Ultrasonic Assisted Stir Casting Research Articles

Tribological behavior of ultrasonic assisted double stir casted novel nano-composite material (AA7150-hBN) using Taguchi technique

A novel Al-7150 nanocomposite material was fabricated with various weight percentages of Hexagonal Boron Nitride from 0.5 to 2 wt% in steps of 0.5 wt% by liquid metallurgy route via ultrasonic assisted double stir casting method. The tribological properties were tested and carried out on pin-on-disc tribometer considering various input parameters like weight percentage of reinforcement, applied load, sliding distance and speed to study the tribological characterization. Taguchi technique using MiniTab 17 software was used to analyse the wear rate of nanocomposites. Different experiments were conducted using Taguchi technique and the regression equations were developed through Analysis of Variance (ANOVA) to investigate the influence of various test parameters such as applied load, sliding distance, sliding speed and the material parameter such as weight percentage of reinforcements. The applied load had the greatest influence on statistical and physical properties of nanocomposites while, the sliding speed exercised its impact on the Coefficient of Friction (COF) of nanocomposite on dry sliding wear and also on the optimal parameters for less wear rate and low COF. The worn-out surface morphology of test specimens was investigated through Scanning Electron Microscope (SEM), Energy-Dispersive X-ray spectroscopy (EDX) system and correlated with the obtained results and conclusions were drawn.

Characterization of friction stir welded AL6063/nano fly ash composite

In this work Aluminum Matrix Composites (AMCs) reinforced with nano fly ash (NFA) particles in 1 wt%, 2 wt% and 3 wt% were fabricated through ultrasonic assisted stir casting process. These composites were subsequently welded through Friction Stir Welding (FSW). It is proposed to explore the effect of NFA on refinement of grain structure and to investigate the mechanical properties of friction stir welded AMC joints. Through Scanning Electron Microscope (SEM) images it is observed that homogeneous dispersion of NFA in the Aluminum matrix material was achieved. The increase in tensile strength and hardness was observed in the developed AMCs. It was concluded that the FSW process is the better option to join Al6063/NFA composites.

Mechanical and wear surface characterisation of aluminium hybrid nanocomposite

The newly engineered metal matrix nanocomposite (MMNC) of Al6061 reinforced with 0.4 wt% SiC and 0.5 wt% Gr hybrid nanocomposites were synthesised by ultrasonic assisted stir casting method. The pin-on-disc equipment were conducted on the prepared samples to investigate the tribological behaviour of the hybrid nanocomposite. The hybrid nanocomposite and wear surfaces have been characterised by field emission scanning electron microscope (FESEM) equipped with an energy dispersive spectrometer (EDS), optical microscope (OM) and 3D profilometer to understand the wear mechanisms. This study shows the effectiveness of incorporation of graphite in the hybrid nanocomposite for reduction of friction, wear and surface roughness. With the introduction of nano SiC and Gr particles into matrix alloy, the number and depth of grooves in worn surface of hybrid nanocomposites decreased. The Al/0.4SiC/0.5Gr hybrid nanocomposite showed superior tribological properties and self-lubricating ability compared to the matrix alloy.

Mechanical and wear surface characterisation of aluminium hybrid nanocomposite

The newly engineered metal matrix nanocomposite (MMNC) of Al6061 reinforced with 0.4 wt% SiC and 0.5 wt% Gr hybrid nanocomposites were synthesised by ultrasonic assisted stir casting method. The pin-on-disc equipment were conducted on the prepared samples to investigate the tribological behaviour of the hybrid nanocomposite. The hybrid nanocomposite and wear surfaces have been characterised by field emission scanning electron microscope (FESEM) equipped with an energy dispersive spectrometer (EDS), optical microscope (OM) and 3D profilometer to understand the wear mechanisms. This study shows the effectiveness of incorporation of graphite in the hybrid nanocomposite for reduction of friction, wear and surface roughness. With the introduction of nano SiC and Gr particles into matrix alloy, the number and depth of grooves in worn surface of hybrid nanocomposites decreased. The Al/0.4SiC/0.5Gr hybrid nanocomposite showed superior tribological properties and self-lubricating ability compared to the matrix alloy.

Achieving high strength and ductility in graphene/magnesium composite via an in-situ reaction wetting process

The dispersibility and interfacial wettability are two essential requirements for fabricating graphene/metal composites with high performance. However, the simultaneous improvement of dispersibility and wettability between the graphene and metal matrix is still a challenge. Herein we attempted to improve the dispersibility, interfacial wettability and mechanical properties of graphene/magnesium composites via an in-situ reaction wetting process. Graphene oxide (GO) was modified with ZnO coating by a coprecipitation route, and the composites were fabricated by an ultrasonic assisted stir casting method. The composites showed a microstructure with homogeneous dispersion of graphene in the matrix. Compared with unreinforced Mg matrix, the composites demonstrated an exceptional and joint improvement in yield strength, hardness, and good ductility. Microstructural examinations revealed that the molten Mg could react with ZnO coating and form an interfacial product composed of MgO during the composite fabrication. The interfacial in-situ reaction could facilitate interfacial wetting and the interfacial product MgO could improve the interfacial bonding between graphene and matrix. The grain-size refinement and load transfer provided by graphene were the two main strengthening mechanisms in the composite. This study provides new insights into the interfacial design of advanced graphene/metal composites with exceptionally high strength and ductility.

Dry Sliding Wear behaviour of cast Al/Al203/Gr hybrid nano-composite using response surface methodology

The newly engineered metal matrix nanocomposite (MMNC) of Al 6061 reinforced with 1.2 wt % Al203 and 0.5 wt % Gr (Al-1.2Al203-0.5Gr) hybrid nanocomposite was prepared by ultrasonic assisted stir casting method. A three-level central composite design test was developed using response surface methodology; parameters such as load, velocity and sliding distance were varied in the range of 10-30 N, 0.4-1.1 m/s and 500–1500 m, respectively. Dry sliding wear tests were performed as per the experimental design using a pin-on disc setup at room temperature. Analysis of variance (Anova) was applied to investigate the influence of process parameters and their interactions viz., Load, velocity, sliding distance on wear, and coefficient of friction (COF). The aim of the study was to identify the process parameters that significantly affect the output features. Further, a mathematical model has been formulated by applying response surface method in order to estimate the tribology characteristics such as wear and COF of the hybrid nanocomposites.

Mechanical Properties and Tribological Behavior of Al6061–SiC–Gr Self-Lubricating Hybrid Nanocomposites

In the present investigation, a newly fabricated Al6061 reinforced with various quantity (0.4–1.6 wt%) of nano SiC in steps of 0.4 and fixed quantity (0.5 wt%) of micro graphite particle’s hybrid nanocomposites were prepared by ultrasonic assisted stir casting method. The influence of nano SiC and graphite content on the mechanical and tribological properties of Al6061 hybrid nanocomposites were studied. The pin-on-disc equipment was used to carry out experiment at 10–40 N applied load, 0.5 m/s sliding speed and 1000 m sliding distance. The Al/SiC/Gr hybrid nano-composite and matrix alloy wear surfaces were characterized by FESEM equipped with an EDS, 3D profilometer to understand the wear mechanisms. The results of Al/SiC/Gr self-lubricating hybrid nano-composites showed improved wear resistance than the Al6061 matrix alloy. The co-efficient of friction of Al/SiC/Gr hybrid nano-composites were lower than those of the unreinforced alloy at various applied load. Compared to matrix alloy, the surface roughness of Al/SiC/Gr hybrid nano-composites had significantly reduced to 66% at low load and 75% at high load. Self-lubricating Al/SiC/Gr hybrid nanocomposites showed superior surface smoothness compared to matrix alloy.

Study of tribological properties of Al-Al2O3 nanocomposites developed through ultrasonic assisted stir casting process

Metal matrix composites (MMCs) have proved their viability as good alternatives to conventional alloys in high strength and stiffness application in industries like automobile, aerospace and mineral processing. Al metal matrix composites (MMCs) are being considered as a group of advanced materials for their lightweight, low coefficient of thermal expansion, and good wear resistance properties. In this work Al6061- nanoAl2O3composite with 1 , 2 and 3 wt. percentage of Al2O3 were fabricated by ultrasonic assisted strir casting process. Further heat treatment of composites was done. Tribological properties have been investigated on pin on disc wear testing machine. It is found thatwear resistance of the composite is considerably higher than that of the matrix alloy and increased with increasing Al2O3 particle content.

Mechanical and Wear Behavior of ZA-27/Sic/Gr Hybrid Metal Matrix Composites

Hybrid metal matrix composites are extensively used because of its high strength and improves the wear resistance properties. In this present study, the work is concentrated on the production of ZA-27 alloy and hybrid composite reinforced with 1.5 weight percentage of silicon carbide (Sic) and 0.5 weight percentage of graphite (Gr). Ultrasonic assisted stir casting method is used for the preparation of the ZA-27/Sic/Gr hybrid metal matrix composite. The hardness and ultimate tensile strength were carried out to test the mechanical properties of the hybrid composite. Pin on Disc testing machine is used to study the dry sliding wear characteristics of the hybrid composite at different operating conditions. The mechanical properties of the hybrid composite increases as compare to the base metal. Wear volume loss of the hybrid composite were decreases when compare to ZA-27 alloy and the worm surfaces were analyzed by using optical microscope.

Study of Fabrication, Testing and Characterization of Al/TiC Metal Matrix Composites through different Processing Techniques

The various techniques for the of fabrication of Al/TiC metal matrix composites such as powder metallurgy, friction stir processing, flux assisted synthesis, accumulative roll bonding and most popular In-situ etc. have been studied. Ultrasonic assisted stir casting process or in other words vortex method via liquid metallurgy method has evolved as economical and simple technique to fabricate metal matrix composites in the recent years. There are very few literature available on fabrication of Al/TiC metal matrix composites through Ex-situ method via stir casting processing.The objective of Metal matrix composites (MMC) focused primarily on improved specific strength, micro hardness, high temperature application, low density, and high wear resistance. Al/TiC are potential materials for aircraft, defence and aerospace applications. The aim of this paper is to study the current research and development in aluminium alloy 6061-titanium carbide based composites by different processing techniques with special focus on in situ and ex-situ stir casting route. Very limited studies have been reported on TiC particulates synthesized with Al matrix composites. TiC particulates reinforced composites are well featured by the particulate-matrix bonding and interface studies particularly with aluminium and proved to be a potential reinforcement for improved mechanical properties in Al/TiC Composites especially for micro hardness, wear and compressive strength.

Mechanical Properties and Dry Sliding Wear Behaviour of Molybdenum Disulphide Reinforced Zinc–Aluminium Alloy Composites

ZA-27 alloy is a lightest alloy which offers excellent bearing and mechanical properties in automobile and industrial applications. In this study, the MoS2 particles with 0.5, 1 and 1.5 (wt%) weight percentages were reinforced in ZA-27 alloy to form composites, which were fabricated by using ultrasonic assisted stir casting method. The ZA-27/MoS2 composite specimens were examined for chemical composition with the aid of XRD technique and EDS. Microstructure analysis of the ZA-27/MoS2 composites was studied using SEM. Tests were conducted for mechanical properties such as tensile strength and hardness on ZA-27/MoS2 composites samples as per ASTM standards. Dry sliding wear behavior of the composites was tested at various operating conditions by using pin-on-disc apparatus. Microstructural images of the ZA-27 composites reveal that there is a uniform dispersion of the MoS2 particles in the base material. From the results it is observed that the mechanical properties increases with ZA-27 reinforced with 0.5 wt% MoS2 composite and further decreases with increase in the filler content. The enhanced wear resistance is observed in ZA-27 reinforced MoS2 composites as compared to the unreinforced alloy. The wear rate of the ZA-27 composites decreases with the increase in filler content, further the worn surfaces as examined using SEM reveals the wear mechanism explaining the improved wear resistance of the particulate composites.

Dispersion of Alumina Nano Particles in Al 2219 alloy by Ultrasonic Assisted Stir Casting Technique

Request augments on a worldwide scale for the new materials. The metal matrix nanocomposites can be used in numerous applications of helicopter structural parts, gas turbine exit guide vane’s, space shuttle, and other structural applications. The key mailman to ameliorate performance of composite matrix in aluminium alloy metal reinforces nano particles in the matrix of alloy uniformly, which ameliorates composite ownership without affecting limit of ductility. The ultrasonic assisted stir casting helped agitation was successfully used to fabricate Al 2219 metal matrix of alloy reinforced with (0.5, 1, 1.5 and 2) Wt.% of nano particles Al2O3. The micrographs of scanning electron microscopy of nanocomposite were investigated it reveals that the uniform dispersion of particles of oxide of nano aluminium in Al 2219 matrix of alloy and with the zero porosity. The mechanical properties showed that the ultimate tensile strength and hardness of metal matrix nano composite Al 2219 / nano Al2O3 lean to augment with increase weight percentage of alumina content in the matrix alloy.

Effect of TiC particles on the mechanical properties of aluminium alloy metal matrix composites (MMCs)

Titanium carbide is the costly reinforcement nano powder mostly used in structural applications, aerospace, automobile industries and specific cutting tools where safety is main consideration factor and reasons are not difficult to understand as far as cost concerned. The primary objective in aircraft or anywhere is safety. In the present research the effect of titanium carbide particles on their mechanical properties with different aluminium matrix has been reviewed. The ultrasonic assisted stir casting is an economical and amenable process for medium to large scale production as compared to other methods such as powder metallurgy and spray forming.The objective of this paper is to study the current research and development in aluminum-based in situ and ex-situ composites by casting route. Very few work has been reported on nano TiC particulates synthesized with Al 6061 using ex-situ method.TiC particulates reinforced composites are attributed to tremendous bond reliability of TiC particulates with aluminium. Titanium carbide is proved to be a potential reinforcement for improved mechanical properties in Al MMCs.

Improvement of Tensile Behaviour of Tin Babbitt by Reinforcing with Nano Ilmenite and its Optimisation by using Response Surface Methodology

Metal Matrix Nanocomposites are made from conventional materials and alloys as matrix materials and had become prominent in improving the mechanical behaviour. In this paper, the authors have fabricated a Tin Babbitt particulate metal matrix nanocomposite reinforced with Ilmenite (FeTiO3). For systematic understanding or effect of processing parameters on the tensile behaviour, the central composite design of response surface methodology was used. Metal matrix nanocomposite was fabricated by using ultrasonic assisted stir casting technique. Stirring time, ultrasonic processing time, Wt.% of nanoparticles were taken as processing parameters. The objective of the work is to improve the tensile behaviour of Tin Babbitt and understand the effect of processing parameters on the tensile strength of the Tin Babbitt metal matrix nanocomposite and then optimise it for maximum tensile strength. It was found that tensile strength was improved due to the nano reinforcement.

Preparation of SiC based Aluminium metal matrix nano composites by high intensity ultrasonic cavitation process and evaluation of mechanical and tribological properties

Request augments on a worldwide scale for the new materials. The metal matrix nano composites can be used in numerous applications of helicopter structural parts, gas turbine exit guide vane's, space shuttle, and other structural applications. The key mailman to ameliorate performance of composite matrix in aluminium alloy metal reinforces nano particles in the matrix of alloy uniformly, which ameliorates composite properties without affecting limit of ductility. The ultrasonic assisted stir casting helped agitation was successfully used to fabricate Al 2219 metal matrix of alloy reinforced with (0.5, 1, 1.5 and 2) wt.% of nano silicon carbide (SiC) particles of different sizes 50nm and 150nm. The micrographs of scanning electron microscopy of nano composite were investigated it reveals that the uniform dispersion of nano particles silicon carbide in aluminium alloy 2219 matrix and with the low porosity. How the specific wear rate was vary with increasing weight percentage of nano particles at constant load and speed as shown in results and discussions. And the mechanical properties showed that the ultimate tensile strength and hardness of metal matrix nano composite AA 2219 / nano SiC of 50nm and 150nm lean to augment with increase weight percentage of silicon carbide content in the matrix alloy.

Influence of Ultrasonic Assisted Stir Casting on Mechanical Properties of Al6061-nano Al2O3 Composites

In this paper, the effect of ultrasonic assisted stir casting on mechanical properties of Al6061aluminium alloy reinforced with nano Al2O3 particles with average size 40nm and weight percentages 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0 has been investigated. The micro-structural analysis indicated the uniform distribution of nano Al2O3 particles in the Al matrix with few clusters of reinforcing particles. The tests of properties resulted in the marginal increase in hardness, tensile strength, compressive strength with ultrasonic assisted stir casting, attributed to uniform distribution of nano reinforcing particles in Al matrix by ultrasonic frequency vibrations at 20 KHz, breaking up the nano clusters.

Characterization of Mechanical Properties and Microstructure of Aluminium Alloy-SiC Composites

In recent years aluminium alloys are widely used in automotive industries due to light weight, good formability, high corrosion resistance and high electrical and thermal conductivity. However, the poor mechanical and tribological properties of pure aluminium alloys limit its wider range of applications. The mechanical properties can be improved by addition of ceramic particles like SiC, Al2O3 etc. AMCs combine the metallic properties of matrix alloys (ductility and toughness) with ceramic properties of reinforcements (high strength and high modulus) and lead to higher strength in tension and compression and higher service temperature capabilities. In this study, AA 5083 alloy-SiC composites have been fabricated by Ultrasonic assisted Stir casting. Different weight % of SiC (3, 5, 8 and 10wt %) were used for synthesis of composites. SEM micrographs show uniform distribution of SiC particles with agglomeration at some places. The application of ultrasonic vibration on the composite during melting not only refined the grain structure of the matrix, but also improved the distribution of nano-sized reinforcement.

Wear Behavior and Micro-structural Study of Al/Al2O3Nano-composites Before and After Heat Treatment

In this study; an advanced ultrasonic assisted stir casting technique has been adopted to incorporate nano-sized Al2O3particle into aluminum alloy 6061 to form particulate nano composite material. Dry sliding wear testing of Aluminum matrix nano composites were performed before and after heat treatment using a pin-on-disc tribometer. The content of Al2O3 nano particles in the composite was varied from 0 to 3.0 weight% and the effect of parameters on wear rate were studied. The sliding wear test is conducted for different loads, speeds and weight % of nano Al2O3particles. The results have shown that wear rate of composite reduces with increasing the nano alumina content. For the same working conditions and processing parameter, wear rate increases with increase in load and with increase in speed. Also, a significant improvement in wear resistance was observed in the heat treated Al-Al2O3 nano-composite as compared un-heat treated composite samples.

Development and Analysis of Al-Matrix Nano Composites Fabricated by Ultrasonic Assisted Squeeze Casting Process

In the present work an attempt has been made to synthesize metal matrix composite using 6061 Al as matrix material reinforced with nano Al2O3 particulates using liquid metallurgy route particularly squeeze casting technique. The nano composites prepared by varying the Al2O3 from 1–3 weight percent. The reinforcement particles were preheated to a temperature of 300°C and then dispersed in molten Al 6061 alloy to improve wettability and distribution. Mechanical properties of the composites fabricated by squeeze casting process were compared with the ultrasonic stir casting process. The results revealed that the mechanical properties like tensile strength, compressive strength and hardness of composite fabricate by the ultrasonic assisted squeeze casting process is higher than that of ultrasonic assisted stir casting process. Microstructure shows that there is significant grain refinement in the composite fabricate by the ultrasonic assisted squeeze casting process than ultrasonic assisted stir casting process.

Development and Wear Analysis of Al- Nano SiC Composite Automotive Cam

Material science and engineering has experienced a tremendous growth in the field of Micron and nanocomposites developed with enhanced chemical, mechanical and physical properties. Cam has been fabricated by Ultrasonic assisted Stir casting process. Different weight % of Nano SiC (1, 2, 3 and 4wt. %) were used for synthesis of composites and composite Cams. Hardness of composites was measured. Further Al-SiCp Composite cams have been tested for accelerated wear at different time intervals. Results shows that the Al-micron SiCp Composite Cam were having the almost same wear resistance as the existing Alloy steel Cam. However weight of composites cam was 1/3 of the alloy steel cam.