This paper presents an experimental and statistical study of the fatigue behavior of unidirectional glass fiber-reinforced epoxy composite rods manufactured using pultrusion technique and modified with nanoparticles of alumina (Al2O3) and silica (SiO2) at four different weight fractions (0.5, 1.0, 2.0 and 3.0 wt.%). Tensile test was performed to investigate the influence of nanoparticles. Addition of alumina nanoparticles up to 3 wt.% increases the tensile strength by 54.76% over the pure glass fiber-reinforced epoxy specimen. For silica nanoparticles, there is an increase in the tensile strength of 31.29% for the content of 0.5 wt.% over the pure glass fiber-reinforced epoxy specimen. As the silica nanoparticles’ content increases over 0.5 wt.%, there is a decrease in the tensile strength. Rotating bending fatigue tests have been conducted at five different stress levels. Fatigue life of glass fiber-reinforced epoxy composite rods modified with alumina nanoparticles increases as the content of the nanoparticles increases. The effect of adding silica nanoparticles on the fatigue life of glass fiber-reinforced epoxy composite rods is relatively insignificant with a small improvement in the content of 0.5 wt.% silica above the pure glass fiber-reinforced epoxy specimens. Two-parameter Weibull distribution function was used to statistically analyze the fatigue life data.
Friction stir processing (FSP) is a modern manufacturing strategy for improving the surface characteristics of materials by modifying their surface via localized plastic deformation. This research focuses on optimization process parameters for tungsten carbide-reinforced 6061 aluminum alloy surface composite using FSP. The effect of the process parameters including tool rotational speed, transverse feed, number of passes, and tungsten carbide particles volume fractions, on ultimate tensile strength (UTS) and grain size of fabricated AA6061/WC surface nanocomposites are investigated. For four factors and three levels, the L27 Taguchi technique is used to formulate the experimental design. The analysis of variance (ANOVA) is used to determine the significance and the percentage contribution of each parameter. The desirability approach is used to optimize the process parameters in terms of tensile strength and average grain size. The results indicate that the proper selection of FSP parameters results in a homogeneous distribution of the WC particles throughout the matrix thereby producing a defect-free AA6061/WC nanocomposite without voids. Also, the severe plastic deformation and heat generation during FSP causes the breaking of coarse particles, WC particles, elimination of porous holes and creates an ultrafine grain-sized structure via dynamic recrystallization. Furthermore, it was concluded that the transverse feed is the most significant factor for ultimate tensile strength with 40.1% contribution whereas the number of passes is the most significant factor for grain size with a 34.7% contribution. The optimum combination of the current process parameters is found to be 1800 rpm rotation speed, 120 mm/min transverse feed, 4.3636% volume fraction, and 3- pass for optimum values of UTS and grain size. The surface composite developed in this work is considered appropriate material for applications requiring lightweight and improved surface properties, such as aerospace, automotive, marine, defense and transportation industries.
Friction stir processing (FSP) is a solid-state microstructural modification technique that has recently become an effective tool to refine microstructures and improve the mechanical properties of metals. In the current study, optimization of FSP parameters, including tool rotational speed, transverse feed, number of passes, and tungsten carbide (WC) nanoparticle volume fractions on mechanical and wear properties of the fabricated AA6061/WC nanocomposite was studied. Optical microscopy and scanning electron microscopy are used for microstructural observations. The process parameters are optimized using the Taguchi technique for single responses towards microhardness and weight loss and the Desirability approach for both responses. The percentage contribution of process parameters is estimated using analysis of variance. The microstructure observation shows that the proper selection of FSP parameters leads to a homogeneous dispersion of the WC particles throughout the matrix, thereby producing a defect-free AA6061/WC nanocomposite without voids. Also, the severe plastic deformation and heat generation during FSP cause the breaking of coarse particles, WC particles, and porous holes and create an ultrafine grain-sized structure via dynamic recrystallization. The results indicated that the microhardness value of the processed composite was found to be 144 VHN, which is 39.81% higher than that of the base metal. Also, the weight loss of all samples decreased as compared to the base metal. Also, it can be observed that the number of passes is the most significant factor for microhardness, with a 40.1% contribution, and for minimum weight loss, the volume fraction is the most significant factor, with a 56.94% contribution. The optimum process parameter combination was found to be 1800 rpm rotation speed, 120 mm/min of transverse feed, 6% volume fraction, and 3 passes that resulted in obtaining optimum values for micro hardness and weight loss. The surface composite developed in this research is considered a suitable material for applications demanding lightweight and enhanced surface properties, including automotive, aerospace, marine, defense, and transportation industries.
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