Uniform Distribution Of Reinforcement Particles Research Articles

Effect of Yttria-Stabilized Zirconia addition along with Cu in development of titanium based metal matrix composite via FSP technique for the application in biomedical devices

ABSTRACT The present study investigated the effect of incorporating Yttria-Stabilized Zirconia (YSZ) and copper (Cu) in the development of Titanium-Based Metal Matrix Composites (TMCs) using the Friction Stir Processing (FSP) technique. The macrostructure of the TMCs, after adding 5% YSZ and 2% Cu, displayed a defect-free, crack-free, and porosity-free surface, indicating the precision of the FSP method. Microstructure analysis revealed a uniform distribution of reinforcement particles and proper dispersion of grains, key for enhancing mechanical properties. The interfacial bonding between titanium and YSZ was exceptionally strong, devoid of cracks and porosity, attributed to the copper additive’s role. The increase in the number of grains per square inch for the Ti/5% YSZ/2% Cu composite (1176.26 grains per square inch at 500×) signified finer grain structure, contributing to a remarkable 48.04% improvement in tensile strength compared to pure titanium. The uniform distribution of reinforcement and strong bonding between titanium and YSZ are the driving forces behind the 46.34% increased in hardness. Additionally, the wear resistance of the composite improved by approximately 76.66%, a vital characteristic for applications facing abrasive conditions. The corrosion testing demonstrated an 8.33% enhancement in corrosion resistance with the Ti/5% YSZ/2% Cu composite.

Identifying stir casting process parameters to maximize strength of LM13 with TiB2 and ZrC hybrid metal matrix composite

Abstract In this study, an LM13 metal-matrix composite was fabricated using two reinforcement particles (hard and soft) of titanium diboride and zirconium carbide. An experimental design was used to narrow down the trials. The significance of the model was tested using Student’s t-test and p values. The response surface statistical method was used to obtain the optimum process parameters for the high-strength hybrid metal matrix composite. From the experimental results, a maximum strength of 209 MPa was gained at a stirrer speed of 700 rpm, weight fraction of TiB2 and ZrC of 9 %, and casting temperature of 675 °C. The ANOVA results showed that TiB2 was the main influential process parameter, followed by the stirrer speed, casting temperature, and zirconium boride. The microstructure showed a fine and uniform distribution of reinforcement particles in the LM13 matrix. The fracture surface exhibited a mixed fracture pattern, which was due to the good bonding between the reinforcement and matrix at the interface.

Friction stir powder additive manufacturing of Al 6061/FeCoNi and Al 6061/Ni metal matrix composites: Reinforcement distribution, microstructure, residual stresses, and mechanical properties

Fusion based additive manufacturing (FBAM) of second, sixth, and seventh series Al alloys and their metal matrix composites (MMC) is difficult due to their higher thermal conductivity and solidification related problems namely porosity, cracks, thermal distortion, and formation of undesired phases. This paper presents friction stir powder additive manufacturing (FSPAM) process as a promising alternative to overcome these problems in producing multi-layer depositions of Al 6061 based MMCs namely Al 6061/6 wt%FeCoNi and Al 6061/6 wt%Ni. Their microstructure, distribution and elemental mapping of reinforcement particles, phase analysis, residual stresses of the MMCs and their correlation with microhardness, tensile strength, and fretting wear characteristics are investigated. Material accumulation on their advancing side was minimized by changing tool rotation direction in consecutive layers which produced smoother surfaces on both sides of their deposition. FSPAM made multi-layer depositions of Al 6061/FeCoNi and Al 6061/Ni MMCs have uniform distribution of reinforcement particles, good bonding between layers without cracks and defects, refined and equiaxed grains facilitated by dynamic recrystallization and pinning effect of reinforcement particles, compressive residual stresses of 39 and 48 MPa, no formation of deleterious intermetallic compounds due to absence of melting of matrix and reinforcement, and bowl-shaped substrate-deposition interface. Microhardness and ultimate tensile strength of the MMCs improved by 11.3% and 22.3%, and 30.5% and 31.5% respectively than Al 6061 alloy depositions, their wear resistance enhanced significantly, but % elongation reduced. This study proves FSPAM to be a potential alternative to FBAM processes for better quality multi-layer deposition of Al alloy-based MMCs.

Effect of fabrication techniques on mechanical and microstructural behavior of AA7075/SiC/ZrC hybrid composite

Aluminum composites are highly sought-after in the industrial sector due to their improved mechanical properties compared to their parent metals. The choice of fabrication technique has a significant impact on the mechanical behavior of the composite. This study investigated the mechanical behavior of an optimized weight-fractioned AA7075/SiC/ZrC hybrid composite using different fabrication techniques. Stir casting, conventional sintering, and microwave sintering methods were employed to produce the composites. By optimizing the ball milling parameters, a uniform distribution of reinforcement particles was achieved throughout the matrix material. XRD, porosity, microstructural, and mechanical tests were conducted on all three composites to analyze the major changes during fabrication. Remarkably, the composites fabricated through microwave sintering exhibited significantly higher strength than the other fabrication methods. Specifically, the microwave-sintered composites displayed a compressive strength of 389 MPa, a tensile strength of 321 MPa, and a strain-to-fracture value of 26%. In contrast, the stir-cast composites showed a larger scale of secondary phases, poor mechanical performance, and elevated porosity. Moreover, when considering the overall production cost associated with the different fabrication techniques investigated in this study, microwave sintering was the most cost-effective method for large-scale production. This suggests that microwave sintering offers superior mechanical properties and economic advantages regarding manufacturing expenses.

Heat treatment behavior of Cr in the form of collagen powder and Al2O3 reinforced aluminum-based composite material

In the present study, collagen powder in the form of Cr has been extracted from chrome-containing leather waste. Extracted collagen powder along with alumina has been used as reinforcement with AA6061 matrix material. The composite material was fabricated by the stir casting technique. Comparative behavior of composite material with and without heat treatment was observed. The microstructure image of the Al/5% Al2O3/5% collagen composite has shown the uniform distribution of reinforcement particles. Proper wettability between the collagen powder, alumina, and matrix material was observed after the solidification for Al/5% Al2O3/5% collagen composite material. Tensile strength, hardness, ductility, and impact strength of composite material were significantly improved after the heat treatment process. However, results showed that ball-milled reinforced composite has a higher Young's modulus as compared to heat-treated composite. The percent porosity of aluminum alloy was found to be 0.18%. However, the porosity of Al/5% Al2O3/5% collagen powder ball milled composite material was found to be 1%. The XRD of the heat-treated Al/5% Al2O3/5% collagen powder composite showed the presence of Al, Al2O3, Cr, and Cr2O3 phases. Thermal expansion and corrosion behavior of the composite were also observed to identify the heat treatment effect on Al/Al2O3/collagen powder composite material.

Study of the corrosion, electrical, and mechanical properties of aluminium metal composite reinforced with coconut rice and eggshell for wind turbine blade development

The gradual global shift from fossil fuels to renewable energy sources such as wind energy for power generation has stirred up a perpetual exigency for sustainable materials for manufacturing wind turbine blades. AMMCs are categories of materials that, over time, have proven reliable as they have been successful in meeting engineering needs in applications requiring high stiffness, moderate strength, and lightweight. The Al8112 alloy was used as the base metal in this study, reinforced with coconut rice and eggshell, to study the corrosion, electrical, and mechanical properties as a viable material for the development of the wind turbine blade. The stir-casting method was used in the preparation. Microstructures, Vickers hardness, tensile strength, electrical conductivity, and corrosion analysis (via the weight loss method) of the prepared composites were analysed. The 3 samples A, B, and C were analysed under 3 media for the corrosion study, such as rainwater, coolant (soluble oil plus water), and nano-lubricants. The results showed that introducing the reinforcements in the matrix of coconut rice and eggshell caused a rise in the hardness and tensile strength. SEM and EDX microstructural analysis revealed a uniform distribution of reinforcement particles in the matrix with the elemental reactions. The corrosion resistance of sample C of the composition (92% aluminium alloy, 5% coconut rice, and 3% eggshell) proved to be higher than that of sample B of the composition (95% aluminium alloy, 2.5% coconut rice, and 2.5% eggshell, and that of the aluminium alloy sample A, with sample C having a corrosion rate of 0.020 mg, sample B having a corrosion rate of 0.021 mg, and sample A having a corrosion rate of 0.022 mg. The composition of the AMMC that exhibits these properties is 92% aluminium, 5% coconut rice, and 3% eggshell. This newly developed material is recommended for applications involving the wind blade.

Fabrication and Mechanical Behaviour Investigation on Aluminium 7075 Boron Carbide and Inconel Alloy 625 Metal Matrix Composite Using Ultra Sonic Stir Casting Method

Aluminium metal matrix composites produced using the ultrasonic stir casting method offer important benefits in aerospace and automotive applications. Aluminium composite material utility has recently increased in all engineering sectors due to its high strength, good wear and corrosive resistance. This study was designed to disperse boron carbide and Inconel Alloy 625 reinforced with aluminium 7075. By varying the weight percentages of boron carbide (2wt percent,4wt percent,6wt percent, and 8wt percent) and Inconel alloy 625 (2wt percent,4wt percent,6wt percent, and 8wt percent) for aerospace applications. The scanning electron microscope was used to examine the morphology and distribution of reinforced particles in a synthetic aluminium composite material. It virtually depicts the uniform distribution of reinforcement particles in the base material matrix (Aluminium 7075). To determine the hardness of the hybrid composite material, a Brinell hardness test was performed. It has been discovered that increasing the reinforcement percentage increases the hardness of the synthesised hybrid composites when compared to the aluminium 7075 base matrix material. Mechanical property testing on fabricated composites specimens of various compositions has been carried out.

Mechanical properties and wear resistance of nano Al/SiC composites fabricated via APB

In this study, Nano AA1100/SiC composites have been fabricated via accumulative press bonding (APB) on the AA1100/SiC composited which have been stir casted. Then, the effect of silicon carbide particles on the mechanical properties, wear resistance and microstructural evolution of these composites have been investigated. To study the effect of Nano SiC Wt.% and as its novelty, all the stir casted samples went under cumulative press bonding process after four cycles to guarantee a uniform distribution of reinforcement particles through the aluminum matrix. The experimental results showed that the strength of these composites were enhanced and the elongation of samples decreased by higher SiC Wt.% contents. Also, there is a significant growing in wear resistance by increasing of SiC content into the Al matrix through stir casting process.

Friction stir processing for tensile strength and microstructure enhancement of Lm25 aluminum alloy – 5% Sicp metal matrix composites

The stir casting method is used to make metal matrix composites and fabricated into plates. The composite material suffers from porosity, uneven distribution of reinforcement particle, and friction stir processing (FSP) is attempted to improve the surface properties of LM25AA-5% SiCp aluminum based metal matrix composite. Tool rotational speed is one of the vital FSP parameters which will influence the processing efficiency predominantly. In this investigation, five different tool rotational speeds of 800, 900, 1000, 1100 and 1200 rpm were used and their effect on tensile strength, microstructure, hardness and ductility of the friction stir processed material were evaluated. From this investigation it is found that the tool rotation speed of 1000 rpm yielded superior tensile strength compared to its counterparts. The formation of finer grains in the stir zone and uniform distribution of reinforcement particles are the main reasons for the superior tensile properties of this material.

Fabrication, microstructural characterization and finite element analysis of functionally graded Al-Al2O3 disk using powder metallurgy technique

In the present work, powder metallurgy technique was employed to fabricate a three-layer functionally graded (FG) disk. The volume fraction of metal-ceramic composition changes radially as layer-1 (100 % Al), layer-2 (95 %Al +5 % Al2O3), and layer-3 (90 %Al +10 % Al2O3). The microstructural investigation was carried out under an optical microscope and SEM (scanning electron microscopy) integrated with EDS, confirming a uniform distribution of reinforcement particles (alumina) in the matrix (aluminum). Interface microstructure indicates a successful fabrication of FGM (functionally graded material) as the transition is uniform in the graded layer without the development of any crack or void at the interface. In comparison to layer-1, the average increase in hardness values was found to be 18 % and 29 % for layer-2 and layer-3 respectively. An increment in hardness was observed in layers where alumina composition is higher. The Archimedes principle was employed to calculate the experimental density of the sample, and the theoretical models were presented to effectively estimate the density of porous FG materials. Furthermore, theoretical models for estimating material properties such as Young's modulus and yield strength of individual layers were proposed on the basis of material composition and particle shapes obtained from the microstructure of FG disk. These material properties were then used in finite element formulation for the application of rotating disk, the validation of which is also proposed. Subsequently, finite element analysis was employed to perform stress analysis on layered FG disk when subjected to centrifugal loading.

Investigation of Microstructural, Mechanical and Tribological Properties of Al8011-TiC Metal Matrix Nano-Composites

Aluminium alloys reinforced by nanoparticles are widely utilized in space vehicles, automotive components and industrial applications due to the unique characteristic of high stiffness to weight ratio. In this research, aluminium alloy 8011-TiC (Titanium Carbide) composites with a various weight percentage of reinforcement such as 5%, 7% and 9% wt.% were produced through stir casting technique. The contribution and uniform dispersion of TiC nano particles in Al 8011 was investigated through microstructural examination, mechanical and tribological behaviour. To sew up the uniform distribution of reinforcement particles over composite metal matrix alloy was investigated using Scanning and Optical Electron Microscope (OEM and SEM) depiction. The pattern of TiC content in the Al8011 alloy was observed through X-ray diffraction technique. Also, specimens are exposed to wear test as per ASTM G99 standard and the weight loss method is adopted. The result exhibits that tensile, yield strength properties and microhardness of nano-composites particles to about increases by 35%, 170% and 150% respectively. The mechanical properties and wear resistance of 7% TiC yields better results compared with Al 8011 alloy and other compositions of augmentations.

Assessment on morphological and mechanical properties of silicon nitride and goat dung ash reinforced Al-Fe-Si alloy hybrid composites

For the past few decades, global goat populations exceeds the world population growth especially in Africa and Asia. Because of this, the bio-waste has been increasing drastically. So, this research aims to utilize the excess goat dung as a reinforcement material for the production of a sustainable composite material with enhanced morphological and mechanical properties. The fabricated hybrid composites consist of Al8011alloy as a matrix material, Goat Dung Ash (GDA) and Silicon Nitride (Si3N4) as a reinforcement particles with various proportions from 0% to 10%. Microstructural analysis was performed to estimate the uniform distribution of reinforcement particles. The inclusion of GDA particles along with the Si3N4 particles increased tensile, flexural, and hardness strength with a minor reduction in impact strength (+21.8%, +7%, +62% and −5.5%) when compared with the unreinforced alloys. The transformation of ductile to brittle phase, clustering, crack propagations, necking, dimples, and cleavage facets were inspected in the fractured specimens. The incorporation of an optimal combination of Si3N4 and GDA reinforcement particles results in fine grain structure which restricts the dislocation moments during the action of external load and also prevents the propagation of slip. Similarly, the strong interfacial bonding and adhesion between the soft ductile Al8011 and the Si3N4/GDA reinforcement particles are attributed to the composites’ strengthening process. This research work proves that the use of bio-waste in the fabrication of composites has the potential benefit in enhancing the morphological and mechanical properties.

Study the effect of stirrer design on the stirring performance of ceramic particle reinforcements in stir casting of Aluminum Matrix Composites

Stir casting is one of the vital methods for making aluminium alloy matrix composites. The main challenge of this technique is getting a homogenous dispersion of reinforcement particles. The uniform distribution of reinforcement particles improves the mechanical properties, so the stirrer must be designed so that it achieves uniform distribution. The main process of stir casting is done in a closed crucible at high temperature with a hidden flow pattern under a variety of various influencing variables; therefore, numerical is more realistic than the analytical approach for forecasting problems. This paper aims to choose the most efficient stirrer design among four different stirrers to attain the best reinforcement particle distribution in the least time in a selected case. ANSYS CFX, the Image process, and visual experiments were conducted to select the optimal stirrer design. This study is unique in that it provides a new methodology for optimizing the stirrer design, and identifying simulation obstacles and future simulation scope for the mixing performance simulation programmers. Finally, any effort to improve mixing efficiency will very certainly result in lower total energy use, fossil fuel consumption, and CO2 emissions, which is the goal of the millennium.

Preparation of mullite/NbN composites through spark plasma sintering

The main objective of this article is to obtain reaction sintered mullite based ceramics through spark plasma sintering process. 5, 10 and 15 wt% NbN particles were mixed with kaolinite and alumina powders as mullite precursor through a wet milling process. The mullite ceramic and composites were fabricated by spark plasma sintering (SPS) method at 1350 °C with initial and final applied pressure of 10 and 50 MPa, respectively. All of prepared composites showed relative density higher than 99% of theoretical density as well as mullite ceramic. The XRD patterns obtained from sintered composites demonstrated dominant crystalline phase of mullite and NbN and also some low-intensity of alumina peaks were observed. The FESEM images of sintered composites illustrated uniform distribution of reinforcement particles for 5 and 10 wt% addition of NbN. While using 15 wt% NbN reinforcement phase lead to form some agglomerates areas. The optimum mechanical properties were obtained for composites containing 10 wt% NbN as bending strength of 441 ± 36 MPa, Vickers hardness of 17.89 ± 0.61 GPa and fracture toughness of 3.79 ± 0.12 MPa m1/2.

Comparative Study of Tensile Properties of Hybrid AA6061/SIC/Carbonized Coconut Shell Micro and Nano Composites

This study synthesized a hybrid aluminium 6061 matrix composite with particulates of silicon carbide, SiCp and carbonized coconut shell (CCSP as reinforcements), and determined the effect of combining SiCp and CCSp reinforcements of different sizes and weight fractions on the strength properties and microstructure of the developed composite. The hybrid aluminium matrix composites were developed using the stir casting method. Several samples of the composites consisting of AA6061 alloy with 3, 6, 9, 12 and 15% by wt. each of CCSp and SiCp with average particle sizes of 38μm and 42.3nm for SiC, and 63μm and 50.01nm for CCSp were produced and characterized for strength. The microstructures of the developed composite materials revealed uniform distribution of reinforcement particles in the base matrix and excellent bonding between the base matrix and reinforcements after casting. The results obtained showed that addition of CCSp and SiCp reinforcement to the alloy increased the tensile strength and hardness. Also, a mathematical model was proposed for predictive tensile strength of nano-composite and validated by comparison with results of the physical experiment and those of other authors. The proposed model is in excellent agreement with experimental data. The nano-particulates reinforced composite presented maximum improvement in ultimate tensile strength value (53.4% and 8.5% of that for the unreinforced matrix and micro-composite respectively) at reinforcement level of 15wt.% nSiC/nCCS.

Mechanical and wear behaviour of TiB2-B4C reinforced Al7075 alloy hybrid composites for aerospace applications

ABSTRACT Present study focuses on the production and characterization of stir cast Al7075-TiB2-B4C hybrid composite. Different weight % of second phase reinforcement has been added with 2, 4, 6, 8 % TiB2, and 4 % B4C. The morphology of the composites shows uniform distribution of reinforcement particles and improved microstructure. As the proportion of TiB2-B4C is increasing in the composite, the density, hardness, and strength have been enhanced. The Al7075-TiB2-B4C composite shows a higher hardness of 93 HRB and improved wear resistance. Moreover, the enhanced yield strength of 522 MPa and compressive strength of 379 MPa have been obtained. A dry sliding wear test was conducted at room temperature by pin-on-disc apparatus under 5 N and 10 N loads, with 400 m, 800 m, and 1200 m sliding distances. The wear resistance of TiB2-B4C composites is highly improved and worn surface damage is reduced. The hardness, tensile strength, and compressive strength of the Al7075-TiB2-B4C composite were enhanced by 17.5%, 15.2%, and 10.8% while compared to raw Al. Worn surface analysis, mechanism of wear, and microstructural changes were described by SEM analysis. On the outset, the incredible properties of Al7075-TiB2-B4C hybrid composites are the best replacement for upper wing applications.

Effect of spark plasma sintering on microstructure and mechanical properties of AA7075/B4C/ZrC hybrid nanocomposite fabricated by powder metallurgy techniques

In the present work, AA7075/B4C/ZrC hybrid nanocomposite has been fabricated by spark plasma sintering (SPS) process at a temperature of 500 °C with a heating rate of 50 °C/min for a period of 5 min. Microstructures and crystal phase structures have been investigated by scanning electron microscopy and X-ray diffraction techniques, respectively. It is observed from the results that the strong and clean interfaces along with uniform distribution of reinforcement particles are present in the SPS-synthesized composites, while the conventionally sintered composites possessed microporous structures. Mechanical properties of the SPS composite are found to be superior as compared to the conventional-sintered composites, where the high tensile and compression strengths of 605 and 712 MPa, respectively, are noted for SPS composite, while it is 502 and 598 MPa, respectively for the conventional-sintered composites. These observed enhanced properties could be attributed to the unique features of the SPS process, such as limited grain growth, clean interface bond formed via the breakage of oxide layers on particle surfaces due to spark discharges, and enhanced diffusion phenomenon that made the interfaces of the composite to be stronger.

Influence of ultrasonic agitation on the abrasive wear characteristics of Al-Cu/ 2 vol% Grp composite

In the present study, the abrasive wear behavior of Al–4.4 wt% Cu composite reinforced with 2 vol% graphite particle (Grp) has been investigated. In the preparation of composite, Ultrasonic Treatment (UT) is provided in the composite melt for the uniform distribution of reinforcement particles. Two bond abrasive wear tests are conducted for composites treated with ultrasound and without UT and base alloy. The results of abrasive wear studies indicate that at 5 and 10 Newton (N) loads, the composite with UT has a higher coefficient of friction (COF) and wear resistance than that of the base alloy (Al–4.4 wt% Cu). Whereas, at 15 and 20 N load, the value of COF and wear resistance is lower for the composite. Two abrasive wear mechanisms micro-plowing and micro-cutting have been observed during the wear tests of base alloy and composites. The analysis of worn-out sample surfaces at higher load reveals that softened material layer due to localized elevation in temperature between two contact surfaces during wearing acts as a tribolayer in base alloy while in composites both softened material layer and graphite layer have worked together as tribolayer.

Evaluation of mechanical properties of aluminium alloy (AA 6082) reinforced with Rice husk ash (RHA) and Boron carbide (B4C) hybrid metal matrix composites using stir casting method

Aluminum alloys are commonly employed in shipbuilding and automotive manufacturing units. The mechanical properties of alloys, such as strength and hardness, can be improved by adding reinforcement to the matrix material. Stir casting is an improved method for uniform dispersion of particles over conventional casting methods. Therefore, an effort is made to fabricate aluminium alloy (AA 6082) composites with different ratios of hybrid reinforcement of Rice Husk Ash (RHA) and Boron Carbide (B4C) reinforcements.The mechanical properties of composites such as tensile strength, hardness, flexural strength, and impact strength were evaluated. The microstructural properties of composites were evaluated using a scanning electron microscope to determine the dispersion of particles in the matrix material. It is found that tensile strength, hardness were improved by 20% as well as the uniform distribution of reinforcement particles in composites.

Fabrication and characterization of Al6063/SiC composites using electromagnetic stir casting process

In this work, metal matrix composites were fabricated using the electromagnetic stir casting process by adding 5 and 10 wt% silicon carbide in Al6063 alloy. Hardness, ultimate tensile strength, and yield strength of the developed Al6063/SiC/5p metal matrix composites have been improved by 17%, 18%, and 37%, respectively, in comparison with Al6063 alloy. Further, an improvement of 25%, 37%, and 71% in hardness, ultimate tensile strength, and yield strength, respectively, have been noted for Al6063/SiC/10p metal matrix composite in comparison with the Al6063 alloy. Results revealed that the hardness and strength of metal matrix composites were increased with silicon carbide addition in Al6063 alloy. The presence of different elements in metal matrix composites was identified by energy-dispersive X-ray spectroscopy and X-ray diffraction techniques. Energy-dispersive X-ray spectroscopy was used for elemental mapping observation of the metal matrix composites. Uniform distribution of reinforcement particles in the matrix with improved mechanical properties of metal matrix composites proved the adequacy of the electromagnetic stir casting process. The presence of facets and dimples in fractographs indicated the mixed mode of fracture. The average percentage porosity presented in Al6063/silicon carbide/5p and Al6063/SiC/10p metal matrix composites was found to be 4.68% and 5.22%, respectively.