Parametric Optimization of Powder-Mixed EDM of AA2014/Si3N4/Mg/Cenosphere Hybrid Composites Using Fuzzy Logic: Analysis of Mechanical, Machining, Microstructural, and Morphological Characterizations

Abstract

This research focuses on a comprehensive exploration of the experimental and mechanical aspects of the electrical discharge machining (EDM) process, specifically targeting the machining characteristics of AA2014/Si3N4/Mg/cenosphere hybrid composites. The aim is to optimize the process parameters for enhanced machining performance through a combination of testing, optimization, and modelling methodologies. The study examines the effects of key EDM variables—peak current, pulse on time, and pulse off time—on critical output responses: surface roughness (Ra), electrode wear rate (EWR), and material removal rate (MRR). Leveraging an L9 Taguchi orthogonal array experimental design, the impact of controllable factors on these responses is analysed. An integrated approach utilizing MATLAB’s logic toolbox and Mamdani’s technique is employed to model the EDM process, and a multiple-response performance index is calculated using fuzzy logic theory, enabling multiobjective optimizations. Furthermore, a mechanical behaviour evaluation of AA2014/Si3N4/Mg/cenosphere hybrid composites is performed through mechanical testing, with a comparison between experimental machining results and predicted values. Scanning electron microscopy (SEM) images reveal the presence of filler reinforcements within the base alloy, displaying an improved microstructure and uniform reinforcement dispersion. An X-ray diffraction (XRD) analysis confirms the major elemental constituents—aluminium, silicon, and magnesium—in the hybrid composites. A microstructural analysis of the hybrid metal matrix composites (MMCs) prepared for EDM showcases closely packed reinforcement structures, circular ash-coloured spots indicating silicon and nitrates, and a fine dispersion of cenosphere reinforcement particles. The study’s outcomes demonstrate a promising application potential for these hybrid composites in various fields.

Exploring Microstructural, Interfacial, Mechanical, and Wear Properties of AlSi7Mg0.3 Composites with TiMOVWCr High-Entropy Alloy Powder

“…The uniform distribution of the HEA reinforcement further influenced the grain growth behavior, ensuring that the reinforcement particles acted as nucleation sites for new grains, promoting a fine-grained microstructure. , The smaller grain size enhanced the composite’s mechanical properties by impeding dislocation movement, thereby increasing its strength and hardness. Additionally, the increased grain boundaries contributed to improved wear resistance …”

“…Additionally, the increased grain boundaries contributed to improved wear resistance. 16 3.3. Mechanical Behavior.…”

“…The friction stir processing (FSP) technique has emerged as a transformative method for developing aluminum-based composites. FSP involves using a rotating tool to stir and consolidate materials in the solid state, facilitating the incorporation of reinforcement materials into an aluminum matrix. , This innovative process eliminates the melting and solidification associated with traditional methods, preserving the material’s integrity and producing a fine, homogeneous microstructure. ,, In the context of aluminum-based composites, FSP enables the uniform distribution of reinforcing elements, such as nanoparticles, fibers, or alloys, within the aluminum matrix. − This leads to enhanced mechanical properties, improved wear resistance, and increased strength without sacrificing the inherent lightweight nature of aluminum. , The FSP technique offers precise control over the composite’s microstructure and properties, making it a promising approach for tailoring materials to specific applications in industries ranging from aerospace to automotive and beyond …”

“… 12 ,, 15 In the context of aluminum-based composites, FSP enables the uniform distribution of reinforcing elements, such as nanoparticles, fibers, or alloys, within the aluminum matrix. 16 − 19 This leads to enhanced mechanical properties, improved wear resistance, and increased strength without sacrificing the inherent lightweight nature of aluminum. 20 , 21 The FSP technique offers precise control over the composite’s microstructure and properties, making it a promising approach for tailoring materials to specific applications in industries ranging from aerospace to automotive and beyond.…”

Advancing Surface Hardness and Wear Resistance: Microwave-Assisted Cladding of Ni-TiC Mixture onto SS-304

“…Nickel (Ni) serves as a versatile coating particle for steel, offering several advantages. Its excellent corrosion resistance protects the underlying steel substrate from environmental degradation, extending its service life [36]. Ni coatings also enhance surface hardness, improving wear resistance and durability.…”