Metal Matrix Composites

Extended Abstract An economic way to reduce shocks and mechanical vibrations in engineering applications is to use high damping materials. For practical applications damping materials must exhibit, simultaneously, good mechanical properties at room and high temperature, and high damping capacity. This requirement is fulfilled when the microscopic mechanisms responsible for the dissipation of the vibration energy (internal friction) are independent of the hardening mechanisms. For most materials these are contradictory requirements. One way to achieve a compromise is to design multiphase composites in which specific phases are assigned specific damping or mechanical strength roles [1] . Metal-ceramic composites are typical examples. The purpose of this research is to explore the use of shape memory alloy as the metal phase in the interpenetrated phase metal-ceramic composite designed for vibration damping applications.

Di era teknologi yang berkembang sangat pesat ini memungkinkan beberapa peneliti dan beberapa perusahaan berlomba-lomba untuk membuat sebuah hal atau ide baru. Karena, di dalam dunia ini perkembangan tidak hanya berjalan secara monoton tetapi harus ada era yang baru untuk menunjang suatu kebutuhan. Seperti pada kajian kali ini yang membahas penelitian material di bidang komposit. Pada saat ini bidang komposit memang cukup unggul dengan kapasitasnya yang sangat berpengaruh pada kebutuhan saat ini. Dalam pengaplikasiaanya pun memiliki keunggulan dalam dunia industri secara jangka panjang dan memiliki keunggulan yang beragam. Tidak jarang material memiliki sifat mekanik dan karakteristik yang tidak sesuai secara ketentuan yang diinginkan. Komposit merupakan gabungan 2 material atau lebih yang tersusun atas campuran material yang mempunyai sifay fisik dan mekanik yang berbeda dan menghasilkan material baru yang memiliki sifay-sifat yang berbeda dengan material penyusunnya. Gabungan dua ...

In the present study, elemental magnesium was reinforced with nano-size alumina particulates. Synthesis of materials was accomplished using the powder metallurgy route. Energy dissipation in the form of damping capacity was determined using free -free type suspended beam arrangement coupled with circle-fit approach. This technique is based on classical vibration theory, by which the geometry and material properties of the metallic specimen are related to measured resonant frequency and structural damping. Using the fact that the ratio of the vibration response to the applied force fits to a circle in the Argand plane for each resonant frequency of the test specimen, the damping factor and natural frequency is predicted accurately for the test specimen. The results revealed that an increase in the alumina content up to 0.4% volume percentage lead to an increase in the damping capacity up to 34%. Attempt is made to correlate the increase in damping with the various microstructural changes arising due to the presence of the nano-size alumina particulates in the composite sample.

A new methodology of using impact-based vibration measurement of a suspended beam coupled with circle-®t approach is discussed to measure damping of SiC particulate reinforced magnesium composites. This study also focuses on the dependence of damping capability of the composite with SiC particulate size variation.

In the present study, the damping capacity of a metal matrix composite is predicted using a micro-mechanical modelling approach. The model is based on finite element analysis of an axisymmetric unit cell, which mimics a pure metallic cylinder with a stiff reinforcing spherical particulate placed at the center. The energy dissipated by the composite is numerically predicted using the unit cell by applying a harmonic load, taking into account the viscoplastic behavior of the processing induced residual plastic strain at the matrix-reinforcement interface of the composite. The model shows that the plastic zone size increases with volume fraction of Ti added which results in a proportional increase in the damping capacity of the composite. The model was validated by comparing the numerical results against an impact based suspended beam experiment conducted at low strain amplitude on Al/Ti samples with different volume fractions of Ti particulates.

Variable elements that influence machining quality and efficiency are wire cut electrical discharge machining (EDM) parameters. These variables, which also affect the pace of material removal, the standard of the surface polish, and the degree of accuracy attained during the EDM process, includes wire tension, wire feed rate, and spark gap voltage. In order to optimise machining processes and reach higher standards of efficiency and quality, it is crucial to look at the wire cut electrical discharge machining (EDM) process parameters. Researchers can identify the best configurations that offer enhanced material removal rates, surface polish, and dimensional accuracy by careful study and understanding of parameters including wire tension, wire feed rate, and spark gap voltage. The advancement of EDM technology and its broad adoption in sectors like aerospace, automotive, and manufacturing, where precise machining is crucial, are made possible by this research endeavour. A decision-making technique called multi-objective optimisation based on ratio analysis (MOORA) is used to assess and rank a large number of options in accordance with multiple requirements or goals. To evaluate the effectiveness of each alternative for each criterion and to assign weights to represent their significance, MOORA uses ratio analysis. Performance ratios are calculated by MOORA to enable a thorough analysis that aids in choosing the most advantageous option while simultaneously taking into account different objectives. Electrical Discharge machine process parameters 2 is got the first rank whereas is the Electrical Discharge machine process parameters 5 has got the last rank. This paper Wire cut Electrical Discharge Machining process parameter Electrical Discharge machine process parameters 2 is got the first rank whereas is the Electrical Discharge machine process parameters 5 regulations is having the Lowest rank.

Due to the rapid growth of high performance electronics devices accompanied by overheating problem, heat dissipater nanocomposites material having ultra-high thermal conductivity and low coefficient of thermal expansion was proposed. In this work, a nanocomposite material made of copper (Cu) reinforced by multi-walled carbon nanotubes (CNTs) up to 10 vol. % was prepared and their thermal behaviour was measured experimentally and evaluated using numerical simulation. In order to numerically predict the thermal behaviour of Cu/CNTs composites, three different prediction methods were performed. The results showed that rules of mixture method records the highest thermal conductivity for all predicted composites. In contrast, the prediction model which takes into account the influence of the interface thermal resistance between CNTs and copper particles, has shown the lowest thermal conductivity which considered as the closest results to the experimental measurement. The experimentally measured thermal conductivities showed remarkable increase after adding 5 vol.% CNTs and higher than the thermal conductivities predicted via Nan models, indicating that the improved fabrication technique of powder injection molding that has been used to produced Cu/CNTs nanocomposites has overcome the challenges assumed in the mathematical models.

Purpose: of this paper is based on the damage analysis by fretting wearing occurred on the composite steel sheets reinforced with TiB2 ceramic particles. There is a real lack to find a reliable data and detail research in literature that makes the purpose of this manuscript. Design/methodology/approach: Fretting is a surface degradation process in which removal of material is induced by small amplitude oscillatory movement between contacting components, such as flexible coupling joint structures etc. The main parameters affecting fretting wear are reported to be normal load, slip amplitude, frequency of the oscillatory movement, contact geometry, surface roughness and material properties. In this study, a finite element-based method is presented for simulating the contact of a rigid cylinder on flat fretting wear for the composite steel sheets reinforced with TiB2 ceramic particles. Findings: The general purpose commercial code ABAQUS was employed; this model can be used to facilita...

The optimization of aluminium wheel casting represents a critical frontier in advancing the structural integrity, aesthetic quality, and performance of automotive components. This investigation offers a comprehensive analysis of the influence of chill cooling methodologies on defect mitigation during the casting of aluminium wheels, specifically targeting the reduction of porosity, shrinkage, and surface irregularities. In this case, the integration of high-fidelity computational fluid dynamics (CFD) modelling with well-controlled physical tests allows for an analysis of the influence of chill material, geometry, and cooling rates on the thermal solidification of Aluminium alloy. The study adequately figures out the relation between the cooling dynamics and its influence on microstructures stating how an engineered chill system alters the velocity of the solidification front thereby creating conditions for a sound cast. By explaining how deflection caused by chill alters microstructure, the research presents a new direction for adjusting casting parameters to achieve optimum mechanical properties, for instance, tensile strength and fatigue limits. This work can be seen as an advancement in the casting technology and stresses the need to evolve towards casting lightweight Aluminium wheels of high performance that are consistently manufactured, highly durable with less scrap material, meeting the precise standards set by the automotive manufacturing industry.

Metallicmatrixcompositesarecombinationsoftwoaremoredifferentmetalsinter metallic compounds are seconds phases in which dispersed phases are embedded within the metallicmatrix.MMC's can be produced by controlling the internal structure of the constituents to get optimum combination of properties. Properties of the MMC's depend on the properties of constituent phases, their relative amount, and dispersed phase geometry including particle size, shape and orientation in thematrix. In this work, comparative studies of Mechanical behavior of aluminum metal matrix metallic composites fabricated under powder metallurgy process to understand their process-structure-property relations. The optimized percentage of Sic reinforcement material has been found out. The variation in the percentage of Sic gives the different mechanical properties.

Metallicmatrixcompositesarecombinationsoftwoaremoredifferentmetalsinter metallic compounds are seconds phases in which dispersed phases are embedded within the metallicmatrix.MMC's can be produced by controlling the internal structure of the constituents to get optimum combination of properties. Properties of the MMC's depend on the properties of constituent phases, their relative amount, and dispersed phase geometry including particle size, shape and orientation in thematrix. In this work, comparative studies of Mechanical behavior of aluminum metal matrix metallic composites fabricated under powder metallurgy process to understand their process-structure-property relations. The optimized percentage of Sic reinforcement material has been found out. The variation in the percentage of Sic gives the different mechanical properties.

this study indicate that the UTS of the composites that were manufactured improved in relation to the amount of B4C present. The Al7075-B4C composite shows the maximum UTS of 134.33 N/mm 2 with B4C addition at 5%. It was established that the addition of B4C resulted in a reduction in percentage elongation. Adding B4C particles to the composites also increases their yield strength. With only 5 wt. % B4C, the highest yield strength of 117.25 N/mm 2 can be attained among all tested compositions for the Al7075-B4C composite. Detailed examinations by SEM analysis of the fracture tension face of the composite material demonstrated that it was inherently brittle.

The machinability of aluminum hybrid composites (AHCs) can be enhanced by utilization of optimum composition and cutting parameters. In this study, the machinability of AHCs containing micron-sized TiB2 and B4C particles was investigated using the face milling operation with a double coated cemented carbide tool. The composites, fabricated via cold pressing and microwave sintering, were subjected to the face milling experiments using a CNC milling machine. The influence of hybrid reinforcement content, feed rate and cutting speed on tool wear and surface roughness was examined during the milling of these composites. After the machinability tests, the worn surface of inserts was examined by a scanning electron microscope to see the wear types. The reinforcement content and cutting speed were obtained to have a much greater effect on the machinability and surface roughness of the hybrid composites compared to the feed rate. Either increasing the feed rate or decreasing the cutting speed provided a larger amount of chip removal until the wear limit. Moreover, the feed rate was obtained to be more effective on the tool wear at lower cutting speeds and higher amounts of hybrid reinforcement.

The study carried out on the Rennie filled unsaturated polyester composites of varying size and different filler concentration reveals changes of the mechanical and physical properties of the composites, these changes in the properties of the Rennie filled polymer composites make them suitable for their use in medical, biomedical and pharmaceutical applications on large extent. This work focuses on the preparation of base polymer matrix (unsaturated polyester) composite materials by (Hand Lay-Up) method, and studying the effect of selected grain size (25, 53, and 90) μm of (Rennie) particles on some properties of the prepared composite. Some mechanical tests were used to evaluate the prepared system (Tensile, Compression, Impact, and Hardness) tests, and a physical test of (Water absorption %), and all tests were accomplished at room temperature. Maximum results of tensile strength, elongation at brake, young’s module, compression strength, flexural strength, flexural modulus, impac...

In this modern era, aluminium metal matrix composites (AMMCs) are replacing all the conventional materials in rapid way due to its outstanding characteristics and play very important role in various industries i.e., automobile & sports. In this research work 5 weight percent of Boron Carbide (B4C) particulates are used to reinforce the AA5052 matrix by easiest and cost-effective stir casting route of liquid processing technique to develop metal matrix composites (MMC). The variation of volume loss, volumetric wear rate, volumetric wear resistance, frictional force, wear depth, and relative wear depth of the developed AMMC and unreinforced AA5052 are investigated at different applied load and compared these properties between them. To analyze these properties, pin-on-disc abrasive wear test were carried out according to ASTM G132 for the applied load range of 5-15N and the density was measured by using Archimedes’ principle. Vickers hardness of the developed compositions is also analysed as per ASTM E92. The results show that at all applied load, AA5052/B4C AMMC having improved wear resistance and reduction in wear rate with lower density & higher hardness as compared to the AA5052 matrix.

This review article summaries the characterization of sliding wear behavior of different ceramic particulate reinforced Aluminium Metal Matrix Composites (AMMC) investigated by various researchers in last few decades. The effect of various parameters i.e. sliding distance, applied load, testing time, testing media, rotational speed, weight fraction of reinforcements, particle size of reinforcements etc. are considered for characterization of various tribological properties i.e. frictional force, coefficient of friction (COF), wear rate etc. of the particulate reinforced AMMCs. For the characterization of these tribological properties, the tests were carried out on the pin-on-disc tribometer as per ASTM G99. AMMCs are demanded materials for this modern age, because they work as functionally graded materials for various industries like automobile, sports, aircraft, marine etc.

This review paper is broadly focused on the effect of the different ceramic particulates (SiC, B4C and Al2O3) on the mechanical properties of the Al and Al alloy. Ceramic Particulate Reinforced Aluminium Metal Matrix Composites (PRAMMCs) provide improved properties i.e. improved hardness, improved strength to weight ratio, tensile & compressive strength, creep & fatigue resistance etc. as compared to conventional Al and Al alloy. Aluminium Metal Matrix Composites (AMMCs) are preferred to use in aerospace, automobile, sports, marine application etc due to its lightweight and high strength property. This manuscript reported the pioneering work of most of the researchers in the field of mechanical characterizations of ceramic PRAMMCs. The effects of weight or volume percentages and particles size of the reinforcement on the properties of AMMCs are discussed in this article.

This article deals with a summary of different fabrication methods of Aluminium Metal Matrix Composite (AMMC). This modern age demands the lightweight materials with very high strength, wear resistance, and corrosion resistance property for various industries i.e. aerospace, automobile, sports, etc. These requirements can't be fulfilled by the monolithic alloy or conventional materials. Metal Matrix Composite (MMC) overcomes these limitations of the monolithic alloys because MMCs have desired properties like high strength to weight ratio, good mechanical as well as good tribological properties and due to its advantageous properties MMCs are used for automobile & aircraft. The use of MMCs reduces the power requirement and also gives low emission and low noise. This article focused on the various techniques developed for the fabrication of AMMCs by the no. of researchers in the last few decades. These methods are either liquid state processing or solid-state processing. In the case of weight-saving requirements, researchers used AMMCs due to its lightweight property.

In this present research particulate reinforced aluminium metal matrix composite is developed by using sand mould and liquid stir casting processing route in which AA5052 reinforced with 5 wt. % SiC particulates of 63µm particle size. The density, porosity, micro-hardness, and compressive strength of SiC particulate reinforced AA5052 MMC were investigated and compared these properties with similar properties of unreinforced AA5052. The microstructure of the developed composite was also analysed by using optical microscopy, SEM, and XRD. Developed particulate reinforced Al metal matrix composite gives improved hardness and compressive strength as compared to the unreinforced AA5052. The addition of 5 wt. % SiC particulates increases the density of AA5052.

The weight saving requirement for automobiles has become more important, since the increase in the environmental issues. For boosting the fuel economy, maintaining safety and performance of modern automobiles; lightweight composite materials are essential. For acceleration of a lighter object, less energy is required as compare to acceleration of heavier one; so the lightweight composite materials offer the great potential for increasing vehicles efficiency. Decrease in fuel consumption gain by reduction in vehicle weight. By replacing steel & cast iron conventional components with lightweight composite materials such as Mg & Al metal matrix composite, carbon & glass fiber reinforced polymer composites can directly reduce the weight of the parts of an automotive i.e. engine block and chassis and results in reduction of fuel consumption by the vehicle. By the use of light composites in automotive can also carry additional advanced emission control system, safety devices, and integrated electronic system without increase in the overall weight of vehicles. It can reduce the exhaust emission and enhanced the fuel economy.

The positive impact of nanoparticles on the behaviour of composite microstructures has been studied. These studies include the material characteristic features, the production methods, suitability with the other phases, surface area, the scattering process, rigidity, and other topics. The assessment of the selection of nanomaterials for a particular tender and their impact on the bulk material connected to loading has remained neglected. This is unfortunate because the review was necessary. As a result, the effects of nanoparticles were investigated in this work, constructed on definite filler categories. It also demonstrated the optimal filler quantity for the improvement of mechanical parameters (such as strength and stiffness) and fracture toughness from both an interlaminar and an intralaminar point of view. In addition, the impacts of soft fillers, hard fillers, and hybrid additives were analysed and grouped to demonstrate how certain fillers might have amazing effects on the enhancement of particular properties. In addition, the most effective application of nanomaterials in relation to loading conditions was articulated in order to provide structural engineering engineers and scientists with a prompt suggestion. This research provides some insight into how nano-filler and nano-particles affect the beginning of damage in fiber-reinforced plastic composites as well as their behaviour.

This research investigates the thermal insulation properties of epoxy composites reinforced with hybrid natural materials, specifically calabash and rice husk ash (RHA). Addressing the increasing demand for sustainable, costeffective, and energy-efficient materials in the construction and automotive industries, we employed a systematic approach involving material characterization, composite fabrication, and thermal performance evaluation via differential scanning calorimetry (DSC). Composites were prepared using varying proportions of calabash and RHA as fillers in an epoxy matrix. Key metrics were analysed, including thermal conductivity, thermal resistance, specific heat capacity, and mechanical properties (Shore D hardness and density). The optimal composite formulationcomprising 20% calabash fiber, 20% RHA, and 60% epoxy resin-demonstrated exceptional thermal performance, achieving a thermal conductivity of 0.284805 W/m•K and thermal diffusivity of 0.131303 m²/s, meeting industrial insulation benchmarks. Comparative analysis with conventional materials, such as fiberglass and polyurethane composites, highlighted the superior thermal performance of the hybrid epoxy composite. This work illustrates the potential of integrating agricultural by-products into advanced materials for sustainable thermal insulation applications.

In the present study, the nickel aluminide NiAl-based composite, reinforced with yttrium oxide Y2O3 with addition of titanium, was prepared by sintering at 1350 ° C for one and a half hours under an atmosphere of argon gas. Experimental investigation on electrical discharge machining of NiAl composite is performed with a view to correlate the process parameters with the responses for indicating the effect of the alloying addition on the machining performance of NiAl. Electro-discharge machining was used to study the machinability of the prepared composite. The machinability of NiAl was investigated based on the material removal rate, electrode wear rate, white layer thickness, and the surface roughness of the machined samples. The machining tests were performed under a wide range of machining parameters involving the pulse current (Ip) (8, 12, and 20) Amp. , pulse on time (TON) (45, 60, and 80) µsec, and pulse off time (TOFF) (20, 35, and 50) µsec, keeping the other parameters at fixed values. Electro-discharge machining process has been successfully modeled using response surface methodology (RSM) and central composite design (CCD) within "Minitab 17" and model adequacy checking is also carried out. The second-order response models have been validated. Analysis of variance (ANOVA) at constant significance levels of 0.05 was used to predict the most affecting parameters on the machining outputs. Optimization plots indicated that the maximum material removal rate (9.9312 µm) can obtained at (TON = 80 µs, TOFF = 20 µm, and Ip = 17.8182 Amp.), minimum electrode wear rate (0.2552 µm) can achieved at (TON = 45 µs, TOFF = 50 µm, and Ip = 8 Amp.), minimum surface roughness can gained at (TON = 45 µs, TOFF = 50 µm, and Ip = 8 Amp.), and minimum white layer thickness (4.9335 µm) can gotten using machining conditions of (TON = 45 µs, TOFF = 50 µm, and Ip = 8 Amp.

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Your article is protected by copyright and all rights are held exclusively by ASM International. This e-offprint is for personal use only and shall not be self-archived in electronic repositories. If you wish to selfarchive your work, please use the accepted author's version for posting to your own website or your institution's repository. You may further deposit the accepted author's version on a funder's repository at a funder's request, provided it is not made publicly available until 12 months after publication.

This paper introduces a study on the influence of process parameters on the machining time in Wire Electrical Discharge Machining of 9CrSi tool steel. In this study, a total of experiments were performed based on full factorial design and the work-piece material was 9CrSi steel. The input parameters including cutting voltage, pulse on time, pulse off time,servervoltage, wire feed and cutting speed were selected for investigation of the effects of the input parameters on the machining time. The influence of the input parameters on the surface roughness were investigated by analysing variance. Furthermore, based on the results of the experiments, a regression equation for determining the machining time wasproposed.

Grinding of metal matrix composites is a challengin g task on account of the hybrid nature of their constituents. In this study, the influence of grind ing process and parameters on surface finish and su rface integrity of MMC workpiece was investigated. A high performance resin bonded diamond grinding wheel was used owing to the abrasive nature of SiC reinfo rcements. As–ground workpiece was characterized by light microscopy, scanning electron microscopy, pro filometry and by variations in near surface microhardness values. The emphasis has also been gi v to the influence of grinding parameters on surface residual stresses. A model of the reinforce ment particles–grinding wheel interaction has been proposed. The experimental material was a powder me tallurgically produced AA–2124 based metal matrix composite reinforced with 25 volume percent of fine (2-3 μm) SiC particles in T6 heattreatment condition.

Variable elements that influence machining quality and efficiency are wire cut electrical discharge machining (EDM) parameters. These variables, which also affect the pace of material removal, the standard of the surface polish, and the degree of accuracy attained during the EDM process, includes wire tension, wire feed rate, and spark gap voltage. In order to optimise machining processes and reach higher standards of efficiency and quality, it is crucial to look at the wire cut electrical discharge machining (EDM) process parameters. Researchers can identify the best configurations that offer enhanced material removal rates, surface polish, and dimensional accuracy by careful study and understanding of parameters including wire tension, wire feed rate, and spark gap voltage. The advancement of EDM technology and its broad adoption in sectors like aerospace, automotive, and manufacturing, where precise machining is crucial, are made possible by this research endeavour. A decision-making technique called multi-objective optimisation based on ratio analysis (MOORA) is used to assess and rank a large number of options in accordance with multiple requirements or goals. To evaluate the effectiveness of each alternative for each criterion and to assign weights to represent their significance, MOORA uses ratio analysis. Performance ratios are calculated by MOORA to enable a thorough analysis that aids in choosing the most advantageous option while simultaneously taking into account different objectives. Electrical Discharge machine process parameters 2 is got the first rank whereas is the Electrical Discharge machine process parameters 5 has got the last rank. This paper Wire cut Electrical Discharge Machining process parameter Electrical Discharge machine process parameters 2 is got the first rank whereas is the Electrical Discharge machine process parameters 5 regulations is having the Lowest rank.

When choosing a material for automobile piston components, be sure to choose one that satisfies all necessary specifications, like durability, resistance to temperature, and wear resistance. To achieve maximum efficiency and effectiveness, factors including cost, weight, and production procedures are also taken into account. Aluminium alloys that are forged iron, and steel are common material for piston components; each has certain benefits and compromises in terms of expense and efficiency. Introduction: Material selection for auto piston components is critical to ensuring top performance and long-term durability. The piston, as a vital engine component subjected to high temperatures, hardship, and wear and tear, necessitates a material that promotes efficient combustion, lowers friction, and maintains its structural integrity. When selecting materials for automobile pistons such as aluminium alloys, wrought iron, or steel, aspects such as heat conductivity, resistance to wear, size, expense, and manufacturing capability are carefully considered to satisfy the specific needs of the application. Research Significance: Aluminum, steel, along with iron are the better frequently used goods for pistons. The effort from the expanding gas at great heat matters about the inside. Cylinder and many other important factors determine proper piston selection Material necessity are balanced more demanding, just as no single material meets all the properties required for a distinct application. Method: The weighted sum method is a decision-making approach that involves assigning weights to different criteria or objectives and combining them to make an overall assessment. It allows decision-makers to prioritize and balance various factors based on their relative importance. By utilizing this method, complex decision problems can be simplified and converted into a single weighted score, facilitating a clearer understanding of trade-offs and aiding in the decision-making process.

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.

These days significant waste metal scrap is generated during the machining operations such as grinding, milling, shaping, forging etc. This waste/scrap is big challenge for the industry due to environmental litigation, such as in grinding industry the scarp contain organic and inorganic compounds. Thus, for reprocessing of this grinding waste will be difficult and it also crate environmental problems.  Current work focus to reuse and produce a value added product from the grinding waste. The Powder Injection Molding (PIM) approach used to create the value added product from the grinding waste. As the PIM product will be inferior in terms of mechanical properties, Carbon Nanotubes are added to improve the mechanical properties. To test the microscopic analysis of the PIM products are tested with SEM and it is observed that the PIM products are porous in nature. The hardness testing suggests that the PIM product will have higher harness number with less porosity.

The wear behaviour comparison of Al/SiC and Al/Al2O3 composites prepared by stir casting technique is investigated to find out the effects of weight percentage of SiC/Al2O3, load and the number of strokes on a reciprocating wear testing machine. The MMC pins are prepared with different weight percentage of SiC and Al2O3 (10, 15 and 20 %). The tests are carried out with different load conditions (25, 50 and 75 N) and different number of strokes (420,780 and 1605 strokes). Wear surfaces of tested samples are examined in Scanning Electron Microscope (SEM). Hardness test and impact test are also carried out on the MMC samples. The experimental results shows that hardness of composites increases with increase in SiC and Al2O3 particle and the impact strength decreases with increase in SiC and Al2O3 content. The volume loss of MMC specimens are less than that of the matrix alloy. The temperature rise near the contact surface of the MMC specimens increases with increase in wt% of SiC and A...

The hardness property and the wear behavior of AA5052 aluminum alloy with the reinforcement Al2O3 particles added in various proportions as 5wt% and 10wt% to fabricate the composite by employing the stir-casting process. The wear resistance property of the fabricated composite was studied under an optical microscope and the hardness property was measured by the Vickers hardness tester. The wear property and the hardness property tend to be optimized with the increase in the Al2O3 reinforcement percentage.

The global market for aluminum-based composites, widely used in manufacturing and construction, is expected to grow significantly. However, enhancing the cost-to-performance ratio is essential to improving their commercial viability. Efficient mixing plays a critical role in many industrial and chemical applications. Stir casting is the leading method for producing aluminum alloy matrix composites, but achieving a uniform particle distribution remains a significant challenge. In this study, the optimal stirrer design was identified using image processing techniques to analyze the distribution of ceramic grains. The stirrer that achieved the most uniform grain distribution was selected, eliminating the need for destructive testing. The mechanical properties of the final products validated the accuracy of the image analysis results.

The synthesis of magnesium silicon nitride (MgSiN 2 ) by direct nitridation of a Si/Mg 2 Si/Mg/Si 3 N 4 powder mixture is described. A nucleation period at 550°C and stepwise heattreatment schedule up to 1350°C was adopted for the synthesis of MgSiN 2 powder, based on TG-DTA measurements. The influence of the ratio of constituents on the final phase composition also has been studied. The content of magnesium and silicon in the starting powder should fulfill the conditions Mg 2 Si/Mg > 3 and Si 3 N 4 /Si tot > 0.5 to obtain single-phase MgSiN 2 . The silicon particle size of <0.5 m is preferable to decrease the time of nitridation. The oxygen content of assynthesized powders is in the range 0.9 -1.2 wt%. However, the oxygen content of MgSiN 2 powder decreases further by the addition of 2 wt% CaF 2 or 0.75 wt% carbon and reaching the lowest value of 0.45 wt% oxygen after carbothermal reduction in an alumina-tube furnace.

The main objective of this paper is to review the works on two broadly used methods of producing metal matrix composites : stir casting method and squeeze casting method. The major issues regarding the use of liquid state method of producing metal matrix composites are; the wetting of the dispersed phase in the metal matrix, reaction between the dispersed phase and the matrix, reinforcement distribution and porosity. Such cases have been studied and improved over a period and the present paper is directed towards a comprehensive review of them.

effect of Nb and C additions on the phase composition, microstructure, and creep resistance of Fe 3 Al-type alloys is investigated. Two alloys, which contained (at. pct) (i) 27.6 Al, 1.15 Nb and 0.19 C (Fe balance) and (ii) 27.1 Al, 1.11 Nb, and 0.76 C (Fe balance), were studied in a temperature range from 873 K to 1073 K (600 °C to 800 °C). The carbide in both alloys was identified as Nb 6 C 5 . The creep data can be rationalized by introducing a threshold stress, below which, the creep rate is negligible. The threshold stress and an effective stress exponent were found simultaneously by a numerical method. Using the obtained values of the threshold stress, the activation energy of creep was determined to be 328 kJ/mol. The effective stress exponent varied from 2.0 to 3.1. A breakdown of power-law behavior was observed at higher stresses. The transition occurred at the normalized creep rate of _ e=D ¼ 10 13 m À2 , which agrees with the rule suggested by Sherby and Burke and the diffusion coefficient D corresponding to the diffusion of Al in Fe-Al.

FeAl-based MIL composites of various iron alloys were fabricated with an innovative "multiple-thin-foil" configuration and "two-stage reaction" strategy. Alternating stacked metal foils were reactive sintered via SPS at 600 o C and 1000 o C to grow intermetallics. The "multiple-thin-foil" configuration reduces reaction time, enables local chemical composition control and allows metal/intermetallic combinations, which cannot be produced via the conventional methods. Fe-FeAl, 430SS-FeAl, and 304SS-FeAl MIL composites can be synthesized with desired metallic/intermetallic ratios, where FeAl is the single intermetallic phase present in the composites. Microstructure analysis via SEM, EDS, and EBSD confirms phase identification and reveals the formation of transition layers. The transition layer, which incorporates the composition gradient between the metal (Fe, 430SS or 304SS) and the FeAl intermetallic phase, provides a gradual change in mechanical properties from the metal to intermetallic layers, and further functions as a chemical barrier into which other undesired intermetallics dissolve. Driven by diffusioncontrolled growth, grains in the transition layers and FeAl regions exhibit ordered arrangement and sintering textures. Hardness profiles from the metal layer to FeAl region reveal the correlation between local mechanical properties and local chemical compositions. In compression testing, the compressive strength can reach 2.3 GPa with considerable plasticity, establishing the best mechanical properties of any MIL composites synthesized to date.

This research investigates the thermal insulation properties of epoxy composites reinforced with hybrid natural materials, specifically calabash and rice husk ash (RHA). Addressing the increasing demand for sustainable, costeffective, and energy-efficient materials in the construction and automotive industries, we employed a systematic approach involving material characterization, composite fabrication, and thermal performance evaluation via differential scanning calorimetry (DSC). Composites were prepared using varying proportions of calabash and RHA as fillers in an epoxy matrix. Key metrics were analysed, including thermal conductivity, thermal resistance, specific heat capacity, and mechanical properties (Shore D hardness and density). The optimal composite formulationcomprising 20% calabash fiber, 20% RHA, and 60% epoxy resin-demonstrated exceptional thermal performance, achieving a thermal conductivity of 0.284805 W/m•K and thermal diffusivity of 0.131303 m²/s, meeting industrial insulation benchmarks. Comparative analysis with conventional materials, such as fiberglass and polyurethane composites, highlighted the superior thermal performance of the hybrid epoxy composite. This work illustrates the potential of integrating agricultural by-products into advanced materials for sustainable thermal insulation applications.

The risk of cracking/debonding of a cement overlay used to repair or strengthen an existing structure is still a key issue. Current bond test methods are not designed to measure the combined effect of peeling (mode I) and shear (mode II) on the interface. A few existing models propose theoretical approaches to predict that, but they were fitted on specific cases and lack in generality. In addition, controversial opinions about the influence of both the moisture level of the substrate surface prior to the application of the overlay and properties of the latter on the loading bond capacity call for further investigations. In this work, a cohesive model is developed to predict the loading bond capacity of an existing concrete structure overlaid by a layer of HPFRC/UHPFRC. Different bond tests were specifically designed for calibrating the cohesive parameters employed into the model, which also takes into account the type of the overlay used and the moisture conditioning level. An experimental campaign confirmed the reliability of the predictions of the proposed theoretical model.

In this research, the mechanical properties (microhardness and wear) of Al-8Si-3Cu-2Zn nanocomposites with 0, 2, and 5% by weight of tungsten disulfide nanoplates have been investigated. The studied nanocomposite was produced through mechanical grinding and hot pressing at a temperature of 510 degrees Celsius. The microstructures of powders before and after mechanical grinding and sintered samples were studied through electron microscopy (SEM). By examining the worn surfaces after the wear test by electron microscope, the cause of weight loss was investigated. The results show that by adding tungsten disulfide nanoplates up to 5% by weight, the microhardness of the samples increases more than twice and from 50 Vickers for Al-8Si-3Cu-2Zn to 101 Vickers for Al-8Si.-3Cu-2Zn nanocomposite reaches -5%WS2. According to the results of the wear tests, the wear rate for Al-8Si-3Cu-2Zn-5%WS2 will decrease by 32% %, compared to the Al-8Si-3Cu-2Zn alloy background. Therefore, Al-8Si-3Cu-2Zn-5%WS2 nanocomposite can be used as a self-lubricating nanocomposite with favorable wear properties.

In electrical discharge machining (EDM), a complete and clear theory has not yet been established. The developed theory (physical models) yields results far from reality due to the complexity of the physics. It is difficult to select proper parameter settings in order to achieve better EDM performance. However, modelling can solve this critical problem concerning the parameter settings. Therefore, the purpose of the present work is to develop mathematical model to predict performance characteristics of EDM on Ti-5Al-2.5Sn titanium alloy. Response surface method (RSM) and artificial neural network (ANN) are employed to develop the mathematical models. The developed models are verified through analysis of variance (ANOVA). The ANN models are trained, tested, and validated utilizing a set of data. It is found that the developed ANN and mathematical model can predict performance of EDM effectively. Thus, the model has found a precise tool that turns EDM process cost-effective and more efficient.

The use of agricultural residue has been considered an economic and environmentally friendly approach for development of aluminium composites. In this study, Al powder (Al) was reinforced with coconut shell ash (CSA), rice husk ash (RHA), and cassava peel ash (CPA) for enhanced physicomechanical performance of the resulting composites. Five samples (A o -Al, A 1 -Al + 15RHA, A 2 -Al + 5CSA + 5RHA + 5CPA, A 3 -Al + 15CPA, and A 4 -Al + 15RHA) were prepared in a two-step stir-casting technique and characterized based on physical, mechanical and metallurgical properties. Microstructural analysis revealed that all the particles bonded well with the aluminum alloy. The densities of samples A 1 , A 2 , A 3, and A 4 reduced by 4.78%, 7.75%, 11.44%, and 14.76%, respectively compared to the control sample A o while porosities rose by 2.1%, 2.23%, 2.56%, and 2.98% respectively. Sample A 2 has the highest tensile strength (39.84 MPa) and hardness (120 HBR) which denote 33.60% and 64.27% enhancement compared to the unreinforced sample. These observations can be attributed to the presence of intermetallic compounds such as Fe 3 Si and Al 6 Fe present in the composites as well as uniformly distributed and strongly bounded reinforcement within the aluminum matrix. The composite made from the combination of the three reinforcements gave the best physicomechanical properties and therefore recommended for engineering applications.

Light magnesium nanocomposites, offering great weight savings, have a great potential to be utilized in aerospace and automotive industries. They have also been attracted much attention to be evaluated as biomaterial recently owing to their in vitro biodegradability and biocompatibility properties. In the present research, the Mg3Zn/TiB2-CNT nanocomposites were successfully manufactured using mechanical alloying, cold compaction at 600 MPa and finally sintering at 560 °C for 1 h. Their microstructural, mechanical, wear and corrosion properties were investigated extensively for comparison with the Mg3Zn alloy. It was found that the microhardness of the Mg3Zn nanocomposites increased directly with the hybrid reinforcement ratio. In parallel to the hardness, an addition of 15 vol % TiB2-CNT reinforcement to the Mg3Zn alloy allowed to the improvement of the compressive strength by of 46.3 % at a reasonable ductility level of ∼7.8 % compared to the Mg3Zn alloy. The crystallite size, decreasing with an augmentation in the reinforcement content steadily, was obtained to be smaller than 100 nm for the bulk Mg3Zn nanocomposites. Moreover, the wear loss of Mg3Zn alloy reduced by ∼45 % upon the incorporation of 15 % hybrid reinforcement due to the occurrence of a stable tribolayer between the working couple. An additional benefit of the incorporation of hybrid reinforcement into Mg3Zn alloy was also obtained in the progress of corrosion resistance significantly. The corrosion rate was recorded to be 1462.6 mpy for Mg3Zn but it decreased to 276 mpy upon the incorporation of 10 % hybrid reinforcement into the alloy.

The present investigation is aimed at studying the effect of dispersoid content and effect of chill on microstructure and mechanical properties of aluminum alloy (LM 13) hybrid metal matrix composites reinforced with garnet and fixed 3wt.% carbon. The size of the garnet particles varies from 50 to 80 μm and amount of addition varies from 3 to 12 wt.% in steps of 3 wt%. By using chills of different material with different volumetric heat capacity (VHC), the effect on the microstructure evolution was examined. Stir casting process was used to produce chill cast aluminum alloy-garnetcarbon particulate composites in moulds containing various chills of copper, steel, iron and silicon carbide to accelerate the solidification. The fabricated composites were tested for their hardness and ultimate tensile strength properties according to ASTM standards. The effect of chill and reinforcement characteristics was presented and compared with the hybrid composite without chill material. Microstru...

The development of lightweight and high-performance materials has become a pivotal focus in automotive engineering due to the growing demand for energy-efficient and environmentally friendly vehicles. This research focuses on the use of Aluminium Metal Matrix Composites (Al-MMCs) as substitute materials for steel in the design and improvement of leaf springs, which are vital in vehicle suspension systems. By employing CAD modelling and FEA, the mechanical behaviour of the developed Al/SiC MMC and Al/B4C MMC leaf springs are analysed and compared under different static load conditions of 12,500 N & 17,500 N. The analysis focuses on deformation, stress distribution, and weight reduction compared to conventional steel leaf springs. These outcomes indicate that Al-MMCs can achieve up to 60% weight reduction with an improvement or comparable stresshandling capacity. Among all the materials, the stiffness and lower deformation at the maximum load indicate that Al/B4C MMC is a potential material for high-performance and lightweight vehicles. This study focuses on the potential of enhancing Al-MMCs for better fuel economy and vehicle performance by using sustainable automotive material choices. The results of this research will provide possibilities for other high-risk automotive applications of composite material by explaining the behaviour and performance of the material and new designs.

This paper presents wire cut electrical discharge machining (WEDM) response characteristics of Aluminium 7075 (Al7075) reinforced with powdered activated carbon (PAC) composite. In recent days WEDM has become a significant machining process in targeting its benefits of contributing improved material removal rate (MRR) and low surface roughness (SR). This is due the rising need for intricate, accurate, and superior structural components, the WEDM process emerges as a formidable alternative to traditional machine tools. In this work Pulse-on time (Ton), pulse-off time (Toff), discharge current (IA) and servo speed rate (SS) are the variables to be given as input and machining responses such as MRR and SR are studied. From Analysis of Variance (ANOVA) study it is found that discharge current and servo speed is the significant parameters. The optimal desirability condition is obtained with input parameters Ip: 2000 mA; Ton: 8.9 μs; Toff: 25 μs and SS: 150 rpm for the precision machining. The optimum response parameters are found as MRR 10.46 mm 3 /min and SR 3.32 μm. Results shows that the model designed for the prediction of MRR produces an above 98.27% and the prediction of SR is above 97.17%. The error percentage among the experimental and predicted MRR and SR were estimated. Additionally confirmatory test is performed with optimal results achieved from response surface methodology (RSM) and desirability technique. Metallurgical tests like electron backscatter diffraction analysis (EBSD) and microstructure are conducted to confirm the surface properties and atomic force morphology (AFM) analysis is applied to clarify the structural features of machined composites. The results revealed that the variation of hard deflection is caused by depression of eroded materials on the top layers of machined surface.