Aluminium reinforced with SiC, Al2O3 and B4C etc. possesses an attractive combination of properties such as high wear resistance, high strength to weight ratio and high specific stiffness. Among the various reinforced materials used for aluminium, B4C has outperformed all others in terms of hardening effect. Particle size reduction of B4C is found to have positive impact on the material hardness. In the view of physical properties, B4C has less density than that of SiC and Al2O3, which makes it an attractive reinforcement for aluminium and its alloys for light weight applications. In this work, Al nano B4C composite prepared by ultrasonic cavitation method was machined by Abrasive assisted electrochemical machining using cylindrical copper tool electrodes with SiC abrasive medium. In this paper, attempts have been made to model and optimize process parameters in Abrasive assisted Electro-Chemical Machining of Aluminium-Boron carbide nano composite. Optimization of process parameters is based on the statistical techniques using Response Surface Methodology with four independent input parameters such as voltage, current, abrasive concentration and feed rate were used to assess the process performance in terms of material removal rate and surface finish. The obtained results were compared with abrasive assisted electro chemical machining of Aluminium-Boron carbide micro composite and the effect of particle size on the process parameters was analyzed.
Recent researches in the domain of casting confirmed that the mechanical properties of aluminum and magnesium based nanocomposites can be appreciably enhanced when ultrasonic cavitation assisted solidification processing is used. Ultrasonic cavitation assisted solidification processing is used for the manufacturing of aluminum and magnesium alloy based metal matrix nanocomposites reinforced with nanoceramic particles. In this solidification processing, formation of clusters have been minimized and the nanoreinforcements were distributed uniformly in aluminum and magnesium matrix nanocomposites. The ultrasonic assisted casting approach will manage the grain dimensions via minimizing agglomeration of nanoparticles in metal matrices. This paper opinions the properties and morphology of aluminum and magnesium based metal matrix nanocomposites fabricated through ultrasonic assisted casting process.
In this work, aluminum (Al) alloy reinforced with boron carbide (B4C) nanoparticles were fabricated using ultrasonic assisted casting process. To investigate the effect of ultrasonic power on processing the metal matrix nanocomposites (MMNCs), the MMNC samples were processed with 1.0 kW, 1.5 kW and 2.0 kW of ultrasonic power. The results indicate that the ultrasonic power play a significant role in dispersing the B4C nanoparticles uniformly in Al melt and it also affects the mechanical properties of the fabricated MMNCs. From microstructural analysis it was observed that the MMNC sample processed with 2.0 kW ultrasonic powers possessed the good dispersion of B4C in the Al melt which is the prime criteria for the good mechanical properties.
Aluminum alloy 6061 reinforced with 1.0 weight percentage of Silicon Carbide (SiC) nanoparticles were fabricated using the novel ultrasonic cavitation assisted stir casting approach. Three types of nanoparticle feeding mechanisms were attempted for fabricating the metal matrix nanocomposites. The fabricated nanocomposites were subjected to tension test, hardness test and scanning electron microscopic analysis. From the tested results, it was found that feeding the particles using Al foils followed by ultrasonic cavitation proved as a suitable method for obtaining the better mechanical properties of the fabricated nanocomposites. Scanning electron microscopy analysis confirmed the uniform dispersion SiC in Al matrix by capsule feeding method. Energy dispersive spectroscopy validates the incorporation of SiC in Al matrix.
In recent years, aluminum alloys reinforced with nanosized ceramic particulates are finding wider applications in various engineering industries like automobile, aircraft, electronics and sports. The requirement of accurate machining of nanocomposite has also gets increased. In this research work, aluminum alloy 6061 reinforced with 1.5 Wt. % of nanoB4C particulate was fabricated in cylindrical shape using ultrasonication assisted casting process. Medium duty lathe with poly crystalline diamond insert tool of 1600 grade was used to turn the Al/B4C nanocomposites. During turning of Al/B4C nanocomposites, cutting parameters like depth of cut, speed and feed were varied as per predefined level. Surface roughness of machined surface and power consumption during machining were measured using surface roughness tester and wattmeter respectively. ANOVA analysis was carried out and the optimum parameters for machining the nanocomposite were found out using MINITAB software. The nanocomposite machined with optimum parameters show good surface finish and consumed minimum power.
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