Showing papers on "Metal matrix composite published in 2021"

Investigation on mechanical, tribological and microstructural properties of Al–Mg–Si–T6/SiC/muscovite-hybrid metal-matrix composites for high strength applications

Abstract: The wide range of aluminium variants (alloys and composites) has made it an important material for aviation, automotive components, auto-transmission locomotive section units, SCUBA tanks, ship, vessels, submarines fabrication and design etc regardless of the fact that the aluminium alloys were being utilized in myriads of sectors owing to its exceptional superior and versatile functional characteristics, the property such as wear-resistant ought to be enhanced in order to further prolong diverse spectrum of applications An aluminium alloy having lower hardness and tensile strength has been incorporated with silicon carbide that drastically strengthens the properties This study involves fabrication of aluminium silicon carbide with muscovite/hydrated aluminium potassium silicate/aluminosilicate in stir casting method to obtain a hybrid metal matrix composite Maintaining a constant amount of aluminium and silicon carbide, muscovite or hydrated aluminium potassium silicate is varied to obtain three distinctive compositions of (Al/SiC/muscovite) composites The mechanical characteristics like tensile-strength, flexural-strength, toughness, hardness, scratch adhesion, percent-porosity and density were studied The dispersion of muscovite and silicon carbide particles were observed by viewing the microstructure photographs obtained using optical microscopy and Scanning Electron Microscope (SEM) EDAX analysis affirms the presence of reinforcing constituents in Al–Mg–Si–T6 alloy matrix A drum type wear apparatus was utilized to evaluate the percentage of wear-loss in different compositions using different loads and it was found that the wear-loss decreases linearly as the muscovite percentage was increased

Optimization on Operation Parameters in Reinforced Metal Matrix of AA6066 Composite with HSS and Cu

Abstract: This optimization investigation focused on the reinforced metal matrix composite of aluminium alloy. Novel of this work is to fabricate the AA6066 composite with HSS and Cu, continually conduct machining tests, and evaluate the tool wear, surface roughness, and thrust force of the stir-casted specimens. The aluminium composite has 90 percentage of AA6066 alloy reinforcement with six percentage of high-speed steel and four percentage of copper alloy made by the casting method. The fabricated composites’ turning parameters were optimized through the Taguchi method. The turning operation can be done with the help of the normal lathe with the CBN insert tool. The operation parameters such as feed, depth of cut, and steam pressure of the cutting fluid were considered with three different equal intervals in each parameter. In this investigation, the L9 orthogonal array method is used to identify the optimum values of the turning parameters among the considered machining parameters concerning the response such as wear on the turning tool and thrust forces created on machining. The outcome based on the parameters was identified and mentioned as the rank order for individual and combination of all responses with different conditions. Then, the separate and combined optimized input parameters were provided as the conclusion.

Synthesis and Characterization of Silicon Nitride Reinforced Al–Mg–Zn Alloy Composites

Abstract: In this work, aluminium metal matrix composite reinforced with hard silicon nitride (Si3N4) particles have been performed experimentally. Squeeze casting technique was adopted to synthesis the novel AMMC for different weight fractions of Si3N4 (3, 6 and 9%). The AMMC is characterized for their tensile strength, micro-Vickers, density and porosity, compressive strength, impact, corrosion and wear resistance, as per ASTM standards. Observation shows that, with the inclusion of Si3N4 particle, the mechanical behaviour, corrosion and wear-resistant of synthesized composites was considerably improved. Scanning Electron microscope micrograph of worn surfaces displays the presence of grooves parallel to the sliding direction and some plastic deformations. The inclusion of Si3N4 shows deep grooving, that is associated with abrasive wear.

Laser cladding process of Fe/WC metal matrix composite coatings on low carbon steel using Yb: YAG disk laser

Abstract: The paper presents the studies of selected properties of Fe/WC metal matrix composite coatings produced using different laser beam power values and different powder feeding rates. Coatings were produced using the Yb: YAG disk laser by laser cladding method. Laser beam powers equal to 600 W, 700 W and 800 W were used. Scanning speed of laser beam was the same for all the coatings and was equal to 600 mm/min. Laser beam spot diameter was 1.64 mm. Two powder feeding rates (6.25 g/min and 12.50 g/min) were applied. In this study macroscopic observation, microstructure and microhardness examination as well as XRD and EDS analysis were carried out. Corrosion resistance was also investigated. In Fe/WC coating produced using slower powder feeding rate dendritic carbides that nucleated on the primary tungsten carbide particles were observed. In the coatings produced using an increased powder feeding rate, a changed type of secondary carbide was observed, which was bar-shaped or plate-shaped. The results of the XRD and EDS analysis of the composite Fe/WC coatings showed the presence of WC, W2C phases as well as M23C6 and (Fe,W)3C complex phases. The mechanism of formation and growth of composite coatings was described on the basis of microstructures obtained. The highest microhardness and corrosion resistance were observed for coatings produced at a powder feeding rate of 12.50 g/min.

Comparative Study of Microstructure, Physical and Mechanical Characterization of SiC/TiB2 Reinforced Aluminium Matrix Composite

Abstract: Aluminium matrix composites impact greatly in modern trends for huge applications in the aerospace and automotive industry due to its better strength to weight ratio and temperature resistance capacity. This work investigated the effect on SiC and TiB2 powder reinforced aluminium matrix composite fabricated by stir casting. Stir casting is a widely used liquid state method of a fabrication technique for preparing metal matrix composite with the help of mechanical stirring. Density, tensile strength, hardness, and fracture analysis were done to observe the development of ceramic particle reinforced aluminium matrix composite. SEM analysis revealed the uniform distribution of reinforcement particles throughout the aluminium matrix. Universal tensile strength and micro hardness of aluminium matrix composite enhanced from 140 MPa to 182 MPa and 66 HV to 81 HV respectively due to the addition of particle reinforcement. The microstructural investigation from the fractured surface of tensile samples indicated ductile nature appeared in Al7075, Al7075/SiC, and Al7075/TiB2 composites due to nucleation and micro-voids formation.

Optimization of powder metallurgy parameters of TiC- and B4C-reinforced aluminium composites by Taguchi method

Abstract: In this work, an aluminium-based metal matrix composite material was developed via powder metallurgy considering various input process parameters. Sintering time, sintering temperature, and compact...

Implications on the influence of mica on the mechanical properties of cast hybrid (Al+10%B4C+Mica) metal matrix composite

Abstract: Hybrid aluminum metal matrix composites have prominence than conventional metals. Aluminum is used as base metal in many metal matrix composites, as it is widely used in industries and researches. The low density that is obtained after alloying is the major advantages of hybrid composite. The present study involves synthesis of Al6061/B4C/Mica hybrid metal matrix composite using stir casting method by mica particles as 3, 4, 5, 6wt.%, while maintaining 10wt.% of boron carbide. The best mechanical properties are reported by inclusion of 3wt.% of mica, while further addition of mica more than 3wt.% pulls down the mechanical properties and hence not sensible. The early-stage of strain hardening, and high tensile strength-yield strength ratio is observed, which concludes the fabricated hybrid aluminum composite is well suitable for automotive-related sheet forming operations.

Influence of B4C and industrial waste fly ash reinforcement particles on the micro structural characteristics and mechanical behavior of aluminium (Al–Mg–Si-T6) hybrid metal matrix composite

Abstract: The expectations over composite materials have been increased especially in automotive and aerospace applications due to its high strength to weight ratio and good mechanical properties. Here, we aim to fabricate a hybrid composite of high strength and low density for automotive application to suits the above needs. In this investigation, the heat-treated aluminum alloy Al–Mg–Si-T6 was initially reinforced with industrial waste fly ash particles at five different weight fractions of 0%, 5%, 10%, 15% and 20%, respectively by stir casting process. The mechanical properties such as tensile strength, compression strength, hardness and density were tested, and microstructure of the composite was evaluated to explain the mechanical properties evolution. From the results, it was concluded that the composite with 10% fly ash shows enhanced at maximum the properties when compared to others. Then, the Al–Mg–Si-T6 – 5% fly ash was further reinforced with boron carbide particles by using three different fractions of 2.5%, 5% and 7.5%, respectively by stir casting process. The microstructural analysis, Scanning Electron Microscope analysis (SEM) and Energy Dispersive X-ray Spectroscopy analysis (EDS) were carried out for the casted samples to evaluate interfacial bonding, agglomeration, clustering and void formation in the hybrid composite samples. The casted samples were also tested for mechanical properties such as tensile strength, compression strength, hardness and density. It reveals that the optimal combination of 10% reinforcement (5% fly ash and 5% boron carbide) shows 18.7% higher tensile strength, 11.3% higher hardness and 38.6% higher compression when compared with the unreinforced Al–Mg–Si-T6 heat treated alloy. It is expected that the present hybrid metal matrix composites can be adopted for the fabrication of drive shaft in race cars.

Improvement of mechanical and wear behavior by the development of a new tool for the friction stir processing of Mg/B4C composite

Abstract: Large and irregular particle sizes of B4C in the Mg matrix are performance-impeding challenges of the as-cast Mg-B4C composites. In an attempt to overcome this, the secondary solid-state friction stir processing of the as-cast Mg-10%B4C composite with a flow-enhancing double-pin tool was carried out and the ensuing result was compared with that of a single-pin tool. The microstructure, hardness, tensile strength, wear, and the fractured surface of the processed composites were investigated and compared. The extra pin-shearing effect and the complex pin-induced interactive material flow of the double-pin tool induce better refinement of the B4C particles in the Mg-10%B4C composite. The use of a double-pin tool increases the stirred and recrystallized vortex/swirl width, kernel average misorientation (KAM) fraction, dislocation density, hardness value at the stirred center (117 HV), and tensile strength (194 MPa) of the Mg-10%B4C composite as compared to the single-pin tool. The double-pin tool changes the fracture path of the composite away from the stirred center owing to the improved material flow and properties of the stirred center. The tribological properties (weight loss, wear rate, and coefficient of friction) of the processed composites are equally improved by the double-pin tool. A double-pin tool is thus recommended for the improvement of material flow, particle-disintegration, mechanical and tribological properties of Mg-based metal matrix composite.

One-step fabrication of the wear-resistant superhydrophobic structure on SiCp/Al composite surface by WEDM

Abstract: Fabricating superhydrophobic structure on metal matrix can significantly improve its usability, such as anti-corrosion, self-cleaning, anti-icing, fluid drag reduction. However, the mechanical strength and wear resistance of the micro-nano structures on the common material (such as plastic/copper/aluminum/stainless steel) are not satisfactory. This paper aims to propose a high-efficiency and easy-operating method for fabricating wear-resistant superhydrophobic structure. Particle reinforced metal matrix composite (SiCp/Al) is chosen as workpiece material which has high specific strength, good wear resistance and low thermal expansion coefficient. A method of one-step fabricating multi-stage micro-nano structures for superhydrophobic structure on SiCp/Al composite surface using wire electrical discharge machining (WEDM) is presented. The primary structure and secondary structure are respectively semicircular groove texture and the surface microstructure from discharge machining. A set of cutting experiments are conducted to analyze the effect of the size of semicircular groove texture on the contact angle (CA) of workpiece surface. The multi-stage micro-nano structures on SiCp/Al composite surface is characterized by optical microscope, SEM, EDS. The experimental data shows that the maximum CA reaches 153.3° when the radius and center distance of semicircular groove texture are 400 μm and 700 μm, respectively. In addition, the superhydrophobic structure on SiCp/Al composite surface by WEDM exhibits excellent wear resistance. Eventually, the theoretical model of CA and the design criterion of semicircular groove texture for superhydrophobic structure are established. Specifically, the superhydrophobic structure can be obtained if the fraction of the solid-liquid area of the total projected surface area is lower than 0.084.

Effect of Solidification Time on Microstructure, Wettability, and Corrosion Properties of A205-T7 Aluminum Alloys

Abstract: In the present study, the grain size, second-phase morphology, hardness, water wetting behavior, and corrosion resistance of A205, as a function of solidification time, were investigated. A205 is aluminum–copper alloy that is described in the AA Pink Sheets as “Primarily used for making metal matrix composites” (AA Registration Record Pink Sheets, ISSN: 2377-6722, Footnote 13, Aluminum Association, 2018) and as defined by AMS as a “dilute aluminum/TiB2 metal matrix composite” (AMS D Nonferrous Alloys Committee in Cast aluminum alloy composite 4.6Cu–3.4Ti–1.4B–0.75Ag–0.27Mg (205.0/TiB2/3p-T7P) investment cast, solution, and precipitation heat treated, SAE International, 2014). To study the effect of solidification time, a step sand casting, with varying section thickness, was made and subjected to a modified T7 heat treatment. Optical microscopy, scanning electron microscopy, energy-dispersive X-ray spectroscopy, and X-ray diffraction analysis were utilized to study microstructure, morphology, elemental composition, and phases in the A205 samples, respectively. Potentiodynamic polarization experiment was used to measure the corrosion resistance of the A205 samples. The casting process was also simulated by use of a commercial software. Conclusions drawn from the simulation process show that larger thickness allows for higher solidification time and greater microporosity. It was observed that solidification time has a direct impact on grain size. The phase identification result shows that the two main phases of the alloys are Al and TiB2, while a modified heat treatment cycle makes a complete solution of copper in the grains. Wetting study shows that surface chemistry is not a controlling factor on contact angles, while corrosion result shows a relationship between solidification time and corrosion resistance of the A205 samples. It was observed that there is almost 70% decrease in corrosion rate from the sample with the least section thickness to the sample with the largest section thickness.

A comparative study of tungsten carbide and carbon nanotubes reinforced Inconel 625 composite coatings fabricated by laser cladding

Abstract: Laser cladding with wire presents clear advantages in economic efficiency and cleanliness over the powder-based system. To find the best coating performance, the Inconel 625 composite coating, and two typical metal matrix composite (MMC) coatings reinforced respectively by tungsten carbide (WC) and carbon nanotubes (CNTs) were fabricated by an off-axis wire cladding system. The differences of morphology, microstructure and mechanical properties among the three samples were investigated. The results showed that the morphology of clad coatings with reinforcement powder generally presented desirable geometric characteristics. The clad coating with WC powder, in particular, presented better wettability compared with the other samples. The main secondary compound of WC dissolution was W2C, which was mainly distributed at grain boundaries. The mechanical properties of powder reinforced MMC coatings were significantly improved. Compared with the Inconel 625 specimen in coating area, the yield strength of the two MMC coatings was improved by 36.3% and 23.4% respectively. In addition, the average microhardness of WC/Inconel 625 coating showed an obvious increase to 589 HV.

Effect of TiB2 Particles on the Morphological, Mechanical and Corrosion Behaviour of Al7075 Metal Matrix Composite Produced Using Stir Casting Process

Abstract: Aluminium metal matrix composites are lightweight high-performance materials mostly applicable in aerospace, automobile and marine applications. In this study, the morphological, mechanical and corrosion behaviour of Al7075 metal matrix composites were investigated to find the effect of reinforcement of TiB2 particles for various weight percentage. Al7075-TiB2 composites were developed by reinforcing the 3–5 µm size TiB2 ceramic particles using stir casting process. The particles with different weight percentage of 2, 4, 6 and 8 were uniformly reinforced with the help of the mechanical stirrer. The energy dispersive X-ray diffraction (EDAX) pattern confirms the presence of TiB2 particles in the composites. SEM and optical microstructures clearly revealed the uniform distribution of TiB2 particles in the aluminium matrix. The additions of TiB2 particles enhance the tensile strength and micro hardness due to the strong interface and load sharing between the matrix and the reinforcement particles. Dry sliding wear test was conducted by varying the applied load and sliding distance. SEM microstructure of worn surfaces shows that addition of TiB2 particles decreases the wear rate due to the presence of stiffer and stronger reinforcement particles. The electrochemical potentiodynamic polarization and salt spray test were also conducted to study the corrosion behaviour of the Al-TiB2 composites. SEM microstructures confirm the occurrence of pitting corrosion and shows that addition of TiB2 particles improves the corrosion resistance.

Processing and preparation of aerospace-grade aluminium hybrid metal matrix composite in a modified stir casting furnace integrated with mechanical supersonic vibration squeeze infiltration method

Abstract: Composite materials are versatile, economical, and alternatives for aerospace applications due to their light in weight and high strength. The extensive range of reinforcements available and advanced material processing technique ensured special attention to composite material development’s in large-scale production at low cost. In the present study, a modified bottom pouring, stir casting furnace integrated with mechanical supersonic vibration squeeze infiltration method was used to develop the aluminium alloy 7075 base cast and hybrid composite. Silicon carbide and graphite reinforcement percentages varied, and their effect on the matrix was evaluated through material characterization, mechanical testing, wear, and corrosion analysis. Distribution of reinforcement particles and their presence in the composite were examined by optical microscopy, scanning electron microscopy, energy dispersive spectroscopy with elemental mapping and X-ray diffraction.Due to high squeeze pressure, 75–80 % ultra-fine grains were present in the cast specimen. Maximum and minimum hardness values were observed in CM4 (167.98 BHN and 168.35 VHN) and CM1 (132.97 BHN and 146.1 VHN) specimens, respectively. Impact strength of developed hybrid composites (CM2, CM3, CM4) decrease with 12 % than the base cast specimen CM1.

Fabrication, Mechanical and Wear Characterization of Silicon Carbide Reinforced Aluminium 7075 Metal Matrix Composite

Abstract: Al7075-SiC composites containing three different weight percentages, 5 %, 10 %, and 15 % of SiC, have been fabricated by powder metallurgy Mechanical and tribological characteristics of Al7075-SiC composites have been investigated under dry sliding conditions The microstructural characterization confirms the even dispersion of SiC particles and good interfacial bonding between the reinforcement – matrix Improved mechanical characteristics are noticed for 15 %SiC composite compared to both 5 & 10 %SiC composites Dry sliding wear examinations have been carried out using pin-on-disc equipment Wear loss and coefficient of friction of samples were measured, and the variation of cumulative wear loss with load is linear for all the composites The wear mechanism appears to be oxidative for all specimens under the given conditions of load and sliding distance as indicated by the optical microscopic worn out surfces Further, the experimentation that the wear loss and coefficient of friction decrease linearly with increase increasing weight % of silicon carbide Response surface methodology confirms that wt% SiC is positively influencing both wear loss and coefficient of friction The best mechanical and tribological properties have been exhibited by the composite reinforced with 15 % SiC

Recent progress in graphene-reinforced aluminum matrix composites

Abstract: Recent years witnessed a growing research interest in graphene-reinforced aluminum matrix composites (GRAMCs). Compared with conventional reinforcements of aluminum matrix composites (AMCs), graphene possesses many attractive characteristics such as extremely high strength and modulus, unique self-lubricating property, high thermal conductivity (TC) and electrical conductivity (EC), and low coefficient of thermal expansion (CTE). A lot of studies have demonstrated that the incorporation of graphene into Al or Al alloy can effectively enhance mechanical and physical properties of the Al matrix. The purpose of this work is aimed to trace recent development of GRAMCs. Initially, this paper covers a brief overview of fabrication methods of GRAMCs. Then, mechanical, tribological, thermal and electrical properties of recently developed GRAMCs are presented and discussed. Finally, challenges and corresponding solutions related to GRAMCs are reviewed.

Synthesis, physico-mechanical and microstructural characterization of Al6063/SiC/PKSA hybrid reinforced composites.

Abstract: The utilization of agro-residues ash as complementary reinforcing materials continues to gain prominence for metal matrix composite (MMCs) development. A rarely investigated but largely available ash among these agro-residues is the palm kernel shell ash (PKSA). Thus, the present study investigates the influence of PKSA particulates hybridized with SiC on the physico-mechanical properties and microstructure of Al6063 metal composites. The composites are synthesized using the double stir-casting technique with SiC held constant at 2 wt.%, while the PKSA contents are varied from 0 to 8 wt.%. The phases present and morphology of the composites are investigated using X-ray diffractometer (XRD) and scanning electron microscopy (SEM), respectively. The density, porosity, hardness, tensile and fracture toughness tests are carried out on the hybrid composites. X-ray diffractometer revealed that for Al 6063, only Al cubic crystal system was identifiable within the matrix. However, for the reinforced composites, major phases identified are Al, Fe3Si, SiC, MgO, and SiO2. The SEM images show that the particulates reinforcements (SiC and PKSA) were uniformly dispersed in the matrix. The percentage porosity for the composites ranged from 2.06 to 2.39%. In addition, hardness, yield strength and ultimate tensile strength of the composites are about 10.3%, 18.5% and 10.4%, respectively better than for Al 6063. However, the percent elongation and fracture toughness are lower for the hybrid composites than for Al 6063 and SiC reinforced composite with values decreasing with increase in ash content. Hence, the MMCs produced will be applicable for light-weight engineering applications.

Mechanical and Tribological Properties of Co-Electrodeposited Particulate-Reinforced Metal Matrix Composites: A Critical Review with Interfacial Aspects

Abstract: Particulate-reinforced metal matrix composites (PRMMCs) with excellent tribo-mechanical properties are important engineering materials and have attracted constant scientific interest over the years. Among the various fabrication methods used, co-electrodeposition (CED) is valued due to its efficiency, accuracy, and affordability. However, the way this easy-to-perform process is carried out is inconsistent, with researchers using different methods for volume fraction measurement and tribo-mechanical testing, as well as failing to carry out proper interface characterization. The main contribution of this work lies in its determination of the gaps in the tribo-mechanical research of CED PRMMCs. For mechanical properties, hardness is described with respect to measurement methods, models, and experiments concerning CED PRMMCs. The tribology of such composites is described, taking into account the reinforcement volume fraction, size, and composite fabrication route (direct/pulsed current). Interfacial aspects are discussed using experimental direct strength measurements. Each part includes a critical overview, and future prospects are anticipated. This review paper provides an overview of the tribo-mechanical parameters of Ni-based co-electrodeposited particulate-reinforced metal matrix composite coatings with an interfacial viewpoint and a focus on hardness, wear, and friction behavior.

Parameters of Porosity and Compressive Strength-Based Optimization on Reinforced Aluminium from the Recycled Waste Automobile Frames

Abstract: Automobile industries were ready to recycle the waste old parts as well as the damaged parts of the old vehicles as much as possible. This study mainly focused on the recycling of the waste and damaged aluminium frames of the automobile bodies. These aluminium-based frames only collected the metal matrix composite created by reinforcement of 3% silicon carbide (SiC) and 3% high carbon steel. The stir casting method is chosen to make the composites. Optimization is done by Taguchi ANOVA technique. Three input parameters such as stir speed, time of squeeze, and the temperature of the preheating were considered. The outputs such as compressive strength and porosity were experimentally measured with the combination of nine (L9) experimental trails. The measured experimental results were analyzed and optimized with the help of Taguchi technique with different plots for clear identification. The optimized parameters based on low porosity and high compressive strength were recommended for conclusion.