Stir Casting Research Articles

Corrosion Behaviour of Commonly Used Epoxy Resin Coated Agro Based Industrial Reinforcements

bstract: In this integrated study, the project aims to develop a novel hybrid green metal matrix composite using stir casting, reinforcing aluminum alloy with Waste materials such as Waste Carbonized Eggshells (WCE), Cow Dung Ash (CDA), Snail Shell Ash (SSA), and Bamboo Leaf Ash (BLA) The experiment incorporates various organic-inorganic mixed coatings, including vinyltrimethoxysilane (VMS), [3-(methacryloxy)propyl] trimethoxy silane (MPMS), and (3-glycidoxyproyl) trimethoxy silane (GPMS), combined with tetraethoxysilane (TEOS), to enhance corrosion resistance. Potentiodynamic polarization curves, SEM images, and salt spray tests are employed to assess coating durability against corrosion. Results indicate significant reductions in corrosion flow with VMS and MPMS coatings, particularly with a 15-20% TEOS ratio, showcasing optimal corrosion resistance against salt spray. This innovative approach combines material recycling and advanced coating techniques to produce a sustainable composite with improved mechanical properties and corrosion resistance.

Fabrication of nano SiC and BF-bonded magnesium alloy (AZ80) hybrid nanocomposite via liquid state stir casting process: characteristics study

ABSTRACT Concerning various materials in the engineering domain, magnesium alloy-based composites are found to have specific properties. They are prepared with ceramic particles via a liquid stirring process, and oxidation results in porousness. Due to this, this research aims to develop cast magnesium alloy (AZ80), nanocomposite and hybrid nanocomposites via a liquid state stir casting process with an argon atmosphere. It contains 0, 2, 4 and 6 wt% of silicon carbide nanoparticles (SiC) and 6 wt% SiC with 3, 6 and 9 wt% of basalt fibre. The developed cast AZ80 alloy, nano and hybrid nanocomposites are subjected to physical, mechanical and wear behaviour studies, and their results are compared. The composite contained 6 wt% SiC, and 9 wt% BF showed low porosity (1.03%), superior tensile strength (359 ± 7 MPa), elastic modulus (23044.58 ± 230 MPa), strain (2.114 ± 0.01 mm), hardness (121 ± 1.02 HV), coefficient of friction (0.421 ± 0.02) and low impact strength (18.25 ± 0.34 J/mm2) and volumetric wear rate (5.36 ± 0.4 mm3/m) compared to others.

BIOACTIVE PROPERTIES AND MORPHOLOGICAL FEATURES OF HYDROXYAPATITE/ZINC OXIDE HYBRID REINFORCED BIO-BASED EPOXY RESIN COMPOSITES FOR DENTISTRY

In this work, hybrid reinforced epoxy biopolymer composites were developed using natural hydroxyapatite and zinc oxide (nHAp/ZnO). The epoxy was reinforced with varying addition of nHAp and ZnO in the steps of 3, 5 and 7 wt. % respectively using stir casting molding process. The developed composites were immersed in simulated body fluid (SBF) at 37oC to determine their bioactivity. Microstructure evaluation using scanning electron microscopy was also used to assess the morphology of the developed composites before and after in vitro test, respectively.The microstructure evaluation in vitro showed good deposition of white-like layers on the surface indicating good bioactivity reaction with the SBF and affirm that the developed biopolymers will react well with living tissue when used in vivo. However, hybrid sample BP5HB showed better apatite-like layer deposition.

Near Dry Powder Mixed Electric Discharge Machining of AA7050 Hybrid Composites Utilizing Composite Tool Materials

Electric Discharge Machining (EDM) is a prominent technique for producing components with complex geometry and intricate shapes. However, productivity depends on the selection of optimal input variables. This research investigates EDM and Near-Dry EDM (NDEDM) on AA7050 hybrid composites, exploring the impact of tool materials, Al2O3 powder concentration, and dielectric fluids on Material Removal Rate (MRR) and Surface Roughness (Ra). NDEDM offers a higher MRR due to localized heating and energy concentration, while hydrocarbon oil EDM provides lower Ra due to cooling and lubrication. Tool material properties, thermal conductivity and bonding strength, affect MRR and TWR. Aluminum composite tools via stir casting display a strong bonding interface, leading to efficient energy transfer and higher MRR, while copper composite tools via friction stir processing exhibit weaker bonding, potentially reducing MRR. Hydrocarbon oil significantly lowers TWR due to effective lubrication and cooling, while near dry EDM results in slightly higher TWR. Al2O3 powder enhances MRR, with an optimal concentration of 1 g/l, while higher concentrations hinder MRR. The presence of Al2O3 powder enhanced the surface quality by reducing the size of the recast layers and producing a smoother surface. Globules, craters, microcracks, pock marks and re-casted layers are the noticeable features spotted on the surface. The results were optimized using the TOPSIS optimization technique and process parameters 32 A current, 30 µs Ton, 3 mm gap distance machined under 3 g/l Al2O3 incorporated hydrocarbon oil dielectric medium using copper composites tool proffers optimal machining performance.

A Review: Characterization Of Aluminium-Metal Matrix Composite Reinforced with Zirconium Diboride

Composite materials with aluminium matrices are used in thermal management, defence, aerospace, automotive and aviation. As the prices of useful items decreased, their usefulness increased. Aluminium is reinforced with other metals, non-metals and ceramics to give it the required physical and mechanical properties such as high tensile strength, great hardness and corrosion resistance. Aluminium-metal matrix composites are known for their exceptional physical and mechanical properties and performance. This work also focuses on the fabrication and characterization of zirconium diboride reinforced aluminium-metal matrix composite. Zirconium diboride particles were used as reinforcement material to fabricate aluminium metal matrix composites by the stir casting method. The microstructure, hardness and tensile strength of aluminum-metal matrix composites and its corrosion behaviour were investigated. The results showed that the inclusion of zirconium diboride particles increased the hardness and tensile strength of aluminum-metal matrix composites. Field emission scanning electron microscopy and x-ray diffraction analysis are used to investigate the microstructural properties of aluminum-metal matrix composites reinforced with zirconium diboride particles. Field emission scanning electron microscopy images showed a uniform distribution of zirconium diboride particles in the aluminum-metal matrix composites matrix. X-ray diffraction analysis showed the formation of an intermetallic compound of aluminium and zirconium diboride. From the review that have been made, we can conclude that the inclusion of zirconium diboride particles increased the mechanical properties and corrosion of aluminium-metal matrix composites.

SiC and MWCNT Blending Actions on Functional Performance of Hybrid AA2024 Alloy Nanocomposite Via Two Step Stir Cast Route

SiC and MWCNT Blending Actions on Functional Performance of Hybrid AA2024 Alloy Nanocomposite Via Two Step Stir Cast Route

Influence of B4C and ZrB2 reinforcements on microstructural, mechanical and wear behaviour of AA 2014 aluminium matrix hybrid composites

Considering their affordability and high strength-to-weight ratio, lightweight aluminium alloys are the subject of intensive research aimed at improving their properties for use in the aerospace industry. This research effort aims to develop novel hybrid composites based on AA 2014 alloy through the use of liquid metallurgy stir casting to reinforce dual ceramic particles of Zirconium Diboride (ZrB2) and Boron Carbide (B4C). The weight percentage (wt%) of ZrB2 was varied (0, 5, 10, and 15), while a constant 5 wt% of B4C was maintained during this fabrication. The as-cast samples have been assessed using an Optical Microscope (OM) and a Scanning Electron Microscope (SEM) with Energy Dispersive Spectroscopy (EDS). The properties such as hardness, tensile strength, and wear characteristics of stir cast specimens were assessed to examine the impact of varying weight percentages of reinforcements in AA 2014 alloy. In particular, dry sliding wear behaviour was evaluated considering varied loads using a pin-on-disc tribotester. As the weight % of ZrB2 grew and B4C was incorporated, hybrid composites showed higher hardness, tensile strength, and wear resistance. Notably, the incorporation of a cumulative reinforcement consisting of 15 wt% ZrB2 and 5 wt% B4C resulted in a significant 31.86% increase in hardness and a 44.1% increase in tensile strength compared to AA 2014 alloy. In addition, it has been detected that wear resistance of hybrid composite pin (containing 20 wt% cumulative reinforcement) is higher than that of other stir cast wear test pins during the whole range of applied loads. Fractured surfaces of tensile specimens showed ductile fracture in the AA 2014 matrix and mixed mode for hybrid composites. Worn surfaces obtained employing higher applied load indicated abrasive wear with little plastic deformation for hybrid composites and dominant adhesive wear for matrix alloy. Hence, the superior mechanical and tribological performance of hybrid composites can be attributed to dual reinforcement particles being dispersed well and the effective transmission of load at this specific composition.

Advances in hybrid aluminium metal matrix composite produced by stir casting route: A review on applications and fabrication characteristics

The sustained demand for lightweight parts, superior strength, and high-efficiency products has made material researchers interested to study and explore new materials with superior properties. One of the most promising materials for meeting this demand is aluminium metal matrix composite. Due to its tailored properties, the usage of composite is currently increasing in the automotive, aerospace, marine, electronic, defence, domestic, and sports sectors. Simplicity, affordability, and bulk production in the stir casting method have attracted the attention of many researchers across the globe. This paper reviews the need for hybrid aluminium metal matrix composites, various aluminium alloys, and reinforcement materials produced by the stir casting technique. In addition, the applications, morphological, mechanical, and tribological behavior of aluminium hybrid metal matrix composites are discussed. This review will assist materials researchers in selecting the matrix and reinforcements for a specific application of aluminium matrix composites using the stir casting route.

Machinability of waste bamboo powder ash reinforced 7075-T651/B4C Hybrid composite in computer numerical control lathe

Metal Matrix Composites (MMC) are novelly prepared with the reinforcement of different wood ash in the matrix material to achieve desired properties. Utilizing the waste material for reinforcement may reduce the material cost. Usually, fly ash from thermal power plants has become a popular reinforcement material for MMC through stir casting and employing in friction stir processing. This research is motivated by using ash of waste bamboo powder (AWBP). The waste of bamboo pieces was collected from the furniture industry. They have been gathered, prepared to ash and used as reinforcement of 4 wt%, 8 wt%, and 10 wt% in stir casting of aluminium alloy 7075-T651 and that was optimized as 8 %. The objective of this research is CNC turning type machinability of AA7075-T651/ B4C/AWBP hybrid Composites. The details of the reinforcement are 2 wt% B4C and 8 wt% AWBP. The effects of such reinforcement in AA7075-T651/ B4C/AWBP hybrid composite have improved the friction and wear behaviours, such as high wear resistance and low wear rate. The composite was cased as circular rods. The CNC turning type machinability was investigated in the CNC turning centre. The cutting speed varied from 1000 rpm to 3500 rpm, the feed rate varied from 100 mm per hour to 200 mm per hour. The Al2O3 nanoparticles concentration on cutting fluids varied from 0.25 wt% to 1 wt%. The response surface methodology was used to optimize the parameters. A mathematical model was developed to predict the responses.

Comparative evaluation of microstructure & mechanical properties of stir-cast A713/TiB2 & A713/TiB2/Graphene hybrid composites

In this study, Aluminum A713 based composites have been developed by choosing TiB2 and Graphene as reinforcements.The composites are fabricated by using the stir casting technique. The prepared composites were characterized using Optical Microscopy (OM), X-ray Diffraction (XRD), Scanning Electron Microscopy (SEM) and Energy Dispersive Spectroscopy (EDS). Tensile strength and microhardness of composites were tested using ASTM standards. The results showed that incorporating TiB2 and Graphene reinforcements into A713 alloy increased its hardness and tensile strength. SEM analysis was employed to evaluate the fracture surfaces and also to identify the impact of TiB2 and Graphene particles.

Microstructure and Mechanical properties of CMT welded AA6063-T6/B4C/ES metal matrix composite using ER5356 filler wire

Aluminium alloy 6063-T6 is a popular choice among different industrial sectors as it portrays various desirable properties like moderate strength, improved corrosion resistance, better weldability and formability etc. These advantages make AA6063-T6 a common choice for matrix in a metal matrix composite. Mostly conventional fusion welding methods like Metal Inert Gas (MIG) and Tungsten Inert Gas (TIG) seem preferable options for welding aluminium and its alloys but it remains a challenge to use them to weld aluminium metal matrix composite. A modified version of MIG i.e. CMT welding, can be explored to overcome the challenges. In this study, an aluminium metal matrix composite has been fabricated with AA6063-T6 as matrix and two reinforcements −one organic, i.e., Eggshell (ES) and one inorganic, i.e., Boron Carbide (B4C), using the conventional stir casting method. CMT welding has been performed on plates cut out from the composites. Microstructure, hardness, tensile strength and residual stress of weld joint of composite have been observed. From micrographs, it is observed that a finer grain has been formed at the Fusion Zone (FZ) in comparison to the Heat Affected Zone (HAZ) and Parent Material (PM). XRD analysis at the fusion line has identified several intermetallic stoichiometric compounds (Al12Mg17, Mg2Si, CaMgSi, CaO, B2O3) and reinforcement B4C and CaCO3 within the matrix volume. The FZ exhibits higher hardness than the HAZ and the PM. Further, the tensile strength of the FZ exceeds that of the unwelded composite due to the presence of metastable strengthening phases of Mg2Si in the FZ, along with reinforcement (B4C and ES) particles. Residual stress analysis reveals tensile stress in the FZ and more compressive stress in the HAZ than in the PM.

Study of Mechanical and Tribological Behavior of Fly ash with E-Glass fibre Reinforced AL MMC’s

AMC’s specimen made by liquid stir casting technique, by addition of fixed 3% E-glass fibers and fly ash particles in different proportions (4, 6 and 8 wt.%) prepared the matrix phase. A uniform distribution of reinforcement is obtained with good bonding with matrix. Dry sliding wear behavior of the aluminum alloy and the composites has been studied and tested using a pin-on-disc wear and friction monitor. The testing carried out on sliding velocity of 1.5, 2.5 and 3.5 m/s and load ranges from 1, 2 and 3kgf. The composite shows better mechanical properties than the base alloy. Abrasive wear resistance improves by addition of fly ash reinforcement

Fabrication and investigation of microstructural, mechanical and wear properties of in situ ZrB2/fly ash/AA7075 hybrid composite

This research explores the microstructural, mechanical and wear characteristics of hybrid aluminum metal matrix composites (HAMMCs). Initially ZrB2 is fabricated by melt reaction and then fly ash incorporated into the aluminum composite melt as secondary reinforcements to fabricate HAMMCs through the ultrasonic agitated stir casting method. Micrographic and phase analysis of the HAMMCs and base alloy is conducted x-ray Diffraction (XRD), and Energy-Dispersive x-ray Spectroscopy (EDS). A wear test was conducted to study the wear properties of alloy and hybrid composite material. The generated wear scar was analyzed using a profilometer to find the wear rate. The tensile strength and hardness of the hybrid aluminum metal matrix composites (HAMMCs) improved remarkably as compared to base alloy. The wear resistance of the fabricated composite also increases on increasing the in situ ZrB2 up to 3 weight fractions.

Optimization of physico-mechanical and erosive wear properties of single/multilayer – coated granite filled aluminum alloy composites

Abstract In the present research, uncoated and coated (CrN/SiN–CrN) granite dust reinforced aluminum alloy (AA 1050, AA 5083) composites samples were fabricated using stir casting and their physical, mechanical and slurry erosion behavior were assessed. The study reveal a persistent increase in void content, hardness, impact strength and stress intensity factor for both uncoated and coated alloy with the inclusion of reinforcement. In contrast, flexural strength and corrosion rate decrease continuously with increased granite content and also with the corresponding coating. Multilayer coated 5083 aluminum alloy composite with 6 wt.% granite particle shows maximum hardness, impact strength and stress intensity factor and minimum slurry erosion rate. The entropy method was applied to the operating parameter to rank the fabricated composites. The performance of each operating parameter is determined using the VIKOR (Vise Kriterijumska Optimizacija Kompromisno Resenje) optimization method. The optimal formulation based on Performance-Defining Attributes (PDAs) is observed for multilayer-coated 6 wt.% granite particulate reinforced 5083 aluminum alloy composites.

Multi-response optimization of reinforcement parameters of aluminum alloy composites by Taguchi method and grey relational analysis

The present work describes the optimization of reinforcement parameters for hardness, thermal conductivity, and coefficient of thermal expansion while developing LM6 alloy/soda-lime glass particulate composite through Taguchi-based Grey Relational Analysis (GRA). Soda-lime glass particle weight % (1.5, 3.0 and 4.5 %), particle size (100, 150 and 300 μm) and pre-heat temperature (260, 380 and 500oC) are varied accordingly to explore the effect of reinforcement parameters on LM6 alloy/soda-lime glass composite properties. Composites are developed through stir casting based on the L9 Taguchi orthogonal array approach. The properties such as hardness, thermal conductivity and coefficient of thermal expansion of developed composites are assessed. Signal to Noise Ratios (S/N ratios) are calculated and used for the optimization of parameters. GRA is employed for multi-response optimization to find the levels of parameters that affect the desirable properties of the composite. Thus, the reinforcement parameters are optimized for attaining the combined objectives of higher hardness, higher thermal conductivity and lower coefficient of thermal expansion values considered in this investigation. The analysis shows that 4.5 wt %, particle size of 200 μm and pre-heat temperature of 380oC are optimal parameter levels. A confirmation test is carried out with the optimal parameter levels and the GRG value of 0.7778 is obtained. The GRG with the initial parameter settings is 0.4711, and the improvement of GRG is found to be 65.1 %. ANOVA is performed on GRG to find out significant parameters and the contribution of each parameter is identified. The wt.% of soda-lime glass is the most significant parameter and its contribution is 92.6 %.

INFLUENCE OF HYBRID NANOCERAMIC PARTICLES ON MECHANICAL PROPERTIES THROUGH TAGUCHI APPROACH

The manufacturing procedures and parameters utilized to manufacture composite significantly change the properties. This study focuses on Hybridized Metal Matrix (HMM) nanocomposite with the influence of Si3N4 and SiC nanoparticles on AA 7075 for its tensile strength and microhardness. The specimen is created using the ultrasonic aided stir casting method, and the effects of processing limitations such as particle weight %, stirrer speed, stirrer duration, and processing temperature on UTS and microhardness are optimized using the ANOVA approach. For the trials, the Taguchi research design based on an orthogonal array L[Formula: see text] is used. This approach is mostly used to frame the structure of parameters to assess the best factor.

Investigation on mechanical behavior of Al6061- coconut shell ash- granite dust reinforced hybrid metal matrix composites manufactured using stir casting technique

Owing to the superior qualities, aluminum metal matrix composites (AMMC) have recently been accepted and suggested as a replacement for traditional materials in a variety of sectors, including automotive, agriculture, aerospace, sports, marine, and many more. To satisfy the industrial requirement, it is necessary to develop economical material with higher mechanical properties like strength, hardness, impact resistance etc. To minimise the environmental impact and depletion of natural resources , it is necessary to Reduce, Recycle and Resuse the solid waste created across the world. This work aims to study the mechanical behavior of hybrid composite of Al6061 reinforced with coconut shell ash (CSA) and granite dust solid waste. Hybrid composite specimens were successfully manufactured using stir casting method. The proportion of granite dust was kept constant at 2 wt percent, whereas the percentage of CSA varied, ranging from 0% to 12% with a multiple of 3. Tests for tension, compression, hardness, and impact were performed to examine the mechanical behavior of the created hybrid composites. SEM & EDAX analysis were carried out to study the microstructure and elemental composition of the hybrid composites. Experimental testing shows that, when the percentage of CSA in the hybrid composite increased, its tensile strength, compressive strength, hardness, and impact strength increased maximum upto 23.65%, 10.12%, 60.89% and 17.38% respectively as compared to base alloy. The experimental findings demonstrated that when compared to matrix and other hybrid composites, the Al6061 alloy reinforced with 2% granite dust and 12% CSA hybrid composite had superior mechanical properties.

Effect of graphene addition on microstructure and wear behaviour of the A356-based composite fabricated by thixoforming process

Employing graphene as reinforcement in an aluminium matrix is a viable approach for developing composites with exceptional mechanical properties and wear resistance owing to its two-dimensional structure and high strengthening efficiency. This study aims to investigate the microstructure and wear behaviour of A356 aluminium matrix composites reinforced with different graphene nanoplatelets (GNPs) amounts (0.3, 0.5 and 1.0 wt%). The feedstock of composites underwent stir casting before being subjected to the thixoforming process. Field emission scanning electron microscopy (FESEM) and transmission electron microscopy micrographs (TEM) demonstrated the microstructure transformation of the composites after fabrication and the presence of carbon elements in the A356 matrix composite, respectively. TEM micrographs also displayed the existence of aluminium carbide (Al4C3) compound in the composites due to the reaction of aluminium matrix and graphene during fabrication. The hardness testing results revealed the hardness of the composite with 0.3 wt% GNPs is higher than that of A356 alloy by showing an improvement of 51.4% after the thixoforming process. The wear resistance of the composites was enhanced by decreasing the wear rate. In comparison with the as-cast and thixoformed A356 alloys, the thixoformed composite reinforced with 0.3 wt% GNPs exhibited the lowest wear rate, demonstrating a reduction of 18.7% and 11.5%, respectively. These findings demonstrated the significance of GNPs as an effective self-lubricating and favourable reinforcement for A356 aluminium matrix composite in the automotive industry.

Effect of SiCp on the solidification process of magnesium

In this paper, SiCp was added to the pure Mg matrix by ultrasound-assisted stir casting to prepare SiCp-reinforced magnesium matrix composites. The solidification process and solidification structure were analyzed. The results show that SiCp reacts with a pure magnesium matrix to form the element Si, which affects the nucleation temperature and phase transition time of alloys. The presence of Si element decreases the nucleation temperature of α-Mg. As the SiCp content increases, more Si elements are present, which leads to a lower nucleation temperature of α-Mg. In addition, elemental Si and Mg undergo a eutectic reaction to form Mg2Si, which prolongs the phase transition. Elemental Si also affects the solidification process of Mg. During solidification, the element Si generated by the reaction is enriched at the front of the solid-liquid interface, leading to compositional undercooling, which results in the growth of α-Mg through a non-flat interface. When the α-Mg solidification is complete, a solid solution rich in Si elements is formed. Subsequently, the Si element precipitates from the α-Mg solid solution by secondary crystallization as Mg2Si distributed at grain boundaries and inside the grains.

Effect of Reinforcement on Micro Structural and Compressive Deformation Behavior on Closed Cell AA7075 Aluminium Foam

Effect of Reinforcement on Micro Structural and Compressive Deformation Behavior on Closed Cell AA7075 Aluminium Foam