interfacial TiC layer of about 2 μm thickness was formed between Al and diamond at 4.0 wt.% Ti addition. The mechanical properties of the Al/diamond composites were enhanced by both the formation of interfacial layer and the strengthening of the matrix. The mechanical strength increased with increasing alloying Ti content, and a tensile strength of 153 MPa was obtained at 4.0 wt.% Ti addition. The tensile flow stress of the composites was found to be in broad agreement with the prediction of the Mori-Tanaka model. The effect of interfacial layer on mechanical properties provides guideline for the production of mechanically reliable Al/diamond composites.