Reinforced Aluminum Metal Matrix Research Articles

Characterization and machining studies of nano borosilicate particles reinforced aluminium alloy composites using AWJM process

This work documents the experimental examination on mechanical properties of novel nano-boro silicate particles (nBSp) reinforced aluminium metal matrix nanocomposite (AMMNC) and machinability evaluation of the fabricated nanocomposite using Abrasive Waterjet Machining (AWJM) by adopting Taguchi's experimental design considering pressure, rate of abrasive feed and stand-off distance. Simultaneous optimization of outputs viz., material removal rate (MRR) and average roughness (Ra) is done by adopting The Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) methodology. In aluminium alloy 7075 (AA7075), different weight fractions of nBSp (3%, 6% and 9%) are reinforced, AMMNC is fabricated via liquid processing technique. Mechanical features like tensile and compressive strength and hardness are assessed based on ASTM procedures. Higher addition of nBSp produces higher tensile strength (22.14%), compressive strength (29.01%), hardness (21.49%), wear resistance (64.51%) and corrosion resistance (98.6%) as compared with as-cast AA7075. Machining studies indicate that with the increase in the percentages of nBSp leads to higher SR and MRR and higher abrasive flow rate is needed for removing material in 9%nBSp nano composite.

2 Way Fluid-Structure Interaction Study of a Wing Structure

Abstract: In this paper a scaled down model of a wing of rectangular planform is designed and the static analysis on the wing is carried out to determine the aerodynamics forces, stresses acting on it and the frequency of various modes. The iteration for the analysis is carried out for three materials namely, Aluminium 7075 T-6, Glass Fibre Reinforced Polymer and Aluminium Metal Matrix Composite. The analysis in the coupled mode is conducted and compared with the results obtained from that of static analysis to observe the changes in the flow pattern and how the structure behaves when the wing is considered to be flexible. In the coupled mode analysis 2 Way Fluid Structure Interaction analysis is carried out. The material properties and the results obtained from the analysis is compared to select the best out of the three materials. The change in the aerodynamic properties of the wing when it is considered to be flexible is also highlighted by a method of comparison. From the results obtained, it is observed that Aluminium Metal Matrix Composite has the least deformation for the same loading and can withstand higher stress. Hence, Aluminium Metal Matrix Composite exhibits better characteristics in comparison with Glass Fibre Reinforced Polymer and Aluminium 7075 T-6. Additionally, it is noticed that the aerodynamic properties of the wing is reduced when it is considered as a flexible structure. This can be highlighted by the 5.42% decrease in the L/D ratio between the CFD analysis and the 2 Way FSI analysis results. Keywords: Fluid Structure Interaction; Flexible Wing; CFD; Coupled Mode Analysis;

Sintering Bonding of SiC Particulate Reinforced Aluminum Metal Matrix Composites by Using Cu Nanoparticles and Liquid Ga in Air.

SiC particulate reinforced aluminum metal matrix composites (SiCp/Al MMCs) are characterized by controllable thermal expansion, high thermal conductivity and lightness. These properties, in fact, define the new promotional material in areas and industries such as the aerospace, automotive and electrocommunication industries. However, the poor weldability of this material becomes its key problem for large-scale applications. Sintering bonding technology was developed to join SiCp/Al MMCs. Cu nanoparticles and liquid Ga were employed as self-fluxing filler metal in air under joining temperatures ranging from 400 °C to 500 °C, with soaking time of 2 h and pressure of 3 MPa. The mechanical properties, microstructure and gas tightness of the joint were investigated. The microstructure analysis demonstrated that the joint was achieved by metallurgical bonding at contact interface, and the sintered layer was composed of polycrystals. The distribution of Ga was quite homogenous in both of sintered layer and joint area. The maximum level of joint shear strength of 56.2 MPa has been obtained at bonding temperature of 450 °C. The specimens sintering bonded in temperature range of 440 °C to 460 °C had qualified gas tightness during the service, which can remain 10−10 Pa·m3/s.

Mechanical and metallurgical studies of multi-walled carbon nanotube–reinforced aluminium metal matrix surface composite by friction stir processing

Mechanical and metallurgical studies of multi-walled carbon nanotube–reinforced aluminium metal matrix surface composite by friction stir processing

Microstructural Characterization and Mechanical Behaviour of SiC and Kaoline Reinforced Aluminium Metal Matrix Composites Fabricated Through Powder Metallurgy Technique

Aluminium metal matrix composites are widely used in the automobile industry due to their superior properties like high strength to weight ratio, high ductility and better corrosion resistance. In this study, the effect of naturally available and low-cost kaoline particles on the microstructural and mechanical behaviour of Al- SiC- Kaoline Hybrid metal matrix composite was investigated. Al-10 % SiC- X% Kaoline (X = 0, 2, 4, 6, 8) composite samples were fabricated through powder metallurgy technique by applying a compaction pressure of 350 MPa. The fabricated composite samples were subjected to Density, Hardness, Tensile and impact tests to study the mechanical behaviour of fabricated hybrid composite. The presence of SiC and Kaoline reinforcements was confirmed by using SEM and X-Ray Diffraction analysis. It was observed that the maximum ultimate tensile strength ( U.T.S ) and maximum Yield Strength ( Y.S) of the hybrid composite were found to be 263 MPa and 202 MPa for Al-10 %SiC-4 %kaoline reinforcement. The formation of the intermetallic compound such as Al2Cu was observed in XRD and SEM analysis for Al-10 % SiC-6 % kaoline and Al-10 % SiC-8 % of kaoline reinforcement which leads to decrease in the U.T.S and Y.S of fabricated specimens. The impact strength of Al-10 %SiC-8 % kaoline found to be decreased by 44.4 % compared to unreinforced Aluminium due to the presence of harder SiC and Kaoline reinforcements particles. To study the fracture mechanism, Scanning Electron Microscopy study was carried on the fractured tensile specimens which reveal that ductile fracture in unreinforced Al, Al-10 % SiC, Al-10 % SiC-2 % Kaoline due to the formation of dimples and brittle fracture was observed in Al-10 % SiC-4 % Kaoline, Al-10 % SiC-6 % Kaoline and Al-10 % SiC-8 % Kaoline due to the existence of cleavages and microcracks. The best suitable combination of mechanical properties was obtained at Al-10 % SiC-4 % Kaoline hybrid composite.

Exploration of Properties of Al 6060/CNT Metal Matrix Nanocomposites

Nowadays the use of composites in all most all manufacturing sectors is developing rapidly and is likely to increase more rapidly shortly. Aluminum alloy is playing a greater role in all engineering fields. Modern mechanical parts require superior properties, the material available in pure form do not have the required mechanical properties such as strength, hardness, corrosion resistance, etc. A Composite is formed by two or more physically and chemically distinct substances and which is fabricated to enhance the distinctiveness of base metal. The Present work has focused on properties of Carbon nanoTubes (CNTs) reinforced aluminum metal matrix Al 6060; Nanocomposites. These Nanocomposites are fabricated by using the stir casting method by varying the CNT reinforcement with a multi-walled size 10 to 15 nm weight percentage (0.3%, 0.7%, and 1%) of the Al 6060 matrix. To study its properties, the fabricated specimens are tested for mechanical properties. The properties of the Nanocomposites are found to be greatly influenced by the increase in weight percentage of reinforcement. With the mixing of different weight proportion reinforced particles by stir casting process properties of Tensile, Flexural, Impact, and hardness strength of composites are increased. The experimental values obtained from tests more useful in the development of Nanocomposites for different applications.

Investigations on the mechanical properties of tungsten carbide reinforced aluminium metal matrix composites by stir casting

The superior qualities of aluminum alloys and low production cost make them an exceptionally alluring possibility for an assortment of utilizations both from scientific and technological perspectives. In this work, the mechanical behavior of Aluminium alloy 6061 – Tungsten carbide (WC) particulate composite is investigated in comparison with unreinforced 6061 Aluminium alloy. Four different weight fractions 1%, 2%, ,3% and 4% of tungsten carbide particulates of size 5 µm are introduced into the melt. The fabrication of specimen was carried out by stir casting process. Tensile strength and Hardness, test were performed on the samples under the stir casting process.

Characterization of Boron Carbide (B4C) particle reinforced aluminium metal matrix composites fabricated by powder metallurgy techniques – A review

Composite materials are in trend in research and industrial fields due to its superior mechanical properties and easy processing techniques. While there are different processing techniques to fabricate the composite materials, powder metallurgy finds unique place in fabrication of composite materials. To enhance the properties of composite materials added reinforcements have to share loads while applying loads, due to high exceptional properties of added reinforcements composite able to withstand high stress values this load transferring mechanisms happens at interface regions of Al-B4C system, to understand the interface chemistry and mechanisms it is must to investigate the interface phenomenon at different conditions. In this paper authors reviewed some of the major important works done on Al-B4C composites fabricated by powder metallurgy techniques.

Fabrication of SiC reinforced aluminium metal matrix composites through microwave sintering

In this study, SiC reinforced aluminum (Al) metal matrix composites were prepared by microwave sintering. The effects of SiC content, pressure and sintering temperature on the density, hardness and microstructure of the composites were investigated. It was found that the relative density of SiC/Al composites is 98.43% when the content of SiC is 5 Vol%. When the SiC content is 15 vol%, the sintering temperature is 770 °C and the pressure is 250 MPa, the density and hardness of the composites SiC/Al composites are 96.14% and 130 HV, respectively. And the SiC particles can be uniformly dispersed in the Al matrix by microwave sintering.

Investigating the effect of heat treatment on B4C reinforced aluminum metal matrix composites

Abstract The present work focuses on investigation of tensile and compressive strengths of AA7050-B4C composites before heat treatment (as-cast) and post heat treatment. Composites with 2, 4, 6 and 8 wt% of B4C were prepared using bottom pouring stir-casting furnace. Microstructural analysis done using EDS and SEM results affirmed that the B4C particulates were homogeneously scattered in the alloy matrix. Solution heat treatment was carried out on cast samples at 530 °C for a period of 2 h. After solution, T6 heat treatment (Artificial Ageing) was performed on the samples at 180 °C for a period of 8 h. Mechanical strength properties- yield strength, ultimate tensile strength and compression strength, were determined according to ASTM standards.

Experimental investigation on mechanical properties of carbon fiber reinforced aluminum metal matrix composite

Many research works were carried out in the field of material science; these researches show that the composite materials are better than the conventional materials due to their enhanced mechanical properties. The recent manufacturing trends, aluminium based composite materials are popular in most of the application like automotive, aircraft, military, and others. The carbon fiber reinforced aluminum metal matrix composites are highly potential materials for aerospace and electronic industries. In the present work, an open die casting method is used to fabricate the AA 6061 based composite material. The AA 6061 is used as a base metal, and the uncoated continuous long spool-type pitch-based carbon fibers are used as reinforcement. The carbon fibers were placed in the format with two-levels of weight percentage 5% and 10%; the carbon fibers were reinforced with a certain distance with AA6061 aluminium alloy; the composite is fabricated with the help of an electric furnace. The composite's mechanical properties were studied by the various mechanical tests and they were compared with the base alloy of AA 6061. The morphological characteristic was studied by the SEM images, which exhibit the uniform distribution of carbon fibers in the composite material.

Jump ablation-based improvement of nanosecond laser processing of SiCp/AA2024 composites

Ceramic particulate reinforced metal matrix composites is a promising material, but it is difficult to be machined. Pulsed laser processing as a advanced technique is widely used in material processing, but the pulsed laser processing of particulate reinforced metal matrix composites is not sufficiently studied. In this work, scanning ablation of SiC particulate reinforced aluminum metal matrix (SiCp/AA2024) composites was conducted using a nanosecond laser. An innovative jump ablation method was proposed, and the composites processing by jump ablation and common ablation were compared. Both plasma’s and nanosecond laser ablation mechanism’s effects on ablation were analyzed. In contrast to common ablation, jump ablation can effectively increase the ablation depth and rate. At an SOR of 95%, the ablation depth was 39 μm and 99 μm in common and jump ablation respectively, and the increasement was nearly 150%. Meanwhile, The matrix and reinforcement phases on the composites’ ablated surface after jump ablation exhibited relatively independent distribution, while the recast layer was thinner and less oxidized than that produced by common ablation.

Semi-empirical model for depth of cut in abrasive waterjet machining of metal matrix composites

Abrasive waterjet machining (AWJM) is one of the versatile unconventional machining processes presently followed in several industries in the machining of variety of engineering materials. Achieving maximum depth of penetration is a prime requirement to achieve higher productivity. As the AWJM involves several process variables, selecting the right combinations of process variables to achieve maximum depth of cut (h) is a cumbersome and time-consuming process. Thus, scientific way of choosing process variables is being attempted by many researchers through suitable modeling techniques. This paper focuses on the development of semi-empirical model using Buckingham’s π theorem to predict the depth of cut (h) during AWJM of unreinforced and reinforced aluminum metal matrix composites (MMCs) and is compared with regression model and experimental data. Experiments were designed according to Box–Behnken method, and cutting trials were performed on unreinforced aluminum and 5%, 10% and 15% volume fraction of boron carbide (B4C)-reinforced 6063 aluminum alloys, MMCs by keeping the process parameters of water pressure (p), mesh size (ms), mass flow rate (ma) and traverse speed (u) each at three levels. The experimental results of depth of cut (h) at different levels of process parameters were analyzed through ANOVA. Based on the experimental results, the combinations such as #80 mesh size, 340 g/min mass flow rate, 200 MPa water pressure and 60 mm/min traverse speed, resulted in higher depth of cut (h). The experimental, semi-empirical and regression models were compared. The models’ predictions are in good agreement with the experimental data under the corresponding conditions.

Recent developments in hybrid aluminium metal matrix composites: A review

This work is done by reviewing the experiments and studies done by various researchers, organizations and institutions on development and mechanical characterization of the hybrid Aluminium metal matrix composites. Metal Matrix Composites or (MMCs) has developed an ever growing interest in recent times for future applications in the aerospace as well as the automotive industries due to their superior strength to weight ratio and higher temperature resistance. MMCs are created by adding a reinforcement material into a metal matrix. Aluminium based metal matrix composites are widely considered one of the best engineering structural elements because of the fact that the possess high strength, high stiffness, high thermal stability, wear resistance and many benefits fitting to its purpose and also varies with the nature and amount of reinforcements used. The work is carried out referring various research papers, publications and educational articles by various authors. The various reinforced aluminium metal matrix composites (AMMCs) reviewed and the development techniques, mechanical property enhancements are put to the analysis. Major reinforcements include silicon carbide, boron carbide, fly ash, tungsten etc while several researches focused on the development of sustainable products by non-conventional and hybrid reinforcements.

Effect of age hardening in the synthesis of Alx-Ni and Alx–Fe reinforced aluminium metal matrix composites

Abstract Al Metal Matrix Composites (MMCs) reinforced with intermetallics have been receiving wide attention in the recent research works due to their superior properties compared to conventional ceramic reinforcements. In the present work Ni and Fe powders were added in to the AA6061 Al alloy through stir casting route. Cast samples were subjected to solutionizing and age hardening (T6) to form intermetallic reinforcements. Composite samples were characterized using optical microscopy, Scanning Electron Microscopy (SEM) and Energy Dispersive Spectroscopy (EDS). Age hardened samples exhibited peak hardness values for 16 h and 6 h of ageing at 180° C for Ni and Fe based intermetallics reinforced samples respectively. Tribological studies reveal that wear rate decreased with increasing weight fractions of powders and Alx-Fe reinforced composites exhibited lower wear rate than AlxNi reinforced composites and adhesive wear was found as the major operative wear mechanism.

Fabrication and Investigation of Mechanical Properties of SiC Particulate Reinforced AA5052 Metal Matrix Composite

In this present research particulate reinforced aluminium metal matrix composite is developed by using sand mould and liquid stir casting processing route in which AA5052 reinforced with 5 wt. % SiC particulates of 63µm particle size. The density, porosity, micro-hardness, and compressive strength of SiC particulate reinforced AA5052 MMC were investigated and compared these properties with similar properties of unreinforced AA5052. The microstructure of the developed composite was also analysed by using optical microscopy, SEM, and XRD. Developed particulate reinforced Al metal matrix composite gives improved hardness and compressive strength as compared to the unreinforced AA5052. The addition of 5 wt. % SiC particulates increases the density of AA5052.

Study on Iraqi Bauxite Ceramic Reinforced Aluminum Metal Matrix Composite Synthesized by Stir Casting

For the past decades researchers are showing immense interest to investigate the natural advantage of preparation of composites from minerals such as bauxite particles, and proved their effectiveness as cost effective reinforcing agents in fabrication of high performance composites. This study, is a new attempt in using the Iraqi natural bauxite powder with different proportions (2, 4 and 6 wt%) in preparation of aluminum metal matrix composites (AMMCs) using stir casting and Mg additives. In experimental work, the bauxite stones were crashed and milled, then the powder was fired at 1400 ○C. The powders were characterized using particle size, XRD and XRF analysis. The AMMCs casts were machined, polished, preheated, and their properties were characterized using hardness measurements, microstructural observations, and calculation of their Young's modulus, Poisson’s ratio and fracture toughness. Also, their fracture toughness were evaluated by means of crack mouth opening displacement (CMOD) measurements from extensometer recordings. The results proved the successful production of AMMCs with improved fracture toughness, hardness and elastic modulus properties using Mg and Iraqi fired bauxite added at 2 and 4 wt% by stir casting. Moreover, results from CMOD measurements showed the effect of addition bauxite particles at 2 and 4 wt% in increasing maximum at failure and CMOD at critical load of the matrix materials to about 25 and 44% , and 32 and 47%, respectively. Also, at these ratios, the calculated fracture toughness of the matrix materials by means of KIC, and young modulus showed improvement at about “22 and 69%”, and “8 and 12%”, respectively. Addition of bauxite at 6% could not give the required improvement in the fracture toughness despite its effects in recording the highest improvements in hardness (57%) and elastic modulus (22%) due to the brittle behavior of AMMCs at this ratio.

Study of Surface Quality During End Milling of SiC Reinforced Aluminium Metal Matrix Composite

In today’s world the composites materials are replacing many conventional materials due to their excellent properties. Aluminum is a less weight and cheap metal that is available in plenty. Silicon carbide is hard abrasive material with good mechanical properties. The aluminum silicon carbide metal matrix composite is finding increased applications in many fields such as automobile and aeronautical applications due to its excellent mechanical properties like high strength, light weight, high specific stiffness and good coefficient of thermal expansion. But their usage is restricted due to the difficulty in the machinability. In this paper two Al/SiC metal matrix composites (Al6061/10-SiCp and Al6061/5-SiCp) by varying the composition of SiC. The composites consist Silicon Carbide (SiC) of 5% and 10% by weight. The composites are prepared by stir casting process. Shell moulding technique is used in manufacturing of the composite materials. The microstructure, tensile strength, compression strength and hardness of the composites are studied. End milling operation is performed on the metal matrix composite slabs by varying the machining parameters. Feed rate and depth of cut were varied by fixing a single spindle speed. The number of experiments is determined using design of experiments (DOE). The effect of the machining parameters on the surface finish is observed by measuring the surface roughness. This process is done on the two metal matrix composites. The effect of SiC percentage in composite and variations in machining parameters on the surface finish was observed.

Synthesis and characterization of zinc oxide reinforced aluminum metal matrix composite produced by microwave sintering

The study focuses on the microstructural, phase transformation, and physical and mechanical aspects of aluminum/zinc oxide composite produced by a hybrid microwave sintering technique. In the present case, zinc oxide nanorods were synthesized through a cost-effective thermal decomposition method. The obtained zinc oxide nanorods’ length was in the range of 76–168 nm observed through high-resolution transmission electron microscopy images and crystallinity nature was confirmed by the bright spot in the selected area electron diffraction pattern. Two different wt% (i.e. 0.5 and 2) of zinc oxide nanorods were utilized for the fabrication of the composite material. The diffraction pattern of the milled powder and energy dispersive spectroscopy results shows effective diffusion of zinc oxide nanorods in the aluminum. The elemental mapping of milled powder illustrates the uniform distribution of the reinforcement over matrix material. The micro-hardness results exhibit a higher hardness of 27.78% with a small fraction of 2 wt%. The nano-indentation results confirm the improvement in the nano-hardness by 32.21% with 2 wt% of zinc oxide with a marginal decrease in elastic modulus by 4.92%.

Mechanical Properties and Tribological Behaviour of Reinforced Aluminium Metal Matrix Composites

This paper focuses the Mechanical properties and tribological behaviour of aluminium (6063) metal which are reinforced with silicon carbide and graphite. Different percentages like7 %, 10%, 12% of silicon carbide and 3%, 5%, 8% of Graphite were added for reinforcement. The manufacturing of components is made by using stir casting method. Mechanical properties like (fatigue, impact, micro structure) and wear test are carried out in this paper. The result concluded that there is an increase in the mechanical and tribological properties with increase in weight percentage of reinforcement.