Search results for: lighting material processing of aluminum metal matrix composites

Authors: Ruitao Li, Zhili Dong, Nay Win Khun, Khiam Aik Khor

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In this study, microstructure and sintering mechanism as well as wear resistance properties of Ti/Al-Cr-Fe metal matrix composites (MMCs) fabricated by spark plasma sintering (SPS) with Ti as matrix and Al-Cr-Fe as reinforcement were investigated. Phases and microstructure of the sintered samples were analyzed using X-ray diffractometry (XRD), scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS) and transmission electron microscopy (TEM). Wear resistance properties were tested by ball-on-disk method. An Al3Ti ring forms around each Al-Cr-Fe particle as the bonding layer between Ti and Al-Cr-Fe particles. The Al content in Al-Cr-Fe particles experiences a decrease from 70 at.% to 60 at.% in the sintering process. And these particles consist of quasicrystalline icosahedral AlCrFe and quasicrystal approximants γ-brass Al8(Cr,Fe)5 and Al9(Cr,Fe)4 in the sintered compact. The addition of Al-Cr-Fe particles into the Ti matrix can improve the microhardness by about 40% and the wear resistance is improved by more than 50% due to the increase in the microhardness and the change of wear mechanism.

Keywords: metal matrix composites, spark plasma sintering, phase transformation, wear

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Authors: Ahmet Yonetken, Ayhan Erol

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Aluminum matrix composites containing 3, 6, 9, 12 and 15% BN has been fabricated by conventional microwave sintering at 550°C temperature. Compounds formation between Al and BN powders is observed after sintering under Ar shroud. XRD, SEM (Scanning Electron Microscope), mechanical testing and measurements were employed to characterize the properties of Al + BN composite. Experimental results suggest that the best properties as hardness 42,62 HV were obtained for Al+12% BN composite. In this study, the powder metallurgy method was used. It is aimed to produce a light composite with Al matrix BN powders. It has been increased in strength and hardness besides its lightness. Ceramic powders are added to improve mechanical properties.

Keywords: ceramic-metal composites, proporties, powder metallurgy, sintering

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Authors: Muhammad Shahid, Muhammad Mansoor

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Increasing demands of contemporary applications for high strength and lightweight materials prompted the development of metal-matrix composites (MMCs). After the discovery of carbon nanotubes (CNTs) in 1991 (revealing an excellent set of mechanical properties) became one of the most promising strengthening materials for MMC applications. Additionally, the relatively low density of the nanotubes imparted high specific strengths, making them perfect strengthening material to reinforce MMCs. In the present study, aluminum-multiwalled carbon nanotubes (Al-MWCNTs) composite was prepared in an air induction furnace. The dispersion of the nanotubes in molten aluminum was assisted by inherent string action of induction heating at 790°C. During the fabrication process, multifunctional fluxes were used to avoid oxidation of the nanotubes and molten aluminum. Subsequently, the melt was cast in to a copper mold and cold rolled to 0.5 mm thickness. During metallographic examination using a scanning electron microscope, it was observed that the nanotubes were effectively dispersed in the matrix. The mechanical properties of the composite were significantly increased as compared to pure aluminum specimen i.e. the yield strength from 65 to 115 MPa, the tensile strength from 82 to 125 MPa and hardness from 27 to 30 HV for pure aluminum and Al-CNTs composite, respectively. To recognize the associated strengthening mechanisms in the nanocomposites, three foremost strengthening models i.e. shear lag model, Orowan looping and Hall-Petch have been critically analyzed; experimental data were found to be closely satisfying the shear lag model.

Keywords: carbon nanotubes, induction melting, strengthening mechanism, nanocomposite

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Authors: Mohamed M. Emara, Heba Ashraf

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This study is to investigation the effect of silicon carbide (SiC) particle size and thermo-mechanical processing on dimensional stability of aluminum alloy 2124. Three combinations of SiC weight fractions are investigated, 2.5, 5, and 10 wt. % with different SiC particle sizes (25 μm, 5 μm, and 100nm) were produced using mechanical ball mill. The standard testing samples were fabricated using powder metallurgy technique. Both samples, prior and after extrusion, were heated from room temperature up to 400ºC in a dilatometer at different heating rates, that is, 10, 20, and 40ºC/min. The analysis showed that for all materials, there was an increase in length change as temperature increased and the temperature sensitivity of aluminum alloy decreased in the presence of both micro and nano-sized silicon carbide. For all conditions, nanocomposites showed better dimensional stability compared to conventional Al 2124/SiC composites. The after extrusion samples showed better thermal stability and less temperature sensitivity for the aluminum alloy for both micro and nano-sized silicon carbide.

Keywords: aluminum 2124 metal matrix composite, SiC nano-sized reinforcements, powder metallurgy, extrusion mechanical ball mill, dimensional stability

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Authors: Essam Shalaby, Alexander Churyumov, Malak Abou El-Khair, Atef Daoud

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A comparative study of the thermal and mechanical behavior of squeezed A359 composites containing 5, 10 and 15 wt.% SiC, (SiC+ Si3N4) and AlN particulates was investigated. Stir followed by squeeze casting techniques are used to produce A359 composites. It was noticed that, A359/AlN composites have high thermal conductivity as compared to A359 alloy and even to A359/SiC or A359/(SiC+Si3N4) composites. Microstructures of the composites have shown homogeneous and even distribution of reinforcements within the matrix. Interfacial reactions between particles and matrix were investigated using X-ray diffraction and energy dispersive X-ray analysis. The presence of particles led not only to increase peak hardness of the composites but also to accelerate the aging kinetics. As compared with A359 matrix alloy, compression test of the composites has exhibited a significant increase in the yield and the ultimate compressive strengths with a relative reduction in the failure strain. Those light weight composites have a high potential to be used for automotive and aerospace applications.

Keywords: metal-matrix composite, squeeze, microstructure, thermal conductivity, compressive properties

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Authors: Magdalena Suśniak, Joanna Karwan-Baczewska

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Microstructure and tribological properties of AlSi5Cu2 matrix composite reinforced with SiC have been studied by microscopic examination and basic tribological properties. Composite material was produced by the mechanical alloying and spark plasma sintering (SPS) technique. The mixture of AlSi5Cu2 chips with 0, 10, 15 wt. % of SiC powder were placed in 250 ml mixing jar and milled 40 hours. To prevent the extreme cold welding the 1 wt. % of stearic acid was added to the powder mixture as a process control agent. Mechanical alloying provide to obtain composites powder with uniform distribution of SiC in matrix. Composite powders were poured into a graphite and a pulsed electric current was passed through powder under vacuum to consolidate material. Processing conditions were: sintering temperature 450°C, uniaxial pressure 32MPa, time of sintering 5 minutes. After SPS process composite samples indicate higher hardness values, lower weight loss, and lower coefficient of friction as compared with the unreinforced alloy. Light microscope micrograph of the worn surfaces and wear debris revealed that in the unreinforced alloy the prominent wear mechanism was the adhesive wear. In the AlSi5Cu2/SiC composites, by increasing of SiC the wear mechanism changed from adhesive and micro-cutting to abrasive and delamination for composite with 20 SiC wt. %. In all the AlSi5Cu2/SiC composites, abrasive wear was the main wear mechanism.

Keywords: aluminum matrix composite, mechanical alloying, spark plasma sintering, AlSi5Cu2/SiC composite

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Authors: Kevlin Govender, Anthony Walker, Glen Bright

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Mass customization is an area of increased importance and the development of rapid tooling applications is pivotal to the success of mass customization. This paper presents a laminated object manufacturing (LOM) process for rapid tooling. The process is termed 3D metal laminate printing and utilizes domestic-grade aluminum foil and epoxy for layered manufacturing. A detailed explanation of the process is presented to produce complex metal laminated composite parts. Aluminum-epoxy composite specimens were manufactured from 0.016mm aluminum and subjected to tensile tests to determine the mechanical properties of the manufactured composite in relation to solid metal specimens. The fracture zone of the specimens was analyzed under scanning electron microscopy (SEM) in order to characterize the fracture mode and study the interfacial bonding of the manufactured laminate specimens.

Keywords: 3D metal laminate printer, aluminum-epoxy composite, laminated object manufacturing, rapid tooling

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Authors: Palanisamy Samyraj, Sriram Yogesh, Kishore Kumar, Vaishak Cibi

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The project is about design and analysis of crankshaft using Al-Al2O3 composite material. The project is mainly concentrated across two areas one is to design and analyze the composite material, and the other is to work on the practical model. Growing competition and the growing concern for the environment has forced the automobile manufactures to meet conflicting demands such as increased power and performance, lower fuel consumption, lower pollution emission and decrease noise and vibration. Metal matrix composites offer good properties for a number of automotive components. The work reports on studies on Al-Al2O3 as the possible alternative material for a crank shaft. These material have been considered for use in various components in engines due to the high amount of strength to weight ratio. These materials are significantly taken into account for their light weight, high strength, high specific modulus, low co-efficient of thermal expansion, good air resistance properties. In addition high specific stiffness, superior high temperature, mechanical properties and oxidation resistance of Al2O3 have developed some advanced materials that are Al-Al2O3 composites. Crankshafts are used in automobile industries. Crankshaft is connected to the connecting rod for the movement of the piston which is subjected to high stresses which cause the wear of the crankshaft. Hence using composite material in crankshaft gives good fuel efficiency, low manufacturing cost, less weight.

Keywords: metal matrix composites, Al-Al2O3, high specific modulus, strength to weight ratio

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Authors: Mohamed Haneef, Shanawaz Patil, Syed Zameer, Mohammed Mohsin Ali

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The emerging technologies and trends of present generation requires downsizing the unwieldy structures to light weight structures on one hand and integration of varied properties on other hand to meet the application demands. In the present investigation an attempt is made to familiarize and best possibilities of reinforcing agent in aluminum 7075 matrix with naturally occurring beryl (Be) and graphene (Gr) to develop a new hybrid composite material. A stir casting process was used to fabricate with fixed volume fraction of 6wt% weight beryl and various volume fractions of 0.5wt%, 1wt%, 1.5wt% and 2wt% of graphene. The properties such as tensile strength, hardness and dry sliding wear behavior of hybrid composites were examined. The crystallite size and morphology of the graphene and beryl particles were analyzed with X-ray diffraction (XRD) and scanning electron microscopy (SEM) respectively. It was observed that ultimate tensile strength and hardness of the hybrid composite increased with increasing reinforcement volume fraction as compared to specimen without reinforcement additions. The dry sliding wear behavior of the hybrid composites decreases as compared to Al7075 alloy without reinforcement.

Keywords: Al7075, beryl, graphene, TEM, wear

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Authors: Elżbieta Cygan, Bączek, Piotr Wyżga

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This paper presents the results of research on the physical, mechanical, and tribological properties of materials constituting the matrix in sintered metallic-diamond tools. The ground powders based on the Fe-Mn-Cu-Sn-C system were modified with micro-sized particles of the ceramic phase: SiC, Al₂O₃ and consolidated using the SPS (spark plasma sintering) method to a relative density of over 98% at 850-950°C, at a pressure of 35 MPa and time 10 min. After sintering, an analysis of the microstructure was conducted using scanning electron microscopy. The resulting materials were tested for the apparent density determined by Archimedes’ method, Rockwell hardness (scale B), Young’s modulus, as well as for technological properties. The performance results of obtained diamond composites were compared with the base material (Fe–Mn–Cu–Sn–C) and the commercial alloy Co-20% WC. The hardness of composites has achieved the maximum at a temperature of 900°C; therefore, it should be considered that at this temperature it was obtained optimal physical and mechanical properties of the subjects' composites were. Research on tribological properties showed that the composites modified with micro-sized particles of the ceramic phase are characterized by more than twice higher wear resistance in comparison with base materials and the commercial alloy Co-20% WC. Composites containing Al₂O₃ phase particles in the matrix material were composites containing Al₂O₃ phase particles in the matrix material were characterized by the lowest abrasion wear resistance. The manufacturing technology presented in the paper is economically justified and can be successfully used in the production process of the matrix in sintered diamond-impregnated tools used for the machining of an industrial floor system. Acknowledgment: The study was performed under LIDER IX Research Project No. LIDER/22/0085/L-9/17/NCBR/2018 entitled “Innovative metal-diamond tools without the addition of critical raw materials for applications in the process of grinding industrial floor systems” funded by the National Centre for Research and Development of Poland, Warsaw.

Keywords: abrasive wear resistance, metal matrix composites, sintered diamond tools, Spark Plasma Sintering

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Authors: Rachit Marwaha, Rahul Dev Gupta, Vivek Jain, Krishan Kant Sharma

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Metal matrix hybrid composites (MMHCs) are now gaining their usage in aerospace, automotive and other industries because of their inherent properties like high strength to weight ratio, hardness and wear resistance, good creep behaviour, light weight, design flexibility and low wear rate etc. Al alloy base matrix reinforced with silicon carbide (10%) and graphite (5%) particles was fabricated by stir casting process. The wear and frictional properties of metal matrix hybrid composites were studied by performing dry sliding wear test using pin on disc wear test apparatus. Experiments were conducted based on the plan of experiments generated through Taguchi’s technique. A L9 Orthogonal array was selected for analysis of data. Investigation to find the influence of applied load, sliding speed and track diameter on wear rate as well as coefficient of friction during wearing process was carried out using ANOVA. Objective of the model was chosen as smaller the better characteristics to analyse the dry sliding wear resistance. Results show that track diameter has highest influence followed by load and sliding speed.

Keywords: Taguchi method, orthogonal array, ANOVA, metal matrix hybrid composites

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Authors: Khurram Munir, Cuie Wen, Yuncang Li

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Magnesium (Mg) metal matrix composites (MMCs) reinforced with graphene nanoplatelets (GNPs) have been developed by powder metallurgy (PM). In this study, GNPs with different concentrations (0.1-0.3 wt.%) were dispersed into Mg powders by high-energy ball-milling processes. The microstructure and resultant mechanical properties of the fabricated nanocomposites were characterized using transmission electron microscopy (TEM), scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDX), X-ray diffraction (XRD), Raman spectroscopy (RS), compression and nano-wear tests. The corrosion resistance of the fabricated composites was evaluated by electrochemical tests and hydrogen evolution measurements. Finally, the biological response of Mg-GNPs composites was assessed using osteoblast-like SaOS2 cells. The results indicate that GNPs are excellent candidates as reinforcements in Mg matrices for the manufacture of biodegradable Mg-based composite implants. GNP addition improved the mechanical properties of Mg via synergetic strengthening modes. Moreover, retaining the structural integrity of GNPs during PM processing improved the ductility, compressive strength, and corrosion resistance of the Mg-GNP composites as compared to monolithic Mg. Cytotoxicity assessments did not reveal any significant toxicity with the addition of GNPs to Mg matrices. This study demonstrates that Mg-xGNPs with x < 0.3 wt.%, may constitute novel biodegradable implant materials for load-bearing applications.

Keywords: magnesium-graphene composites, strengthening mechanisms, In vitro cytotoxicity, biocorrosion

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Authors: P. G. F. Siqueira, N. G. S. Almeida, P. M. A. Stemler, P. R. Cetlin, M. T. P. Aguilar

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The processing of metals through Equal Channel Angular Pressing (ECAP) leads to their remarkable strengthening. The ECAP dies control the amount of strain imposed on the material through its geometry, especially through the angle between the die channels, and thus the microstructural and mechanical properties evolution of the material. The present study describes the design of an ECAP die whose utilization and maintenance are facilitated, and that also controls the eventual undesired flow of the material during processing. The proposed design was validated through numerical simulations procedures using commercial software. The die was manufactured according to the present design and tested. Tests using aluminum alloys also indicated to be suitable for the processing of higher strength alloys.

Keywords: ECAP, mechanical design, numerical methods, SPD

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Authors: Yaseri Dahlia Apritasari

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Visual comfort is important for the building occupants to need. Visual comfort can be fulfilled through natural lighting (daylighting) and artificial lighting. One strategy to optimize natural lighting can be achieved through the facade second skin design. This strategy can reduce glare, and fulfill visual comfort need. However, the design strategy cannot achieve light intensity for visual comfort. Because the materials, design and opening percentage of the facade of second skin blocked sunlight. This paper discusses aluminum material for the facade second skin design that can fulfill the optimal visual comfort with the case studies Multi Media Tower building. The methodology of the research is combination quantitative and qualitative through field study observed, lighting measurement and visual comfort questionnaire. Then it used too simulation modeling (DIALUX 4.13, 2016) for three facades second skin design model. Through following steps; (1) Measuring visual comfort factor: light intensity indoor and outdoor; (2) Taking visual comfort data from building occupants; (3) Making models with different facade second skin design; (3) Simulating and analyzing the light intensity value for each models that meet occupants visual comfort standard: 350 lux (Indonesia National Standard, 2010). The result shows that optimization of aluminum material for the facade second skin design can meet optimal visual comfort for building occupants. The result can give recommendation aluminum opening percentage of the facade second skin can meet optimal visual comfort for building occupants.

Keywords: aluminium material, Facade, second skin, visual comfort

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Authors: Sai Harshini Irigineni, Suresh Kumar Reddy Narala

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The industrial applicability of aluminium metal matrix composites (AMMCs) has been rapidly growing due to their exceptional materials traits such as low weight, high strength, excellent thermal performance, and corrosion resistance. The increasing demand for AMMCs in automobile, aviation, aerospace and defence ventures has opened up windows of opportunity for the development of processing methods that facilitate low-cost production of AMMCs with superior properties. In the present work, owing to its economy, efficiency, and suitability, powder metallurgy (P/M) technique was employed to develop AMMCs with pure aluminium as matrix material and titanium diboride (TiB₂) as reinforcement. AMMC samples with different weight compositions (Al-0.1%TiB₂, Al-5%TiB₂, Al-10%TiB₂, and Al-15% TiB₂) were prepared through hot press compacting followed by traditional sintering. The developed AMMC was subjected to metallographic studies and mechanical characterization. Experimental evidences show significant improvement in mechanical properties such as tensile strength, hardness with increasing reinforcement content. The current study demonstrates the superiority of AMMCs over conventional metals and alloys and the results obtained may be of immense in material selection for different structural applications.

Keywords: AMMCs, mechanical characterization, powder metallurgy, TiB₂

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Authors: I Made Gatot Karohika, Shigeyuki Haruyama, Ken Kaminishi

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In this study, we proposed a three-layer metal gasket with Al, Cu, and SUS304 as the material, respectively. A finite element method was employed to develop simulation solution and design of experiment (DOE). Taguchi method was used to analysis the effect of each parameter design and predicts optimal design of new 25A-size three layer corrugated metal gasket. The L18 orthogonal array of Taguchi method was applied to design experiment matrix for eight factors with three levels. Based on elastic mode and plastic mode, optimum design gasket is gasket with core metal SUS304, surface layer aluminum, p1 = 4.5 mm, p2 = 4.5 mm, p3 = 4 mm, Tg = 1.2 mm, R = 3.5 mm, h = 0.4 mm and Ts = 0.3 mm.

Keywords: contact width, contact stress, layer, metal gasket, corrugated, simulation

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Authors: Dalila Hammiche, Lisa Klaai, Amar Boukerrou

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Following this trend, natural fiber reinforcements have been gaining importance in the composites sector. The effectiveness of natural fiber–reinforced PLA composite as an alternative material to substitute the non-renewable petroleum-based materials has been examined by researchers. In this study, we investigated the physicochemical, particle size and distribution, and thermal behavior of prickly pear seed flour (PPSF). Then, composites were manufactured with 20% in PPSF. Thermal, morphological, and mechanical properties have been studied, and water absorption tests as well. The characterization of this fiber has shown that cellulose is the majority constituent (30%), followed by hemicellulose (27%). To improve the fiber-matrix adhesion, the PPS was chemically treated with alkali treatment. The addition of PPSF decreases the thermal properties, and the study of the mechanical properties showed that the increase in the fiber content from 0 to 20% increased Young’s modulus. According to the results, the mechanical and thermal behaviors of composites are improved after fiber treatment. However, there is an increase in water absorption of composites compared to the PLA matrix. The moisture sensitivity of natural fiber composites limits their use in structural applications. Degradation of the fiber-matrix interface is likely to occur when the material is subjected to variable moisture conditions.

Keywords: biopolymer, composites, alcali treatment, mechanical properties

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Authors: G. Purushotham, Joel Hemanth

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An investigation has been carried out to fabricate and evaluate the strength and soundness of chilled composites consisting of nickel matrix and fused silica particles (size 40–150 μm) in the matrix. The dispersoid added ranged from 3 to 12 wt. % in steps of 3%. The resulting composites cast in moulds containing metallic and non-metallic chill blocks (MS, SiC, and Cu) were tested for their microstructure and mechanical properties. The main objective of the present research is to obtain fine grain Ni/SiO2 chilled sound composite having very good mechanical properties. Results of the investigation reveal the following: (1) Strength of the composite developed is highly dependent on the location of the casting from where the test specimens are taken and also on the dispersoid content of the composite. (2) Chill thickness and chill material, however, does significantly affect the strength and soundness of the composite. (3) Soundness of the composite developed is highly dependent on the chilling rate as well as the dispersoid content. An introduction of chilling and increase in the dispersoid content of the material both result in an increase in the ultimate tensile strength (UTS) of the material. The temperature gradient developed during solidification and volumetric heat capacity (VHC) of the chill used is the important parameters controlling the soundness of the composite. (4) Thermal properties of the end chills are used to determine the magnitude of the temperature gradient developed along the length of the casting solidifying under the influence of chills.

Keywords: metal matrix composite, mechanical properties, corrosion behavior, nickel alloy, fused silica, chills

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Authors: Tahir Ahmad, Abubaker Khan, Muhammad Kamran, Muhammad Umer Manzoor, Muhammad Taqi Zahid Butt

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Metal Matrix Composites (MMC) is a class of weight efficient structural materials that are becoming popular in engineering applications especially in electronic, aerospace, aircraft, packaging and various other industries. This study focuses on the development of carbon fiber reinforced copper matrix composite. Keeping in view the vast applications of metal matrix composites,this specific material is produced for its unique mechanical and thermal properties i.e. high thermal conductivity and low coefficient of thermal expansion at elevated temperatures. The carbon fibers were not pretreated but coated with copper by electroless plating in order to increase the wettability of carbon fiber with the copper matrix. Casting is chosen as the manufacturing route for the C-Cu composite. Four different compositions of the composite were developed by varying the amount of carbon fibers by 0.5, 1, 1.5 and 2 wt. % of the copper. The effect of varying carbon fiber content and sizes on the mechanical properties of the C-Cu composite is studied in this work. The tensile test was performed on the tensile specimens. The yield strength decreases with increasing fiber content while the ultimate tensile strength increases with increasing fiber content. Rockwell hardness test was also performed and the result followed the increasing trend for increasing carbon fibers and the hardness numbers are 30.2, 37.2, 39.9 and 42.5 for sample 1, 2, 3 and 4 respectively. The microstructures of the specimens were also examined under the optical microscope. Wear test and SEM also done for checking characteristic of C-Cu marix composite. Through casting may be a route for the production of the C-Cu matrix composite but still powder metallurgy is better to follow as the wettability of carbon fiber with matrix, in that case, would be better.

Keywords: copper based composites, mechanical properties, wear properties, microstructure

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Authors: M. Ramachandra, G. Dilip Maruthi, R. Rashmi

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This paper aims to study the corrosion property of aluminum matrix nanocomposite of an aluminum alloy (Al-6061) reinforced with zirconium dioxide (ZrO₂) particles. The zirconium dioxide particles are synthesized by solution combustion method. The nanocomposite materials are prepared by mechanical stir casting method, varying the percentage of n-ZrO₂ (2.5%, 5% and 7.5% by weight). The corrosion behavior of base metal (Al-6061) and Al/ZrO₂ nanocomposite in seawater (3.5% NaCl solution) is measured using the potential control method. The corrosion rate is evaluated by Tafel extrapolation technique. The corrosion potential increases with the increase in wt.% of n-ZrO₂ in the nanocomposite which means the decrease in corrosion rate. It is found that on addition of n-ZrO2 particles to the aluminum matrix, the corrosion rate has decreased compared to the base metal.

Keywords: Al6061 alloy, corrosion, solution, stir casting, combustion, potentiostat, zirconium dioxide

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Authors: Dhaladhuli Pranavi, Amirtham Rajagopal

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There are various failure modes in ceramic matrix composites; notable ones are fiber breakage, matrix cracking and fiber matrix debonding. Crack nucleation and propagation in microstructure of such composites requires an understanding of interaction of crack with the multiple inclusion heterogeneous system and interfaces. In order to assess structural integrity, the material parameters especially of the interface that governs the crack growth should be determined. In the present work, a nonlocal phase field approach is proposed to model the crack interface interaction in such composites. Nonlocal approaches help in understanding the complex mechanisms of delamination growth and mitigation and operates at a material length scale. The performance of the proposed formulation is illustrated through representative numerical examples. The model proposed is implemented in the framework of the finite element method. Several parametric studies on interface crack interaction are conducted. The proposed model is easy and simple to implement and works very well in modeling fracture in composite systems.

Keywords: composite, interface, nonlocal, phase field

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Authors: S. Ghanaraja, Subrata Ray, S. K. Nath

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Particle reinforced Metal Matrix Composite (MMC) succeeds in synergizing the metallic matrix with ceramic particle reinforcements to result in improved strength, particularly at elevated temperatures, but adversely it affects the ductility of the matrix because of agglomeration and porosity. The present study investigates the outcome of tensile properties in a cast and hot forged composite reinforced simultaneously with coarse and fine particles. Nano-sized alumina particles have been generated by milling mixture of aluminum and manganese dioxide powders. Milled particles after drying are added to molten metal and the resulting slurry is cast. The microstructure of the composites shows good distribution of both the size categories of particles without significant clustering. The presence of nanoparticles along with coarser particles in a composite improves both strength and ductility considerably. Delay in debonding of coarser particles to higher stress is due to reduced mismatch in extension caused by increased strain hardening in presence of the nanoparticles. However, higher addition of powder mix beyond a limit results in deterioration of mechanical properties, possibly due to clustering of nanoparticles. The porosity in cast composite generally increases with the increasing addition of powder mix as observed during process and on forging it has got reduced. The base alloy and nanocomposites show improvement in flow stress which could be attributed to lowering of porosity and grain refinement as a consequence of forging.

Keywords: aluminium, alumina, nano-particle reinforced composites, porosity

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Authors: R. Eslami-Farsani, S. M. S. Mousavi Bafrouyi

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During past decades, increasing demand of modified Fiber Metal Laminates (FMLs) has stimulated a strong trend towards the development of these structures. FMLs contain several thin layers of metal bonded with composite materials. Characteristics of FMLs such as low specific mass, high bearing strength, impact resistance, corrosion resistance and high fatigue life are attractive. Nowadays, increasing development can be observed to promote the properties of polymer-based composites by nanofillers. By dispersing strong, nanofillers in polymer matrix, modified composites can be developed and tailored to individual applications. On the other hand, the synergic effects of nanoparticles such as graphene and carbon nanotube can significantly improve the mechanical, electrical and thermal properties of nanocomposites. In present paper, the modifying of FMLs by nanofillers and the dispersing of nanoparticles in the polymers matrix are discussed. The evaluations have revealed that this approach is acceptable. Finally, a prospect is presented. This paper will lead to further work on these modified FML species.

Keywords: fiber metal laminate, nanofiller, polymer matrix, property modification

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Authors: Mohammad M. Khan, Pankaj Agarwal

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The present investigation deals with the microstructures, mechanical and detailed wear characteristics of in situ TiC particles reinforced zinc aluminum-based metal matrix composites. The composites have been synthesized by liquid metallurgy route using vortex technique. The composite was found to be harder than the matrix alloy due to high hardness of the dispersoid particles therein. The former was also lower in ultimate tensile strength and ductility as compared to the matrix alloy. This could be explained to be due to the use of coarser size dispersoid and larger interparticle spacing. Reasonably uniform distribution of the dispersoid phase in the alloy matrix and good interfacial bonding between the dispersoid and matrix was observed. The composite exhibited predominantly brittle mode of fracture with microcracking in the dispersoid phase indicating effective easy transfer of load from matrix to the dispersoid particles. To study the wear behavior of the samples three different types of tests were performed namely: (i) sliding wear tests using a pin on disc machine under dry condition, (ii) high stress (two-body) abrasive wear tests using different combinations of abrasive media and specimen surfaces under the conditions of varying abrasive size, traversal distance and load, and (iii) low-stress (three-body) abrasion tests using a rubber wheel abrasion tester at various loads and traversal distances using different abrasive media. In sliding wear test, significantly lower wear rates were observed in the case of base alloy over that of the composites. This has been attributed to the poor room temperature strength as a result of increased microcracking tendency of the composite over the matrix alloy. Wear surfaces of the composite revealed the presence of fragmented dispersoid particles and microcracking whereas the wear surface of matrix alloy was observed to be smooth with shallow grooves. During high-stress abrasion, the presence of the reinforcement offered increased resistance to the destructive action of the abrasive particles. Microcracking tendency was also enhanced because of the reinforcement in the matrix. The negative effect of the microcracking tendency was predominant by the abrasion resistance of the dispersoid. As a result, the composite attained improved wear resistance than the matrix alloy. The wear rate increased with load and abrasive size due to a larger depth of cut made by the abrasive medium. The wear surfaces revealed fine grooves, and damaged reinforcement particles while subsurface regions revealed limited plastic deformation and microcracking and fracturing of the dispersoid phase. During low-stress abrasion, the composite experienced significantly less wear rate than the matrix alloy irrespective of the test conditions. This could be explained to be due to wear resistance offered by the hard dispersoid phase thereby protecting the softer matrix against the destructive action of the abrasive medium. Abraded surfaces of the composite showed protrusion of dispersoid phase. The subsurface regions of the composites exhibited decohesion of the dispersoid phase along with its microcracking and limited plastic deformation in the vicinity of the abraded surfaces.

Keywords: abrasive wear, liquid metallurgy, metal martix composite, SEM

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Authors: Mohammad Mahdi Mohammadi

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Zinc-coated steel sheets have been joined with aluminum samples in an overlapping as well as in a butt-joint configuration. A bi-metal-wire composed from aluminum and steel was used for additional welding experiments. An advantage of the laser-assisted bi-metal-wire welding is that the welding process is simplified since the primary joint between aluminium and steel exists already and laser welding occurs only between similar materials. FEM-simulations of the process were chosen to determine the ideal dimensions with respect to the formability of the bi-metal-wire. A prototype demonstrated the feasibility of the process.

Keywords: car body, steel sheets, formability of bi-metal-wire, laser-assisted bi-metal-wire

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Authors: Ahmet Yönetken

Abstract:

Al metal matrix composites reinforced with AlN have been fabricated by Tube furnace sintering at various temperatures. A uniform nickel layer on Al(%1AlN)%19Ni, Al(%2AlN)%18Ni, Al(%3AlN)%17Ni, Al(%4AlN)%16Ni, Al(%5AlN)%15Ni powders were deposited prior to sintering using electroless plating technique, allowing closer surface contact than can be achieved using conventional methods such as mechanical alloying. A composite consisting of quaternary additions, a ceramic phase, AlN, within a matrix of Al, AlN, Ni has been prepared at the temperature range between 550°C and 650°C under Ar shroud. X-Ray diffraction, SEM (Scanning Electron Microscope) density, and hardness measurements were employed to characterize the properties of the specimens. Experimental results carried out for 650°C suggest that the best properties as comprehension strength σmax and hardness 681.51(HV) were obtained at 650°C, and the tube furnace sintering of electroless Al plated (%5AlN)%15Ni powders is a promising technique to produce ceramic reinforced Al (%5AlN)%15Ni composites.

Keywords: electroless nickel plating, ceramic-metal composites, powder metallurgy, sintering

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Authors: Ebrahim Akbarzadeh, Josep A. Picas Barrachina, Maite Baile Puig

Abstract:

This study focuses on a novel method for dispersion and distribution of reinforcement under high intensive shear stress to produce metal composites. The polyacrylonitrile (PAN)-based short carbon fiber (Csf) and Nextel 610 alumina fiber were dispersed under high intensive shearing at mushy zone in semi-solid of A356 by a novel method. The bundles and clusters were embedded by infiltration of slurry into the clusters, thus leading to a uniform microstructure. The fibers were embedded homogenously into the aluminum around 576-580°C with around 46% of solid fraction. Other experiments at 615°C and 568°C which are contained 0% and 90% solid respectively were not successful for dispersion and infiltration of aluminum into bundles of Csf. The alumina fiber has been cracked by high shearing load. The morphologies and crystalline phase were evaluated by SEM and XRD. The adopted thixo-process effectively improved the adherence and distribution of Csf into Al that can be developed to produce various composites by thixomixing.

Keywords: aluminum, carbon fiber, alumina fiber, thixomixing, adhesion

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Authors: Mohammad S. Rouhi, Magdalena Juntikka

Abstract:

Processing of polymer fiber composites has a remarkable influence on their mechanical performance. These mechanical properties are even more influenced when using recycled reinforcement. Therefore, we place particular attention on the evaluation of micromechanical models to estimate the mechanical properties and compare them against the experimental results of the manufactured composites. For the manufacturing process, an epoxy matrix and carbon fiber production cut-offs as reinforcing material are incorporated using a vacuum infusion process. In addition, continuous textile reinforcement in combination with the epoxy matrix is used as reference material to evaluate the kick-down in mechanical performance of the recycled composite. The experimental results show less degradation of the composite stiffness compared to the strength properties. Observations from the modeling also show the same trend as the error between the theoretical and experimental results is lower for stiffness comparisons than the strength calculations. Yet still, good mechanical performance for specific applications can be expected from these materials.

Keywords: composite recycling, carbon fibers, mechanical properties, micromechanics

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Authors: V. J. Pillewan, D. N. Raut, K. N. Patil, D. K. Shinde

Abstract:

Forging, milling, turning, grinding and shaping etc. are the various industrial manufacturing processes which generate the metal waste. Grinding is extensively used in the finishing operation. The waste generated contains significant impurities apart from the metal particles. Due to these significant impurities, it becomes difficult to process and gets usually dumped in the landfills which create environmental problems. Therefore, it becomes essential to reuse metal waste to create value added products. Powder injection molding process is used for producing the porous metal matrix framework. This paper discusses the presented design of the porous framework to be used for the liquid filter application. Different parameters are optimized to obtain the better strength framework with variable porosity. Carbon nanotubes are used as reinforcing materials to enhance the strength of the metal matrix framework.

Keywords: grinding waste, powder injection molding (PIM), carbon nanotubes (CNTs), matrix composites (MMCs)

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Authors: A. Chiker, A. Benamor, A. Haddad, Y. Hadji, M. Hadji

Abstract:

Metal matrix composites (MMCs) have been of big interest for a few decades. Their major drawback lies in their enhanced mechanical performance over unreinforced alloys. They found ground in many engineering fields, such as aeronautics, aerospace, automotive, and other structural applications. One of the most used alloys as a matrix is nickel alloys, which meet the need for high-temperature mechanical properties; some attempts have been made to develop nickel base composites reinforced by high melt point and high modulus particulates. Among the carbides used as reinforcing particulates, chromium carbide is interesting for wear applications; it is widely used as a tribological coating material in high-temperature applications requiring high wear resistance and hardness. Moreover, a set of properties make it suitable for use in MMCs, such as toughness, the good corrosion and oxidation resistance of its three polymorphs -the cubic (Cr23C6), the hexagonal (Cr7C3), and the orthorhombic (Cr3C2)-, and it’s coefficient of thermal expansion that is almost equal to that of metals. The in-situ synthesis of CrC-reinforced Ni matrix composites could be achieved by the powder metallurgy route. To ensure the in-situ reactions during the sintering process, the use of phase precursors is necessary. Recently, new precursor materials have been proposed; these materials are called MAX phases. The MAX phases are thermodynamically stable nano-laminated materials displaying unusual and sometimes unique properties. These novel phases possess Mn+1AXn chemistry, where n is 1, 2, or 3, M is an early transition metal element, A is an A-group element, and X is C or N. Herein, the pressureless sintering method is used to elaborate Ni/Cr2AlC composites. Four composites were elaborated from 5, 10, 15 and 20 wt% of Cr2AlC MAX phase precursor which fully reacted with Ni-matrix at 1100 °C sintering temperature for 4 h in argon atmosphere. XRD results showed that Cr2AlC MAX phase was totally decomposed forming chromium carbide Cr7C3, and the released Al and Cr atoms diffused in Ni matrix giving rise to γ-Ni(Al,Cr) solid solution and γ’-Ni3(Al,Cr) intermetallic. Scanning Electron Microscopy (SEM) of the elaborated samples showed the presence of nanosized Cr7C3 reinforcing particles embedded in the Ni metal matrix, which have a direct impact on the tribological properties of the composites and their hardness. All the composites exhibited higher hardness than pure Ni; whereas adding 15 wt% of Cr2AlC gives the highest hardness (1.85 GPa). Using a ball-on-disc tribometer, dry sliding tests for the elaborated composites against 100Cr6 steel ball were studied under different applied loads. The microstructures and worn surface characteristics were then analyzed using SEM and Raman spectroscopy. The results show that all the composites exhibited better wear resistance compared to pure Ni, which could be explained by the formation of a lubricious tribo-layer during sliding and the good bonding between the Ni matrix and the reinforcing phases.

Keywords: composites, microscopy, sintering, wear

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