Characterization, machinability studies, and multi-response optimization of AA 6082 hybrid metal matrix composite

Abstract

This work investigated the effect of carbonized eggshell and fly ash on the microstructure, mechanical properties and machinability of AA 6082. The fabrication method selected for this study was stir casting. For the hybrid metal matrix composite, the weight fraction was 2.5wt% carbonized eggshell and 2.5wt% fly ash. The microstructural examination of the cast composite showed an even dispersal of the reinforcing phases in the aluminium matrix. Density analysis saw a 10.66% reduction of the cast composite in comparison to the aluminium alloy. Improvements of 12.32%, 21.91%, and 8.30% were recorded for the microhardness, tensile strength and compressive strength respectively. The wear studies of the cast samples revealed coefficients of friction (CoF) of 0.499 and 0.290 for the base metal and the AMC respectively. For the machinability studies, the surface roughness and flank tool wear were the responses under consideration. The design of experiments was conducted using the Taguchi method. The input parameters for this investigation was the cutting speeds (100 mm/min, 200 mm/min, 300 mm/min), feeds (0.1 mm/rev, 0.2 mm/rev, 0.3 mm/rev) and depths of cut (0.5 mm, 1.0 mm, 1.5 mm). For the multi-response optimization, Taguchi based grey relational analysis was used. The analysis of variance (ANOVA) of the grey relational grade (GRG) revealed that the feed was the most influential factor on the surface roughness and tool wear. The initial optimization showed the optimal cutting speed, feed and depth of cut as 200 mm/min, 0.2 mm/rev and 1.5 mm respectively. The confirmatory experiments revealed that the optimal combination of factors was 200mm/min, 0.2 mm/rev and 0.5 mm for the cutting speed, feed and depth of cut respectively.

Carbonization Temperature and Its Effect on the Mechanical Properties, Wear and Corrosion Resistance of Aluminum Reinforced with Eggshell

“…The wear parameters selected for the study were 20 N, 120 mm, 120 s, and 1 mm/s for the applied load, sliding distance, sliding time, and sliding velocity, respectively. The volumetric wear rate was determined using the Archard equation shown in Equation (2).…”

“…The tribology study of the cast samples under consideration was done by analyzing the coefficient of friction (COF) and the volumetric wear rates. The wear rates were obtained using Ackards's equation shown in Equation (2). Results from the COF depicted in Figure 6 show that the wear-resistant properties of samples C1 and C4 (900 and 1200 • C, respectively) were improved relative to the base metal.…”

“…Aluminum matrix composites (AMCs) are being sought after owing to their attractive mix of properties not limited to good strength-to-weight ratio, high stiffness, and good corrosion resistance [1]. This has opened up potential areas of application not limited to aerospace, marine, and automobiles [2]. The advent of aluminum matrix composites highlighted the use of synthetic materials as reinforcements.…”

Corrosion Properties of Aluminum Alloy Reinforced with Wood Particles

“…The composites formed from aluminum have been used in manufacturing roofing sheets, electronic packaging applications, and other household items such as aluminum foil due to their good thermal properties and light weight [7][8][9][10]. In recent years, aluminum matrix composites (AMCs) have been widely developed, especially with the use of easily sourced agricultural residue as reinforcement [11]. Furthermore, AMCs have been used in microelectronics, bicycles, and golf clubs due to their high resistance to corrosion and light weight [6,11,12].…”

“…In recent years, aluminum matrix composites (AMCs) have been widely developed, especially with the use of easily sourced agricultural residue as reinforcement [11]. Furthermore, AMCs have been used in microelectronics, bicycles, and golf clubs due to their high resistance to corrosion and light weight [6,11,12]. The selection of fabrication routes has also been one of the criteria for developing aluminum composites.…”