Synthesis of an Aluminum Alloy Metal Matrix Composite Using Powder Metallurgy: Role of Sintering Parameters

Abstract

Powder metallurgy-based metal matrix composites (MMCs) are widely chosen and used for the development of components in the fields spanning aerospace, automotive and even electronic components. Engineered MMCs are known to offer a high strength-to-weight (σ/ρ) ratio. In this research study, we synthesized cylindrical sintered samples of a ceramic particle-reinforced aluminum metal matrix using the technique of powder metallurgy. The samples for the purpose of testing, examination and analysis were made by mixing aluminum powder with powders of silicon carbide and aluminum oxide or alumina. Four varieties of aluminum composite were synthesized for a different volume percent of the ceramic particle reinforcement. The hybrid composite contained 2 vol.% and 7 vol.% of silicon carbide and 3 vol.% and 8 vol.% of alumina with aluminum as the chosen metal matrix. Homogeneous mixtures of the chosen powders were prepared using conventional ball milling. The homogeneous powder mixture was then cold compacted and subsequently sintered in a tubular furnace in an atmosphere of argon gas. Five different sintering conditions (combinations of temperature and sintering time) were chosen for the purpose of this study. The density and hardness of each sintered specimen were carefully evaluated. Cold compression tests were carried out for the purpose of determining the compressive strength of the engineered MMC. The sintered density and hardness of the aluminum MMCs varied with the addition of ceramic particle reinforcements. An increase in the volume fraction of the alumina particles to the Al/SiC mixture reduced the density, hardness and compressive strength. The sintering condition was optimized for the aluminum MMCs based on the hardness, densification parameter and cold compressive strength. The proposed powder metallurgy-based route for the fabrication of the aluminum matrix composite revealed a noticeable improvement in the physical and mechanical properties when compared one-on-one with commercially pure aluminum.

Physical and mechanical behavior of aluminum-magnesium alloy matrix hybrid composite fabricated through friction stir consolidation process

“…Where r c is density of magnesium matrix composite (AZ61), rl is density of liquid, Wr c is weight of magnesium matrix composite in air, DWr c is change of magnesium matrix composite in air and in liquid. 26 Likewise, the theoretical densities were calculated using equation (2). Where r c is the density of composite, rr is the density of reinforcement multiplied by its ratio in percentage volume and prior to calculation of theoretical density, the percentage weight converted into percentage volume of reinforcements.…”

Microstructural and Radioactive Shielding Analyses of Alumix-231 and Alumix-231 Reinforced with B4C/SiC/Al2O3 Particles Produced through Hot Pressing

“…Another common but advantageous method for our study, the MMC production method, is powder metallurgy (PM). Powder metallurgy is a promising and efficient technique that offers energy efficiency and economic viability for manufacturing simple as well as intricate components with precise dimensions . Our team preferred to benefit from the advantages of powder metallurgy as it worked with macrosized powders in the experiments conducted in this study.…”

“…The mixture is then compacted into a preform followed by a sintering process to bond the particles together. Additional heat treatments may be applied to enhance the matrix-reinforcement interface and improve the composite properties . It is important to note that these are general methods for preparing metal matrix composites, and specific variations and modifications may exist depending on the desired composite composition, geometry, and application.…”

“…Powder metallurgy is a promising and efficient technique that offers energy efficiency and economic viability for manufacturing simple as well as intricate components with precise dimensions. 16 Our team preferred to benefit from the advantages of powder metallurgy as it worked with macrosized powders in the experiments conducted in this study. This method involves the blending of metal powders with the desired reinforcement materials.…”

“…Additional heat treatments may be applied to enhance the matrix-reinforcement interface and improve the composite properties. 16 It is important to note that these are general methods for preparing metal matrix composites, and specific variations and modifications may exist depending on the desired composite composition, geometry, and application. The selection of the appropriate preparation method depends on factors, such as the desired properties, cost considerations, and the nature of the reinforcement and matrix materials being used.…”