Exploration of Mechanical, Tribological, Corrosion and Machineability

Characteristics of Aluminum-based Metal Matrix, hybrid and nano Composites

Strengthened with ceramic reinforcements by various processing techniques
Mohammed Yunus, Rami A. AlFattani and Turki S. Alamro

Department of Mechanical Engineering, Umm Al Qura University, Makkah city, Kingdom of Saudi Arabia.

Abstract:

When better performance with low specific weight is required, Metal Matrix Composites
(MMCs) are effective at overcoming the primary drawback of conventional monolithic materials,
which is their combined lack of density and strength. Surface composites are currently preferred
over bulk composites because modern applications call for improved surface quality. Friction stir
processing (FSP) solves this problem with traditional methods since the treated zone does not
melt and recast. FSP is a cutting-edge method for solid state surface processing. Aluminum metal
matrix composites (Al-MMCs) are commonly used in aerospace, automotive, sports goods, and
military applications because of its high strength-to-weight ratio, improved wearability, and
resistance to corrosion. The present project aims to create high-performance, unique aluminum
surface composites using FSP. This will be performed by altering the Yttria nanoparticle
concentrations (4,7.5, 10 vol%) and further examining the Al matrix's functionality and
fundamental performance. This study will examine the distribution of yttria, grain refinement,
density, improvement of tensile strength and micro hardness, fracture surface analysis, and wear
behavior. Using optimization approach, the ideal settings for lowest wear rate and friction
coefficient will be investigated.
Keywords: Aluminium Metal matrix composites; Corrosion behavior; Surface composites; Machinabilty;
Friction Stir Processing.

1. Introduction:
The development of lightweight materials has given the automobile industry a number of options for
reducing vehicle weight. Because fuel consumption and vehicle weight are directly correlated, reducing
the weight of a vehicle can improve its fuel efficiency and price-to-performance ratio. Development of
new materials, methods of processing, and surface and thermal treatments are essential to this field's
advancement. Composites made from several types of structures that satisfy the demands of specified
design and function are packed with desirable characteristics that restrict the scope for classification.
According to the kind of base material utilized, such as metal, polymer, and others, composites may
generally be divided into three categories: metal matrix composites, ceramic matrix composites, and
polymer matrix composites. Additionally, the composites are divided into three categories based on the
type of reinforcing substance used: Laminar Composites; Short Fiber; Long Fiber; Fiber Reinforced
Composites In addition to these primary divisions, composites are further divided into a variety of names,
including metal-ceramic composites, metal-metal composites, and others, depending on the kind of
matrix and reinforcing material used. Typically, a composite's qualities are superior than those of its
parent components, like as High strength to weight ratio; superior wear resistance; light weight; elevated
strength and stiffness; improved joining qualities; ease of casting, etc.

To generate relative motion via sliding or rolling, there must be friction. Friction is often divided into two
categories: dry friction and fluid friction. Abrasive wear is described as wear that occurs when a hard
surface moves against a softer surface and creates a groove later. This abrasive wear is the cause of the
majority of failures in the real world. Abrasive wear is produced when hard particles or asperities on one
of the sliding surfaces develop a cut or groove. This hard object or substance might have come from the
environment or one of the sliding pairs. Sticky Wear Adhesive wear happens when there is a constrained
bonding between the contacting or sliding surfaces, which results in material loss from each surface or
relocation from one surface to another of the sliding pairs. The condition for adhesive wear to happen is
that the sliding surfaces must be in close contact. Thin lubricating films, oxide coatings, and other
materials can be used to separate the sliding surfaces in order to lessen the likelihood of adhesive wear
happening. Accretive Wear When solid particles impact a surface, it results in material loss or removal
from the surface, which is known as erosive wear. A liquid or gas that may or may not carry entrained
particles imposing on a surface can also generate erosive wear or erosion. When the particle impingement
angle is minimal, the erosive wear resembles the abrasive wear extremely closely. On the other hand,
when the particle impingement angle is significant, the material will be removed by plastic flow or brittle
fracture dislodging. Wears from Surface Fatigue Wear on the solid surface is caused by fracture that
results from material fatigue. The term "fatigue" is typically used to describe failure that occurs when a
solid is subjected to opposing cycle loads, such as tensile and compression over specified stress values.
The production of microcracks on the subsurface under repetitive stress on the surface, which is mostly
on the weaker places, is the same phenomena that happens here. This tiny fracture begins to spread when
cyclic force is applied repeatedly, leading to material loss. Vibration, which results in cyclic loading, is
the primary source of fatigue wear.

Corrosive Wear (v) The majority of materials used in real-world applications are not thermodynamically
stable, which causes them to interact with airborne oxygen to produce oxide films. When exposed to
glide across other surfaces, the inadequate adhesion between these layers and the material surface made
removal simple. Unprotected metal surfaces slowly deteriorate due to corrosion wear, which can be
brought on by the environment, acids, gases, alkalis, etc. Electrical sparks are produced by electrical
energy, and the thermal energy (heat) generated by the electrical sparks removes the substance. The
fundamental idea behind electro discharge machining is this.
EDM is an unusual machining method that is primarily used to machine materials that are challenging to
work with conventionally. Complex geometries in sizes ranging from tiny to big that need to be
electrically conductive can be machined using EDM. Polymers, for instance, cannot be machined with
EDM because they are not electrically conductive. Generally speaking, there are two sorts of EDM
applications: EDM die sinking • EDM wire cut While a thin conducting wire is used in wire cut EDM to
cut the materials, die sinking EDM uses a solid conductive tool with the necessary shape. Also known as
spark, wire EDM A lean single-strand metal wire is used in EDM, a form of electrical discharge
machining, to ignite work material in the presence of dielectric fluid (generally de-ionized water).
WEDM is typically used to cut plates up to 300 mm thick and to make punches, tools, and dies out of
hard materials that are difficult to process using conventional methods. The residual stress on the
machined surface is minimal since larger cutting forces are not used. Because of these low residual
stresses, even if material that has not been stress-relieved might flex during the machining process, slight
changes in the mechanical characteristics of the machined material are estimated if energy/power each
pulse is sufficiently modest (as in the finishing process). Due to the inherent characteristics of this
technique, wire EDM makes it simple to produce complex components and precise works out of hard
conductive materials. The majority of research focus in the areas of advanced engineering and automotive
applications has been on aluminum-based MMCs since they outperform an unreinforced aluminum alloy
in terms of mechanical, microstructural, and tribological features [1].

The reinforcing material and matrix should be carefully chosen in order to provide these all-
encompassing properties. Based on careful consideration, the reinforcing material is chosen. Based on its
chemical composition, ability to wet the reinforcement, dispersion, and bonding with the matrix alloy, the
reinforcement material is carefully chosen. Strong tensile strength, low density, high thermal
conductivity, and hardness are all characteristics of the reinforcing materials. The stir casting technique
(SCT) is the most common and simple method for producing MMCs [2]. In this process, ceramic
reinforcement material is added to a liquid aluminum melt before the mixtures are allowed to solidify up.

2. Research Objectives:
• Creation of a high-strength aluminum surface composite based on different combinations of ceramic
reinforcements like yttria, Silicon carbide, silicon nitrides, boron nitride, boron carbides etc.
• Examining the influence of variables on mechanical, tribological, machining and corrosion properties
and determining the ideal setting to improve strengths, wear, type of environment and machinability
behavior for newly created hybrid, nano composite materials.
• Analyzing the impact of machining settings while they are being used for determining the ideal
parameter combination for non-traditional machining of the newly created composite like wire-EDM,
water jet machining etc.
• Multi performing characteristics improvement for enhanced multi quality attributes of various
characteristics mentioned above.

3. Materials and Methodology:

The following headings summarize the key aspects of this work: The fabrication of metal matrix
composites, hybrid and nano composites (MMC), microstructure study of MMC, optical microscopy,
scanning electron microscopy, mechanical behavior investigation, tensile strength testing of MMC,
microhardness testing of MMC, density testing of MMC, impact strength testing of MMC, corrosion
behavior investigation, wear behavior investigation, dry sliding,

Understanding the distribution pattern of reinforcement, the bonding between reinforcement and
matrix, and determining the porosity in the composite are the key goals of microstructure studies.
Magnesium can be added to the composite during production to lessen its porosity.

3.1. Optical Microscopy:

Understanding the structure of materials is a common purpose for the optical microscope. A grain's size,
shape, and organization may all be seen under an optical microscope. The detection of fracture,
checking for corrosion, and assessing surface contamination are some of the other primary uses of
optical microscopy in material analysis.

3.2. Scanning Electron Microscopy:

It is a tool that is mostly used to see the sample's surface. Scanning electron microscopy provides insight
into the uniformity of the reinforcements in the matrix. Additionally, details on the crystalline structure,
the orientation of reinforcements, and the chemical makeup may all be discovered. From a chosen spot
on the sample, the aforementioned information can be taken. The following details can then be shown
in a two-dimensional picture that is created. Understanding phases based on crystalline structure may
also be accomplished using the SEM.

3.3. MECHANICAL BEHAVIOUR INVESTIGATION The material is highly suited for engineering applications
if it has good mechanical qualities. The material frequently has to be bent into a certain shape for a
variety of uses. Applying external tension will do this.Therefore, it is crucial to have a thorough grasp of
the material's mechanical behavior.

The material with good mechanical properties is well suited for engineering applications. In many cases,
the material has to be deformed to a particular shape for various applications. This can be done by
applying external stress. Therefore a proper understanding of the mechanical behavior of the material is
essential.

3.3.1. Tensile Strength Testing of MMC:

Tensile strength is the term used to describe a material's capacity to bear a tensile load. Tensile stress
will be applied to the material in engineering applications. The attribute is referred to as ductility if the
material can flex when subjected to tensile stress. The material's ductile characteristic causes it to flex
and might be viewed as a warning before breakdown. The fragile material won't give this warning and
will instantly fracture. Due of this, ductile materials are frequently chosen over brittle ones in
engineering applications. Tensile testing is the most effective way to determine how ductile a material
is.The Universal Testing Machine is often used to conduct the tensile test. The reinforcements will
improve the slip mode transition, which will improve the material's ductility.

3.3.2. Microhardness Testing of MMC:

A key factor in decreasing material wear and tear, according to MMC testing, is hardness. Basically, the
capacity of a material to resist indentation may be referred to as its hardness. Up to a certain point,
adding reinforcements will enhance toughness. The reinforcements will widen the grain boundaries,
which will help the material withstand deformation.

One crucial physical characteristic is density.

By applying the Archimedes principle, it may be assessed.

It is crucial to practical application, particularly in the field of transportation.

The density of the composite material will rise with the addition of reinforcements.

There shouldn't be any more variety.

Numerous applications in the field of engineering can make use of materials with a lower density and
higher strength.

3.3.3. Density Testing of MMC:

A key factor in decreasing material wear and tear, according to MMC testing, is hardness. Basically, the
capacity of a material to resist indentation may be referred to as its hardness. Up to a certain point,
adding reinforcements will enhance toughness. The reinforcements will widen the grain boundaries,
which will help the material withstand deformation.

Materials having a lower density and better strength are useful in many technical applications. One
crucial physical characteristic is density. By applying the Archimedes principle, it may be assessed. It is
crucial to practical application, particularly in the field of transportation. The density of the composite
material will rise with the addition of reinforcements. There shouldn't be any more variety.

3.3.4. Impact Strength Testing of MMC:

Compared to alloys, composite material exhibits low resistance to localized loading. Impact testing is
crucial for composite materials because of this. The kind, size, form, and grain orientation of the
reinforcement will all affect how the material responds to an impact load. Through the absorption of
kinetic energy through elastic and plastic deformation, the material will be able to withstand an impact
load. As was already noted, composite materials have a lower propensity for plastic deformation as
compared to alloys. Charpy Pendulum Test and Izod Test are the two most used impact testing
techniques.

3.4. CORROSION BEHAVIOUR INVESTIGATION:

Corrosion is a destructive phenomena that results in material degradation and, in the end, structural
failure. When choosing materials for a product, the corrosion rate is a crucial consideration. Some of the
factors that contribute to metal corrosion include the environment, temperature, acids, stress
concentration, and fractures. Both general corrosion and pitting corrosion apply to it. Giving a material a
protective coating, po larizing it, and adding corrosion inhibitors are a few ways to reduce the rate of
corrosion. Corrosion research is crucial in the world of materials since it may reduce material losses and
preserve the materials.

3.5. WEAR BEHAVIOUR INVESTIGATION:

In material tribology, wear rate is a crucial feature. It may be described as the gradual elimination of
substance. Two sliding surfaces' mutual friction is the primary cause of wear. Cutting tool wear will
lower production quality. A structural change, plastic deformation, surface fissures, corrosion, and
material gain are some of the other significant impacts of wear. To forecast wear in industrial
applications, a thorough material wear research is required.

3.5.1. Dry Sliding:

One solid surface above the other while under stress allows for the study of dry wear rate. Adhesion,
abrasion, and surface roughness are the key contributors to dry wear rate. The load, speed, and distance
are the three primary variables in a dry wear rate research. Retaining reinforcements will help us lower
the rate of wear.

3.5.2. Wet Sliding:

Understanding how materials will operate in a wet environment is crucial. Friction will be decreased by
lubricating oil application. Lubricating oil will be given continuously during wet sliding. The specimen's
wear rate is then assessed under various normal load, sliding speed, and sliding distance conditions. Wet
sliding will result in a lower wear rate than dry sliding.

3.6. FUZZY LOGIC MODELING:

The system is described through fuzzy logic modeling employing a combination of linguistic and
numerical variables. It may be created in a short amount of time. In contrast to conventional modeling
approaches, it requires minimal or no training data. It can also be modeled using shaky or insufficient
data. It may be applied to describe nonlinear and uncertain functions. In addition to being cited by
Suresh et al., this modeling approach may be used to a variety of operating circumstances.

3.7. OPTIMIZATION:

Optimizing is mostly done to reduce waste and increase desired features. Following the experiment, it is
possible to examine the results and do optimization. After analyzing the reaction based on the
combination, calculating the, and modeling the experimental results, it is possible to carry it out. The
goal of optimization is to get the most done with the least amount of resources.

Followings are the various investigations will be carried out.

 In this present study, the main focus will be on the dry sliding wear and abrasive wear properties of
the developed composite materials may include wear studies under wet and high temperature
conditions.

 In this present work, Machinability characteristics of the developed composites are studied under
milling, drilling process only. Hence, other traditional machining processes such as drilling, turning and
non-traditional machining processes such as ECM and WEDM can also be considered for machinability
studies.

 Random optimization techniques such as particle swarm algorithm, genetic algorithm, simulated
annealing algorithm and ant colony algorithm will be employed to optimize the input parameters in
wear and machinability studies.

 The effects of the reinforcing phase on the mechanical behavior of the developed composites will also
be studied by conducting experiments such as compression test, impact test and fatigue test.

 The corrosion behavior of the fabricated composites can be studied in detail under various acidic
environments to analyze the influence of reinforcements on corrosion resistance of the composites.

4. Outcomes of the research work

1. Other available fabrication techniques such as friction stir Processing, powder metallurgy and
squeeze casting, spark plasma sintering etc. will be tried and analyzed so that a final conclusion in
terms of more appropriate fabrication technique can be drawn.
2. The variety of Aluminium based metal matrix, hybrid metal matrix and nano composites can be
prepared through various technologies.
3. Based on the statistical analysis, various input factors affecting mechanical, electrical, tribological,
corrosion and machining characteristics to determine the most significant process parameters
affecting tensile strength, flexural strength, impact, wear, machining outputs, corrosion strength etc.
5. High end properties like tensile strength, higher stiffness, Higher flexural strength, Impact strength
will extend them their applications in the different fields like harsh environments where material has
to withstand severe conditions.
6. Improved SEM and XRD analysis would suggest the presence of different reinforcements in
Aluminium based composites.
7. It will make more advanced material.

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