Mechanical properties of melt infiltration and powder metallurgy fabricated aluminum metal matrix composite

Abstract

Metal foams have drawn an increasing interest especially in applications where weight and energy absorption are critical. Despite the extensive studies available on their characterization and enhanced fabrication techniques, limited work was found on the possibility of producing a porous composite foam. The objective of this article is to investigate two new synthesis techniques for manufacturing metal matrix composite foam that is, powder metallurgy and melt infiltration. Both techniques are studied using Sodium Chloride (NaCl) as a space holder in an aluminum-based metal matrix and graphene nanoparticles as reinforcements. The effect of the quantity added of both the space holder and graphene is studied using designed experiments. Although powder metallurgy provided lower baseline hardness, experimentation results suggest the superiority of the process over melt infiltration in terms of porosity and hardness. Results suggest that baseline aluminum hardness can be increased by up to 21.5% using powder metallurgy and 15% using melt infiltration. In terms of porosity, powder metallurgy porosity increased baseline more than ten folds while melt infiltration only doubled the baseline porosity. Moreover, it is easier to control the macroscopic shape, density, and distribution of the pores using powder metallurgy. It is also easier to disperse the reinforcement homogenously. Results will support several industries such as military, automotive, medical, and aerospace in developing this innovative material with superior properties and coping with their need for advanced applications.

An Overview of the Mechanical and Tribological Characteristics of Non - Ferrous Metal Matrix Composites for Advanced Engineering Applications

“…The high percentage of micro porosities in the composite fabricated via powder metallurgy was due to un-sintered material and oxide formation while porosities in the composite prepared via melt filtration was due to gas trapped in the melt. [39] CuCrZr/CuZrAl Metallic glass Spark plasma sintering Volume fraction of metallic glass affected the electrical conductivity of the composite. There was an improvement in electrical conductivity for metallic glass content less than 30 wt.…”

Microstructure and Mechanical Properties of Metal Foams Fabricated via Melt Foaming and Powder Metallurgy Technique: A Review

“…In addition, the microstructure of metal foams is also influenced by the fabrication technique used. Table 1 shows the various studies on the morphology and microstructures of metal foams developed by melt foaming and powder metallurgy The microstructures of metal foams formed using different foaming agents and space holders have been mentioned [ 48 , 49 , 50 , 51 , 52 , 53 , 54 , 55 , 56 , 57 , 58 ].…”

Effects of simultaneous rotational ultrasonication and vortex-induced casting technique on particle distribution and grain refinement in AA7075/h-BN nanocomposites

“…The most common cost-effective bulk fabrication methods for synthesizing nanocomposites are as follows: stir casting, ultrasonic-assisted casting, and infiltration casting process. 12,18…”

“…The most common cost-effective bulk fabrication methods for synthesizing nanocomposites are as follows: stir casting, ultrasonic-assisted casting, and infiltration casting process. 12,18 The properties of AA7075 nanocomposites fabricated by the mechanical stirring process were analyzed by several researchers. Baradeswaran and Elaya 19 fabricated AA7075 with Al 2 O 3 and graphite particles using the mechanical stirring method.…”