Effects of milling time on sintering properties and formation of interface Al4C3 on graphite reinforced Al-4.5Cu-1.5Mg nanocomposite

Abstract

Aluminum-based metal matrix nanocomposites have been extensively researched and developed for aerospace and automotive applications. Al-4.5Cu-1.5Mg with 0.5 wt% graphite were milled for 2 h, 4 h, 6 h, and 8 h using shaker mill under argon gas. The phenomena of deformation, fracturing, and cold welding during shaker mill were investigated to observe how the shaker mill effects on their morphology and formation of intermetallic phases due to its very high speed. Sintering under ultra-high purity argon gas for 99.9999% was done to produce high density materials. Intermetallic phase Al4C3 was found as a result reaction between aluminum and graphite during milling. Formation of Al4C3 is very important to the alloy as an interface between matrix and reinforcement particle in order to have higher hardness. A decrease in Peaks Cu and followed by an increase in Al2Cu precipitation in the XRD pattern occurred with increasing milling time. The role of Al2Cu precipitation is very important in improving mechanical properties, resulting in the highest hardness value reaching 97 HV and a density value of 83% at 8 h of milling.

Producing Metal Powder from Machining Chips Using Ball Milling Process: A Review

“…According to the above review, ball milling is a widely used process and has advantages for grinding materials into fine powders or slurries for various applications [ 55 , 124 , 125 ]. Critical processing parameters, such as rotation speed, grinding time, and ball-to-powder ratio, can significantly affect the efficiency and outcome of the grinding process [ 157 , 158 ]. A higher ball-to-powder ratio can improve process efficiency but also increases wear on the grinding media and jar [ 157 , 159 ].…”

“…Therefore, it is crucial to take into account both the material properties and the desired output when determining the optimal processing settings. Additionally, it is possible to use alternative materials for ball mill jars and balls based on specific application requirements [ 158 , 160 ]. Despite these considerations, the ball mill process remains a versatile and significant tool across various industries.…”

“…The most challenging feature of a powder particle is its hardness; hence knowing its hardness is crucial when selecting milling media [ 158 , 163 ]. The more efficient the mill, the tougher the milling medium will impact on the quality of final products [ 164 ].…”

“…The size of the balls can range from a few millimeters to several centimeters in diameter, depending on the application and the desired grinding outcome [ 120 , 173 ]. The ratio of the grinding media to the material being ground, known as the ball-to-powder ratio, can also have an impact on the grinding outcome [ 72 , 158 , 174 , 175 , 176 ]. A larger ball-to-powder ratio typically results in a more efficient milling process but may also lead to increased wear on the grinding media and jar [ 72 , 114 , 146 , 174 , 177 ].…”

“…Therefore, a novel method of recycling copper chips and transforming them into tiny particles using a ball mill needs further investigation. In future trends, researchers are currently exploring ways to improve this method and utilize it in the synthesis of innovative materials with unique characteristics and functionalities [ 74 , 129 , 158 ]. Additionally, including industrial case studies or collaborating with industry partners (with appropriate confidentiality agreements) can help bridge the gap between academic research and real-world applications.…”