Development of Hot Equal Channel Angular Processing (ECAP) Consolidation Technique in the Production of Boron Carbide(B4C)-Reinforced Aluminium Chip (AA6061)-Based Composite

Abstract

The production of metal matrix composites (MMCs) through recycled materials is a cost-saving process. However, the improvement of the mechanical and physical properties is another challenge to be concerned. In this study, recycled aluminium 6061 (AA6061) chips reinforced with different volumetric fractions of boron carbide (B4C) were produced through hot equal channel angular processing (ECAP). Response surface methodology (RSM) was carried out to investigate the dependent response (compressive strength) with independent parameters such as different volumetric fractions (5-15%) of added contents of B4C and preheating temperature (450 – 550°C). Also, the number of passes were examined to check the effect on the mechanical and physical properties of the developed recycled AA6061/B4C composite. The results show that maximum compressive strength and hardness of recycled AA6061/B4C were 59.2 MPa and 69 HV respectively at 5% of B4C contents. Likewise, the density and number of pores increased, which were confirmed through scanning electron microscope (SEM) and atomic force microscopes (AFM) analysis. However, the number of passes enhanced the mechanical and physical properties of the recycled AA6061/B4C composite. Therefore, the maximum compressive strength and hardness achieved were 158 MPa and 74.95 HV for the 4th pass. Moreover, the physical properties of recycled AA6061/B4C composite become denser of 2.62 g/cm3 at the 1st pass and 2.67 g/cm3 for the 4th pass. Thus, it can be concluded that the B4C volumetric fraction and number of passes have a significant effect on recycled AA6061 chips.

Response surface methodology and machine learning optimisations comparisons of recycled AA6061-B4C–ZrO2 hybrid metal matrix composites via hot forging forming process

“…Table 3 demonstrates the experimental design and predicted model UTS strength, RSM findings of tensile strength responses were generated after multiple number of experiments which investigated the parameters of preheating temperature, ZrO 2 and B 4 C volume fraction proportions. The presented pareto chart determines the factors magnitude which are crossing the line reference where, the reference lines confirm that the investigated parameters are significant absolute values cause interactions between parameter towards to the UTS materials strength [ 2 , 49 , 50 ].…”

“…Due to economic constraints, production difficulties and materials modification limitations, process enhancement is necessary to achieve further improvement in cost savings, efficiency enhancement, and hybrid material properties. Over the past two decades, composites made from recycled Al-alloys have taken the lead in light metal processing techniques, specifically through solid-state recycling (direct recycling) [ 1 , 2 ] (see Fig. 12 ).…”

Recent Advancements in Material Waste Recycling: Conventional, Direct Conversion, and Additive Manufacturing Techniques

“…Using continuous dynamic recrystallization, they achieved ultra-fine grain structure. Alimi et al [253] recycled AA6061chips reinforced with different volumetric fractions of boron carbide using ECAP. The results indicated that boron carbide and the number of passes have a significant effect on the recycled AA 6061 chips.…”

Recycling Aluminium AA6061 Chips with Reinforced Boron Carbide (B4C) and Zirconia (ZrO2) Particles via Hot Extrusion

“…The highest reported values of compressive strength were samples one and five. The material properties were strengthened by producing dislocations that pile up the total work hardening of the processed deformed specimens [38]. Therefore, the compression strength differed depending on the percentage values of reinforced particles mixed to aluminium AA6061 chips during the forming process.…”