Experimentation and Optimization of Multilayered Aluminum-Based Functionally Graded Materials

Abstract

According to current industrial and societal demands, product manufacturing is now highly competitive. The current research is primarily focused on the creation of functionally graded materials that are essential for automotive cylinders and their internal components. Since aluminum plays a significant role in automobile components, layerwise deposition of the matrix and reinforcements is used. Aluminum alloy (Al 356) was investigated in weight proportions of 100, 95, and 90%, while the reinforcement varied from 0 to 7.5%. The particulate reinforcements were chosen to be silicon carbide (SiC) and nickel (Ni). Zinc stearate is used as lubricating agent to enhance the free-flow compaction process and to avoid the wastage in synthesis. The compressed specimens were examined for various mechanical and microstructural characterization. An ultimate compressive strength of 328 MPa and 68 BHN was achieved at 85% Al, 5% SiC, and 7.5% Ni, as per research criterion. Scanning electron microscopy (SEM), energy dispersive X-ray analysis (EDAX), and X-ray diffraction analysis (XRD) images of the inclusions and matrix are compatible and compact due to the excellent bonding. The process variables were adjusted using Taguchi optimization, which shows that the sintering duration and compaction pressure are crucial for the validation of manufacturing and characterization.