Silicon Carbide Metal Matrix Composites Research Articles

Investigations on the microstructural evolution and mechanical properties of novel Al 6061/7075–granite–SiC metal matrix composites fabricated through two-stage stir casting

This study aims to explore the untapped potential of scrap granite particles as reinforcement to enhance the performance of monolithic Al alloy. Through a two-stage stir casting process, the aluminium alloy matrix (AA6061/AA7075) is reinforced with waste granite particles (GP) (5 wt.% and 2 wt.%) and silicon carbide (SiC) (2 wt.%). The microstructural, mechanical and tribological properties of aluminium-based single and hybrid reinforced composites are investigated using ASTM standards. Microstructural characterisation, including optical microscopy (OM), scanning electron microscopy (SEM) and X-ray diffraction (XRD), confirms the presence of grain refinement and microstructural strain in the composites. The tensile, hardness, impact energy and wear resistance properties of M2 (AA6061, 2 wt.% GP) and Z1 (AA7075, 2 wt.% SiC) composites surpassed those of M1 (AA6061, 5 wt.% GP) and Z2 (AA7075, 2 wt.% SiC, 2 wt.% GP) composites, underscoring their enhanced performance. M2 composite demonstrates a significant 14.97% increase in hardness and a precise 0.82% increase in tensile strength compared to M1. Similarly, the Z1 composite showcases a remarkable 50.1% improvement in hardness and 22.2% enhancement in tensile strength compared to their respective counterpart (Z2). SEM-based fractography analysis of tensile and impact test specimens revealed the presence of dimples, cleavage facets, river lines, intergranular cracks and disbonding, offering valuable insights into the failure mode. Furthermore, the worn surfaces exhibited wear mechanisms involving abrasion and adhesion-delamination. The utilisation of granite particles as reinforcement in these composites resulted in significantly improved properties, positioning them as a promising alternative for future sustainable materials.

Weight Optimization of Chassis of an Automotive Vehicle using ANSYS

The objective of this paper is to find out the most favourable material and immensely fitted cross-section for TATA 11O9 TRUCK ladder chassis. This research aims to optimize the weight of the chassis. For this we have taken three materials like structural steel, carbon fiber and Aluminium silicon carbide metal matrix composite. The automotive chassis is the vehicle's base, providing strength and support to the numerous body sections such as suspension, engine, power train, and so on. Recent advancements in the realm of automobiles have expanded rapidly, particularly in the current context. Problem faced by modern days vehicle is the heavy weight. So here we try to decrease the weight of chassis frame by using various method and increase the strength, efficiency of chassis. Reducing the weight of chassis results in increase in performance of vehicle, reduce fuel consumption, less wear and tear of tire. The designing of the chassis is done on software SOLIDWORKS and further analysis is done on ANSYS19.2. The current chassis mass with traditional material is 1560 Kg which is made up of structural steel, whereas the chassis mass with Aluminium carbide metal matrix composite material is 523.45 Kg. According to the analysis, the chassis mass has been reduced by 66.44%, which would eventually hinder the vehicle's performance.

Evaluation of mechanical properties of Al-B4C and Al-SiC metal matrix composites – A comparison

This paper deals with the comparison of Mechanical properties of aluminum alloy (LM 25) with boron carbide and aluminum alloy with silicon carbide metal matrix composite. The boron carbide of particle size 35 to 40 µm and silicon carbide of similar particle size were used as reinforcements. This addition gives excellent hardness and good impact strength. The fabrication was done by using stir casting., The samples are prepared and mechanical testing like tensile, hardness, and impact was done. It was found that aluminum alloy with boron carbide showed better tensile and impact strength whereas aluminum alloy with silicon carbide showed better hardness. The structure was characterized by using optical microscope.

Optimization of external roller burnishing process on magnesium silicon carbide metal matrix composite using response surface methodology

Optimization of external roller burnishing process on magnesium silicon carbide metal matrix composite using response surface methodology

Optimisation of Drilling Parameters of Metal Matrix Composites using Genetic Algorithm in the Taguchi Method

This work presents the machining parameters optimization on machining metal matrix composites using genetic algorithm in the Taguchi method with the objectives of minimization of surface roughness, cutting force, maximization of metal removal rate, cutting power, specific cutting energy, cutting power and machining time. Experiments were conducted on aluminium silicon carbide Metal Matrix composite using TiN coated HSS twist drills. Optimal setting of parameters have been identified using Taguchi Technique and Genetic algorithm. Genetic algorithm is developed in ‘C’ language. The presented work gives a better results and it can be used for any machining parameter optimization in solving multiple response problems.

Dielectric Fluid Parameter Optimization in Machining of Composite Material using WEDM Process

Wire Electric Discharge Machining (WEDM) has become most popular among the non-conventional machining processes because of precise machining and accuracy of parts. The process is preferable for accurate machining of complex geometries in hard materials such as Aluminium Silicon Carbide metal matrix composite. In this work, an attempt is made to analyze and optimize the dielectric fluid parameters in machining of Al/SiCp 10% work material. The input variables such as volume flow rate, flow velocity and chemical composition of dielectric medium used in the WEDM are chosen for this. Taguchi’s L9 orthogonal array is used to conduct experiments in WEDM machine and ANOVA results have confirmed the influence of chosen parameters on the output responses. Computer simulation model of the WEDM tank with dielectric fluid, work piece and nozzle is presented using Fluent software. The Fluent model is analyzed based on the maximum removal of debris in the work material. Optimization is carried out to maximize the Material Removal Rate (MRR) and minimize surface roughness. The results obtained from Taguchi’s optimization and Fluent analysis have been validated by carrying out tests on WEDM. The study shows that volume flow rate and flow pressure can adequately influence MRR and surface roughness.

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.

Machinability investigations on high-speed drilling of aluminum reinforced with silicon carbide metal matrix composites

In this work, the research efforts have been made to investigate the effect of important drilling parameters such as spindle speed and feed rate on effectiveness of process and quality of holes during drilling of difficult-to-machine Al/SiC metal matrix composite using diamond-coated cemented carbide tool. Thrust force, hole diameter, delamination factor, surface roughness, tool wear, and chip analysis of the drilled holes were investigated at different spindle speeds (3000–9000 rpm) as well as feed rates (0.05–0.2 mm/rev), respectively. The outcomes of this study reveal that thrust force varies directly with the feed rate, but inversely with the spindle speed. Both the hole diameter and the delamination factor shows a rough proportionality with the feed rate, although the rates of variation are slow at the high spindle speed combined with a high feed rate. Similarly, the hole surface roughness increases with the feed rate, while the moderate spindle speeds produce better surface roughness. Smaller chips were found for all spindle speed. Adhesive and abrasive wear mechanisms are prominent on drill bit and drill wear occurs on both drill tip and secondary cutting edge. Drilling at moderate spindle speeds of 5000 rpm and 7000 rpm is the most suitable for the hole drilling in the Al/SiC metal matrix composites.

Characterization of Stir Cast Aluminium Silicon Carbide Metal Matrix Composite

Aluminium silicon carbide metal matrix composites (Al-SiC MMC) are gaining wider acceptance in various fields like aerospace, aircrafts, automobile, substrate in electronics, turbine blades, etc, due to their high strength, stiffness, high corrosion and wear resistance, good thermal and electrical properties and good damping capability. In this work Al-SiC MMCs are fabricated by mixing molten aluminium with Silicon carbide by the aid of mechanical stirring, called stir casting method. Also in this work, the stir casting process parameters are optimized within the range to obtain good mechanical characteristics and uniform mixing of reinforcement, which is a major concern in stir casting. The processing parameters that were investigated include stirrer speed, volume fraction of reinforcement, number of blades on stirrer and diameter ratio. Microstructure observed through optical microscope was correlated to clustering tendency of reinforcement particles. The results of mechanical characterization study and microstructure study show that the stirrer speed, volume fraction of reinforcement, diameter ratio, and number of blades on stirrer appears to have significant effect on mechanical properties and clustering tendency of reinforcement particles

Experimental investigation of machining characteristics for Al-SiC12% composite in Electro-discharge machining

The advancement of modern materials has led to the emergence of Metal matrix composites (MMCs), of which Aluminium metal matrix composite has flexible use in recent trend. The reason to acclaim Aluminium metal matrix composite use in this paper is due to the fact that it has striking properties as compared to other metals. In the present work, aluminium alloy is mixed with silicon carbide (SiC) with 12% weight in order to fabricate the metal matrix composite.This paper aims to investigate the effect of process parameters such as pulse on time (Ton), pulse off time (Toff) and peak current (Ip) on metal removal rate (MRR), tool wear rate (TWR) and surface roughness (SR) during Electrical discharge machining (EDM) on Al-12%SiC metal matrix composite. Experimental work is followed by Central composite design (CCD) method with various combinations of process parameters. Response surface methodology (RSM) is adopted for mathematical modelling and correlating the process parameters with the responses. Analysis of variance (ANNOVA) is used to analyse significance of the derived prototype. This paper gives light upon the development of mathematical models with the use of EDM upon Al-12%SiCmetal matrix composite and the results were validated with analysis of variance (ANOVA).

Analysis of Stir Cast Aluminium Silicon Carbide Metal Matrix Composite: A Comprehensive Review

Aluminium silicon carbide metal matrix composites are used in various fields like aerospace, aircrafts, underwater, automobile, substrate in electronics, golf clubs, turbine blades, brake pads etc. Several fabrication techniques are available for the production of aluminium silicon carbide metal matrix composites (Al-SiC MMC). Among the various methods, stir casting route is simple, less expensive, and used for mass production. The main limitations of stir cast Al-SiC MMC are improper distribution of SiC reinforcement in matrix and less wettablity of SiC reinforcement particle with molten Al. Literature survey indicate that various properties of stir cast Al-SiC MMC depends upon fabrication method, volume fraction, shape, size of particles and distribution and properties of constituents. Since metal matrix composites (MMC) lack structural simplicity its analytical modeling is complex. Further, the involvement of several parameters which affect composite properties, makes the experiments difficult. This review paper contemplates the need of simulation or numerical methods for the prediction of mechanical characteristics of Al-SiC MMC.

Micro-scale modeling of phase-level elastic fields of SiC reinforced metal matrix multiphase composites using statistical approach

This work is devoted to development of instruments of the statistical mechanics as well as to their application in studying microstructural behavior of the metal matrix composites reinforced with randomly positioned silicon carbide (SiC) particles. The micro-scale representative volume element (RVE) models of the materials were studied. Their microstructure was described with the correlation functions of different orders. Analytical expressions for the local stress and strain fields’ statistics were obtained using the solution of the boundary value problem in statistical formulation. The developed analytical model allows to take into account both geometrical parameters of microstructure and physical–mechanical properties of constituents. The case studies of multiphase Ti+SiC and Al+SiC metal matrix composites were investigated. Analysis of influence of the microstructural parameters on behavior of each of the phases was performed with obtaining of the numerical results for the statistics of stress and strain fields.

New Theoretical Modelling of Thermo-Elastic Behaviour Using the Geometric Average: Theoretical and Numerical Investigations

For the first time, Eshelby–Kroner self-consistent model extended to thermo-elastic loading is developed using the geometric mean for performing the set average operations. A new homogenization Eshelby–Kroner self-consistent approach is developed using a geometric average during thermo-mechanical loading. The description of the material thermo-elastic behaviour is carried out through new, appropriate, geometric polarisation tensors. In this paper, the classical Eshelby–Kroner thermo-elastic model based upon the arithmetic mean is used as a reference. A discussion and comparison between both average types is also provided. In particular, the coefficient of thermal expansion of silicon carbide, identified in the range 398–998 K from the knowledge of the thermal expansion of aluminium–silicon carbide metal matrix composites and pure aluminium samples do not depend on the average type chosen for achieving the computations.

EFFECT OF SILICON CARBIDE PERCENTAGE ON FRACTURE TOUGHNESS OF ALUMINIUM SILIOCN CARBIDE METAL MATRIX COMPOSITES

Metal matrix composites are composites in which one component will be a metal and other metal or non metal. It has wide applications in various fields like automobile, turbines blades etc which needs good mechanical properties. This thesis work studies about Aluminium Silicon Carbide metal matrix composites and their properties. Earlier studies revealed that as the percentage of Silicon Carbide is increased the properties get increased up to a limit and fracture toughness gets reduced beyond that. Here, in this work different percentage of SiC is added and fracture toughness is analyzed in terms of Stress intensity factor since fracture toughness cannot be calculated directly. Both software simulation and experimental methods has been done to find out the best percentage composition.

An experimental investigation during finishing of particulate reinforced Al/10 wt% SiC<SUB align="right">p-MMC on developed AFF setup

This paper presents the improved results of an experimental investigation during abrasive flow finishing (AFF) of particulate reinforced aluminium silicon carbide metal matrix composite (Al/SiCp-MMC). The influence of AFF process parameters, e.g., abrasive mesh size, number of cycles, extrusion pressure, percentage of abrasive concentration and media viscosity grade on arithmetic mean value of surface roughness height (Ra, μm) and maximum peak-valley surface roughness height (Rt, μm) have been investigated. Experimental results show that the achieved Ra is as low as 0.005 µm and improvement in surface finish over conventional machining, i.e., reaming is 96.07%. Mathematical models for Ra and Rt are developed for proper selection of the to AFF process parameters. From the test results and SEM micrographs of the workpiece samples before and after AFF, suitable range of process parameters can be selected to achieve better surface finish. Taguchi method-based experimental design, L18 (61 × 37) mixed orthogonal array, S/N ratios are employed to identify the optimal parametric combinations for minimum Ra and Rt. This paper also attempts to explain the basic mechanism of material removal during AFF of Al/10 wt% SiCp-MMC.

Ultra-Fine Grained Al-SiC Metal Matrix Composite by Rotary Swaging Process

In present study microstructural evolution during swaging on aluminium alloy based metal matrix composite (MMC) reinforced with 15% volume fraction silicon carbide (SiC) particles is presented. Samples were swaged at room temperature in steps with reducing die dimensions using rotary swaging technique. SEM and TEM are used to study the microstructural characteristics of swaged samples. SEM observations were made to understand the flow and deformation characteristics of deforming aluminium matrix in the presence of second phase and reinforced SiC particles during swaging. TEM observations on swaged samples confirmed the formation of ultra-fine grains in Al-15%SiC MMC. It is shown that the dynamic recrystallisation occurring in the proximities of second phase particles during the deformation at room temperature, leads to very fine grained microstructure.

Performance Evaluation of PCD 1300 and 1500 Grade Inserts on Turning A356 Alloy with 20% Reinforcement of SiC Particles

Aluminum silicon carbide Metal Matrix Composites (Al-MMC) are widely used in aeronautical and automobile industries due to their excellent mechanical and physical properties. However the harder reinforcement particles make machining difficult. Tool wear occurs more quickly and reduces the life of the tool. This paper presents the experimental investigation on turning A356 matrix metal reinforced with 20 % by weight of Silicon carbide (SiC) particles, fabricated in house by stir casting. Fabricated samples were turned on medium duty lathe with Poly crystalline Diamond (PCD) inserts of 1300 and 1500 grade exposed to various cutting conditions. Parameters such as power consumed by main spindle, machined surface roughness and tool wear are studied. Scanning Electron Microscope (SEM) images support the result. It is evident that, surface finish, and power consumed are good for 1500 grade when compared with 1300 grade at higher cutting speed and tool wear is strongly dependent on the abrasive hard reinforcement particles.

Modeling and analysis of roundness error in friction drilling of aluminum silicon carbide metal matrix composite

Friction drilling is a newer nontraditional hole-making chipless process, which is used to make holes in materials that are used in aerospace, automotive, commercial and industrial products, electronic packaging, and thermal management. In friction drilling, a rotating conical tool is applied to penetrate work-material and create a hole in single step. In this study, comprehensive analysis on friction drilling of Al/SiCp metal matrix composites is carried out. This article discusses the roundness (hole diameter accuracy) errors on dry friction-drilled holes. The parameters considered for the experiment are: the composition of workpiece, workpiece thickness, spindle speed, and feed rate. The effect of parameters on roundness errors is analyzed using experimental design matrix and empirical relation between the process parameters and roundness error is established using response surface methodology. Analysis of variance is used for analyzing the results. The influences of individual input process parameters on roundness error are analyzed and presented in this study.

An investigation of the effect of work piece reinforcing percentage on the machinability of Al-SiC metal matrix composites

This paper presents the study of the tool wear mechanism in machining the metal matrix composites (MMC) and its dependence on the percentage of reinforcing with MMC. Aluminum alloy (A356 - SiC) silicon carbide metal matrix composite of two samples, were prepared in-house by using stir casting method. Samples having 10 and 20% silicon carbide particles (grain size ranging from 55 to 85 mm) by weight are fabricated in the form of cylindrical bars. Experiments were conducted in the medium duty lathe by using polycrystalline diamond (PCD) insert. Optimum parameters were obtained by analyzing the power consumed on an average surface roughness (Ra) of the machined component. By setting these optimum parameters at a constant machining condition, tool wear study was carried out for a time duration of 100 min. The result showed that the tool flank wears was maximum while machining 20% of the SiC reinforcing MMC when compared with 10% of the SiC reinforcing MMC. The result proved that the influence of SiC particles’ weight percentage was a dependent parameter on tool wear. The main mechanism of tool wear in machining Al-SiC MMC includes two-body abrasion and three-body abrasion. However, the tool wear images were captured by optical microscope and SEM, which supported the result. Key words: Machining, PCD, Al-SiC-MMC, different percentage of SiC reinforcing, power consumed, tool wear.

Workability studies on Al–5%SiC powder metallurgy composite during cold upsetting

The present technical work reports on the workability performance along with the consolidation behavior of aluminum (Al) and Al–5% silicon carbide (SiC) powder metallurgy composites during cold compaction. An experimental work has been carried out to investigate the powder compaction behavior of Al–SiC metal matrix composites. SiC of particle sizes 120, 75, and 45 μm has been pre-alloyed with Al powders of particle size ranging from −37 to 75 μm. Various particle size additives of SiC have been used as a second-phase particle in this work with the intension of predicting the mechanical and metallurgical properties of the metal matrix composites studied. The pressure applied for the preparation of compacts have been considered as 220–260 kN in order to prepare the samples of heights in the range of 30 to 32 mm, and the diameter of the compacted sample was 26.11 mm. The densification during compaction is measured by means of the presence of voids in the compacts applying the mass constancy principle. The effect of particle size on the metal matrix composites proposed has been completely investigated under two different stress state conditions such as plane and triaxial.