mechanical properties of aluminium matrix composite ... · and powder metallurgy (pm) [46] to...

Mechanical Properties of Aluminium Matrix Composite Including

SiC/Al2O3 by Powder Metallurgy-A Review

Musa Alhaji Ibrahim 1, 2,

,Yusuf Sahin 2, Auwalu Yusuf Gidado

1, M.T. Said

3

1Department of Mechanical Engineering, Kano University of Science and Technology Wudil, Kano, Nigeria, 2 Department of Mechanical Engineer-

ing, Faculty of Engineering, Near East University, Nicosia, Cyprus, 3 Department of Mechanical Engineering, Faculty of Engineering, Bayero Uni-

versity, Kano, Nigeria.

Email: [email protected], [email protected], [email protected], [email protected]

ABSTRACT

Powder metallurgy (PM) method for mass production of components plays a significant role in the fabrication of advanced ma-terials for automobile, aerospace, defense, petroleum and chemical industries at cheaper rate. Aluminum Matrix Composites (AMCs) including silicon carbide/Aluminum oxide (SiC/Al2O3) has received increased attention due to its excellent mechanical properties such as hardness, strength, low density, corrosion resistance and toughness. PM gives better mechanical properties due to good wettability between the matrix and the reinforcements, uniform microstructure with desirable phases in the compo-site. This paper examines the effect of powder processing variables such as milling time, milling speed, compaction pressure, sintering time and temperature on the mechanical properties of the AMC when adding to the different sizes and volumes of SiC and Al2O3. Keywords : Mechanical Properties; Silicon Carbide; Alumimium Oxide; Powder Metallurgy; Aluminium Matrix Composites

1 INTRODUCTION

Composite is a multi-elements material possessing unique properties than the individual elements [1]. Decades ago, re-search is focused upon exceptional materials like composite [2]. Composite could be polymer, ceramic or metal base. Metal matrix composites (MMCs) are a helpful class of engineering material having a light metal matrix in which hard fragments are added thus possessing special importance [3], [4], [5], [6], [7]. Popularly applied matrices are magnesium (Mg) [8], cop-per (Cu) [9], titanium (Ti) [10] and aluminum (Al) [11] or their alloys. These matrices are better for the fabrication of MMCs. Particulates, whiskers and fibers are utilized as reinforce-ments[12]. Particulate Al2O3 and SiC MMCs are widely used as reinforcements. AMCs including SiC/Al2O3 show better stiffness, hardness and tensile strength [13], [14], [15]. These composites have been used in automobile, aerospace, defense, chemical, structural as well as electronics industries [16], [17], [18], [19], [20], [21], [22]. The strength of AMCs is a function of volume fraction as well as refinement of the reinforcements [23]. These particulate metal matrix composites (PMMCs) with better properties have given rise to a fresh breed of manipu-lated engineering materials [24], [25]. Interfacial relation be-tween matrix and reinforcement, dimension of ceramics, vol-ume fraction and homogeneous dispersion of the reinforce-ments and nature of bonding determine the structure and properties of these composites [26], [27], [28]. Different tech-niques are used to fabricate AMCs including SiC/Al2O3. Pow-der metallurgy (PM) is one such method used for its special attributes like lower temperature, cost effective and homoge-neous distribution of reinforcements within matrix [29]. The mechanical properties of AMCs are a function of amount, size, type of reinforcement and processing method used [30], [31]. With respect to the size, nano scale yields wonderful mechani-

cal property [33], [34]. When SiC and Al2O3 are introduced into the matrix hardness, tensile and elastic modulus are im-proved [34], [35]. Higher amount of reinforcement give better hardness, tensile strength and stiffness but loss of ductility and fracture toughness are witnessed [36]. PM processing var-iables like sintering time, temperature, compaction load affect the mechanical properties of AMCs [37]. Hence, this article will review mechanical properties of aluminum matrix includ-ing SiC/Al2O3 produced via PM.

2 PROCESSING ROUTES FOR ALUMINIUM MATRIX

COMPOSITES (AMCS)

The method of processing AMCs has been categorized into ex situ whereby reinforcements are added into the matrix and in situ in which there is production of hard particles by reaction process [38], 40]. Industrially, there are solid and liquid routes [41]. For liquid are squeeze casting [42], ultrasonic assisted casting and conventional stir casting [43] and solid include micro wave and conventional sintering [44], spark plasma [45] and powder metallurgy (PM) [46] to mention but a few. Selec-tion of these depends upon optimum temperature for infiltra-tion, wettability and adverse reactions at the interface [47] size, type, volume fraction of reinforcement, its distribution, simplicity, matrix-particle bonding, cost and control of matrix morphology play role in the mechanical properties of the AMCs [48]. 2.1 Solid State Process

2.1.1 Powder Metallurgy

Powder metallurgy (PM) involves less temperature, cost effec-

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International Journal of Advancements in Research & Technology, Volume 8, Issue 3, March-2019 ISSN 2278-7763 23

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tive [49], [50] and parts of complex geometry are easily fabri-cated by it [51] and in mass at cheaper rate [52], [53]. Funda-mentally the steps in PM are mixing, compaction in a die or mold and sintering in a furnace for consolidation [54] and sec-ondary operation might be applied for special behavior or dimensional precision [55] as indicated in Fig. 1.

Fig. 1. Powder metallurgy process steps [56].

Mechanical properties are improved by PM due to thorough dispersion of the reinforcing particles within the matrix [57]. Correlation has been established among size, amount, type and surface nature of reinforcement and properties of compo-site produced by PM [58], [59], [60]. Generally, when the size of reinforcement is scaled to nano the property will be good but fabrication becomes complicated [61]. The advantages and disadvantages of PM are given in Table 1.

TABLE 1

PM ADVANTAGES [62] AND DISADVANTAGES [63].

Advantages Disadvantages

Parts have controlled porosity Tooling and equipment are ex-

pensive

Better mechanical properties are

obtained

Parts have low strength and duc-

tility

Parts of near net shapes are

achieved High cost of powder materials

2.1.2 Mechanical alloying (MA) and milling (MM)

MA involves continuous cold welding, fracturing and welding again of powder particles in a high mill [64], [65], [66]. MA is capable of producing numerous equilibrium and non-equilibrium alloy states beginning from ordinary or preal-loyed powders [67]. Due to high energy given to the particles during milling, composite fabricated from this technique is of exceptional properties [68] such as absence of voids [69]. It was developed by John Benjamin when he wanted to fabricate nickel-based oxide dispersion strengthened (ODS) super al-loys for industrial applications [70]. MA involves material transfer in order to have a uniform material [71]. The method begins with a small amount of powders put into an enclosure along with the grinding medium mixed via agitation at high speed for a fixed period. Transfer of energy takes place be-tween the grinding media and the powders thereby reducing size of the powders into smaller sizes media. Thereafter, the grinded powders are pressed, degassed and consolidated [72].

While in MM there is no transfer of material the main purpose is to reduce the powder particles size to the barest minimum and increase surface area required [73]. More so, the main important factors in the process are the raw materials, mill and the process variables such as milling speed, time, ball-to-powder ration, process control agent and temperature [67]. Paraffin, stearic acid and methanol are utilized as process con-trol agents acting as lubricants in order to reduce the impact of cold welding and eventual production of large powders clus-ters [74]. As the powders are plastically deformed, internal structure enhancement of the powders might take place thus yielding a nanostructured composite. Lubricants, milling time and tools may contaminate the powders and as such the pro-cess need to be controlled. More so, as the material is consoli-dated, impurities may affect the microstructural evolution and grain development thereby reducing the mechanical proper-ties of the composite. Fig. 2 shows the representation of MA process. Advantages and disadvantages MA as provided in Table 2.

TABLE 2

MA ADVANTAGES [30], [75] AND DISADVANTAGES [75]


Parts have high strength Compaction forces involve are high

Homogenization is obtained Small sizes of powder due to re-

striction

No need for post treatment Difficult to produce intricate shapes

Powder composition is regu-

lated Spontaneous burning of powder

The process is mechanized Tooling and equipment expensive

Fig. 2. Simplified block diagram of a typical mechanical alloying process [76 ].

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2.1.3 Spark Plasma Sintering (SPS)

SPS also called field assisted sintering (FAST) is manufactur-ing method involving direct current actuated, low voltage as well as pressure assisted sintering [77], [78], [79], [80] to fabri-cate dense composite with perfect grain growth/ size [81], [82]. Joule heating provides high heating rates, allowing dense ceramics to be obtained under uniform heating at relatively low temperatures and in short processing times [83], [84], [85], [86], [87], [88]. Fig. 3 shows the SPS set-up. The technique can be applied to fabricate modern compounds [89]. It is the same with hot pressing though there is difference in the manner of heat production and transmission to the material being sin-tered [90]. In SPS process, the green compact (powder) placed in a die is simultaneously subject to arc electric discharge pro-duced by pulse electric discharge and external pressure. On the microscopic level, electric discharge process occurs thereby accelerating material diffusion.The outside pressure applied is usually 20-3000 N/M2 and heating rate of 100-10000C/minute [91]. This method regulates porosity thus gives desirable be-haviors [92]. The fastness of the method guarantees densifica-tion of the composite whilst eliminating coarsening which happens in conventional densification process [92], [93], [94], [95] thus enhancing mechanical properties [96–98]. Ad-vantages and disadvantages of SPS as provided in Table 3.

Fig. 3. Schematic drawing of an SPS process [82].

SPS technique takes place under empty space or a shielded gas at atmospheric pressure. However the mechanism of SPS is still unclear thus, fundamental study needs investigation.

TABLE 3

ADVANTAGES [99], [98], [100], [101], [102], [103], [104] AND DIS-

ADVANTAGES [45], [105], [106], [107] OF SPS/FAST


Better mechanical properties and

high density at same temperature It is expensive

Energy efficient and saving Applied only to a simple

symmetrical shape

2.1.4 Hot isostatic pressing (HIP)

Hot isostatic pressing (HIP) consolidates materials fabricated via casting and PM routes. The mechanical operation of these materials is a function of dispersion, structure and amount of porosity which impair the mechanical behavior such as tensile strength, fatigue resistance and fracture toughness [108]. It comprises of application of high temperature and uniform pressure to the green compact in all direction in the presence of argon as the fluid medium [109] in built vessel [110] to con-solidate the materials [111] as shown in Fig. 4. Due to pressure and temperature applied at the same time it was named ‗gas pressure bonding‘ [112]. HIP is being utilized to remove flaws and synthesize denser ceramics [113]. HIP improves on the mechanical properties such as fatigue, creep, ductility and impact resistance in addition to removal of inspection [114]. Up to now, HIP is seen as better tool of enhancing mechanical behavior of a large number of materials [115]. Table 4 gives the merits and demerits of HIP

Fig. 4. Hot isostatic pressing (HIP) [116].

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TABLE 4

ADVANTAGES [117] AND DISADVANTAGES [118] OF HIP


High composite densification Only applied to simple part‘s shape

Reduced temperature application Parts require secondary operation

Grain growth is slowed Expensive

2.1.5 Microwave Sintering (MWS)

Microwave is an integral section of electromagnetic spectrum travelling at the speed of light having a wavelength between 1 mm to 1 m similar to 300 GHz to 300 MHz. In contrast to tradi-tional sintering, MWS deals with conversion of electromagnet-ic energy into thermal energy in place of heat transfer [119]. The medium of transfer of microwave energy (MWE) to the material is molecular interaction with the electromagnetic field. Because MWE could infiltrate material and transmit en-ergy, heat is thus produced all over the material‘s volume leading to volumetric heating [119], [120], [121], [122], [123], [124]. In MWS, heat produced from the inside of the material being sintered, is radiated outwards owing to penetrative in-tensity of the microwave leading to temperature differential and differences in microstructure and behaviors. To eliminate this, a ‗bi-directional microwave-assisted rapid sintering has been developed [82]. This procedure ensures uniform heating between the core and the edge of the material and shown in figure 5 (b). MWS produces composite with fine microstruc-ture and better mechanical properties [125], [126] due to quick heat transfer that reduces processing time [127], [128]. MWS is novel, promising, attractive, efficient, valuable and economical [129], [130], [131] manufacture method. Table 5 shows the ad-vantages and disadvantages of MWS.

TABLE 5

ADVANTAGES [132], [133]AND DISADVANTAGES [134] OF MWS


Heating is rapid and contactless Processing time is very short

Material heating is selective and

equipment portable Tooling is expensive

2.2 Liquid Process

2.2.1 Stir Casting

Stir casting otherwise referred to as vortex technique is com-monly utilized to fabricate AMCs including SiC/Al2O3 [135], [135], [136], [137], [138], [139], [140]. This method involves in-troducing the reinforcements into the molten metal and then cast to the desired geometry. Prior to incorporating the rein-forcements, the melt should be degassed by an appropriate medium to avoid reaction with atmospheric oxygen [141]. Uniform distribution of reinforcements can be realized through a rotor rotating inside the liquid metal creating a vor-tex and injection of a gas carrying the reinforcements into the liquid [142]. The well distributed slurry so fabricated can be

shaped by traditional casting method: squeeze casting, per-manent mold casting and sand casting [143], [144]. Gas en-trapment, slag in the melt leading to high porosity and micro-defect; unnecessary chemical reaction between the matrix and the reinforcements, poor matrix-reinforcement wetting are associated with the route [145], [146]. These negatively affect the mechanical properties of the composite. To surmount these issues, process variables like melt stirring time, melt holding temperature, temperature of the molten metal, choice of ma-trix and reinforcement should adapted [147]. Fig. 5 shows the representation of the stirring casting method. Table 6 shows the advanatges and disavantages of stir casting method.

Fig. 5. Fundamental stir casting process [148].

TABLE 6

ADVANTAGES [148], [149] AND DISADVANTAGES [151], [152] OF

STIR CASTING METHOD


It is simple, flexible, economical and

suitable for mass production

Difficult to achieve homogeneity

and high porosity

Good matrix-reinforcement inter-

face and near net shapes

Possibility of reaction between

matrix and reinforcement and poor

wetting due to high temperature

2.2.2 Spray-Up

Here a hand-held spray gun is employed to spray pressurized matrix and reinforcement in the form of chopped fibers. Usu-ally, the reinforcement used is roving glass that go past the spray gun where it is chopped with a gun [153], [154]. Rein-forcement and matrix might be sprayed at the same time in-dependent of one another. Curing is done either at high tem-perature or at normal temperature. After curing, mold is opened and the material is ejected for additional processing. The duration of curing depends on the kind of polymer used for composite processing. The products of this technology are

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heavy, rich in resin and poor mechanical properties [154]. Fig. 6 shows the spray-up process. This method has many ad-vantages and disadvantages as provided in Table 5.

Fig. 6. Spray-Up method [154].

TABLE 5

ADVANTAGES AND DISADVANTAGES OF SPRAY-UP METHOD [155]


It is simple and tooling is

cheap

Products are heavy due to richness

in resin and short fibers are added

Quick deposition of fiber and

resin

Mechanical properties are com-

promised due to low viscosity of

resin

2.2.3 Squeeze Casting

This process integrates a forging and casting in which a mol-ten metal solidifies under the action of pressure. The matrix in form of molten metal is incorporated into reinforcement either under pressure or without pressure [155–156]. The method consists preheating, pouring, application of pressure, infiltra-tion and withdrawal of the composite from the punch and die system [157]. The process can be indirect or direct. Many pro-cess variables contribute to the quality of squeeze cast compo-site including mold temperature, pressure and its duration, pouring temperature, time delay in pressurizing the melt, die temperature and filling velocity [158]. Adequate regulation of these principal variables may remove possible defects in the cast composite. However, no standard is set on how to control

these variables. Disadvantages and advantages as provided in Table 6. Fig. 7 indicates the squeeze casting method.

Fig. 7. Pressure applied on the melt [158].

TABLE 6

ADVANTAGES [160] AND DISADVANTAGES [159–161] OF SQUEEZE

CASTING METHOD


Simple and flexible Difficult to achieve homogeneity

Economical for mass produc-

tion

Possibility of reaction between

matrix and reinforcement

Good matrix-reinforcement

interface

High porosity in composite and

poor wetting

2.2.4 ULTRASONIC-ASSISTED CASTING (UAC) UAC uses wave frequency of 20 KHz to 18 KHz. When this wave moves past a liquid, successively interchanging dilation, cycles and compression are generated as shown in Fig. 8. This wave is generated by means of mechanical vibration having a frequency of 18 KHz. This produces micro bubbles that grow in the liquid [162]. When they can no longer absorb the suffi-cient energy, explosion occurs (cavitation) [163]. This explo-sive action of cavitation breaks agglomeration of particles and distribute them uniformly within the liquid. UAC is good at disintegrating agglomeration formation which happens in nanocomposites because of low wettability and high tendency of cluster of nanoparticles [164], [165], [166]. At every cavita-tion cycle, bubbles explosively fall in less than 6-10 second with the ‗hot spot‘ reaching a temperature of 5000 °C, pressure of 1000 atm, and heating/cooling rates >1,010 K/S during mi-croseconds transient [167]. Table 7 gives the advantages and

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disadvantages of the above process.

Fig. 8. Schematic of Ultrasonic-assisted casting [166].

TABLE 7

ADVANTAGES [167], [168] AND DISADVANTAGES [169] OF UAC


Homogeneity and better mechanical

properties

It is expensive due to tooling

involved

UAC can be applied in the production of

bulk composite

High sound frequency is in-

volved

3 MECHANICAL PROPERTIES OF AL/SIC REINFORCED

COMPOSITES

Ran, Verma and Purohit, (2012) reinforced Al with SiCp by powder metallurgy process. The powders were mechanically alloyed for 12 to 15 milling hours at 78 rpm. The powders un-derwent cold isostatic pressing at 600 MPa at a rate of 3.27 KN/s in a mold and then pressed in a die using 500 KN pres-sure. The green compact was sintered at 580°C for 1800 second and 600°C 2700 seconds. The result indicated increase in hard-ness, compressive and tensile strengths and that milled pow-der had better properties than un-milled [170]. Donnell and Looney (2001) introduced SiC of varying size to AA6061 via conventional powder metallurgy. The blend was compacted in

a die at 235 ± 5 MPa at a rate of 7 MPa/s, sintered at 617 ± 20C for 70 minutes and 614 ± 10C for 50 min. The result showed that as the size of the SiC decreased the yield strength was improved but its toughness or ductility decreased with in-crease in the volume fraction of SiC and that there was ade-quate dispersion of the reinforcement within the matrix [171]. Erdermin et al. (2015) investigated the mechanical properties of workably graded Al2024-SiC composite and found out that hardness increased at 30 and 40 wt. % SiC and reduced when the amount of SiC was increased to 50 and 60%. The decrease in hardness was attributed to high porosity [172]. Nuruzzamm and Kamaruzzuman (2016) incorporated SiC into aluminum to

investigate the impact of amount reinforcement, sintering temperature and compaction force on composite. The finding revealed that increasing the amount, sintering temperature as well as pressing force enhanced the hardness and density of the composite. The optimum hardness was achieved at 30%, under the application of 15 ton and 500oC. [173]. Al-Raheed et al. (1993) reinforced aluminum alloy with different percentage of SiC [174]. Both findings revealed increase in hardness and tensile strength with increase in reinforcement contents of SiC as shown in figure 10. However, tensile strength decreased above optimum value of 30-wt% SiC. Dalatkhan et al. (2012) manufactured AMC via friction stir process by reinforcing AA5052 of 5µm and 5nm SiC ceramics. It was observed that with the change in rotational speed, direction between friction stir process passes, decrease in size of SiC and increase in the number of passes enhanced the hardness of the composite [175]. The impact of SiC particle size in Al nanocomposite was studied by El-Kady and Fathy (2014) fabricated via PM. It was shown that reducing the size to nano scale greatly enhanced the hardness (72 HV) and the compressive strength (601 MPa) at 10 wt.% SiC and 70 nm Fig. 9 and Fig. 10 [176]. Hossain, Aarabi and Mohammadkhani (2015) studied the effect of amount and nano SiC on pure aluminium alloy composite fabricated by PM and reported that there was an increase in the hardness and tensile strength with increase in the amount and decrease in size of SiC. The best results were achieved at 10% of SiC and sintering temperature of 650oC [46].

Fig.9. Impact of size and amount of SiC on hardness [176].

Fig.10. Effect of SiC size and amount on hardness and compressive strength [176].

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Joosawat, Panomtang and Wongtimnoi (2017) introduced sili-ca sand into porous aluminum via PM technique to improve the mechanical properties of the Al. The materials were blend-ed at 100 rev/m for 4 hours. The blended powders were com-pacted at room temperature under 400 MPa, heated at 5500C for 5 hours. They observed that hardness, porosity and com-pressive strength improved with increase in content of silica sand while density decreased. However, increasing the silica above 15%, hardness and compressive strength decreased [177].While studying the effect of binary reinforcements of multi-carbon nanotube and silicon carbide on mechanical and microstructure of AMC. Wagh and Jayakumar (2016) observed increase in hardness and ultimate tensile strength as the amount of the MCNT and SiC increased but ductility de-creased. The maximum hardness 49 BHN and UTS 246.41 MPa were obtained at 1.5% of reinforcements. The loss in ductility was due to increase in contents of MCNT and SiC which raised the hardness [178]. Reddy et al. (2017) prepared Al/SiC nano composite via MWS and hot extrusion. The SiC was added in volume fraction of 0, 0.3, 0.5, 1.0 and 1.5 % to the Al. They reported that increasing the volume fraction enhanced the compressive and tensile strength of the composite though ductility was lost and better mechanical properties were shown by hot extrude composite at 1.5 % of SiC [179].

4 MECHANICAL PROPERTIES AL/AL2O3 REINFORCED

COMPOSITES

Nuruzzaman etal. (2016) manufactured AMC by reinforcing aluminum with Al2O3 at various amount via conventional powder metallurgy. The blend was pressed at 20 ton in a die, sintered at two different temperatures of 550oC and 580oC. It was found out that density and compressive strength of AMC affected by sintering temperature and the amount of Al2O3

[180]. Knowles et al. (2014) introduced 10 wt. % and 15 wt. % SiC reinforcement particles with average size lower than 500 nm into Al 6061. The sample was compacted with a load of 50 tons, heated to 4500C in 15 min, and held for 20 min. The re-sult indicated that as the amount of reinforcement, ball-milling energy, sintering temperature and pressing pressure increased the Young modulus, yield strength and ultimate tensile strength also increased. This improvement in mechanical properties was due to homogeneous distribution Al2O3 in Al and proper bonding between the two [181].Garbiec et al. (2015) reinforced Al with Al2O3 in 5%, 10%, 15% and 20% through spark plasma method. The four samples were sin-tered at 6000C at a pressure of 50 MPa. The sintering rate was 1500C per minute for 150s. Current was passed through the samples for 125ms that lasted 5 min. The result revealed im-provement on hardness, compression and tensile strengths as the amount of Al2O3 increased. The maximum micro hardness of 1355 MPa and compression strength were achieved at 20% Al2O3 while stiffness of 100 GPa and tensile strength of 160 MPa were obtained at 15% Al2O3 [182]. Table 8 shows the me-chanical properties results of the experimental studies of some selected MMC.

TABLE 8

TENSILE, COMPRESSION STRENGTH AND STIFFNESS OF AL- AL2O3

AND ELEMENTAL AL RESULTS [182]

Material

Micro in-

dentation

hardness

(GPa)

Tensile

strength

(MPa)

Compression

strength

(MPa)

Young

Modulus

(GPa)

Al 396 ± 4 97 ± 1 169 ± 2 74 ± 2

Al–Al2O3 5% 611 ± 4 118 ± 5 170 ± 2 58 ± 1

Al-

Al2O3 10% 743 ± 28 151 ± 3 196 ± 1 84 ± 4

Al–Al2O3 15% 897 ± 43 160 ± 13 232 ± 2 100 ± 10

Al–Al2O3 20% 1355 ± 22

96 ± 13 247 ± 2 94 ± 3

More so, strain decreased due to increase of the amount of reinforcements with pure Al having the greatest strain and 20% alumna with lowest strain. The porosity also affects the mechanical properties of sintered composite as shown. Small volume of porosity decreased ductility therefore, in usage where high ductility is needed it is important to decrease the porous level [183]. Min et al. (2005) studied the effect of sinter-ing temperature on Al 2xxx reinforced with alumina (Al2O3) produced through powder metallurgy technique. The findings showed that as the sintering temperature and holding time increased the densities and sinterability increased. By exten-sion, the hardness, tensile and compressive strengths in-creased [184]. Rahimian et al. (2009) investigated the impact sintering temperature and volume fraction of Al2O3 on me-chanical of Al. The sample was fabricated through powder metallurgy. The results revealed hardness, tensile and com-pressive strengths increased as the sintering temperature and content of reinforcements increased. However, when the amount of reinforcements and sintering temperature reached optimum value, compressive and tensile strengths dropped sharply [185] as shown in Fig. 11 and Fig. 12.

Fig. 11. Effect of Al2O3 particle content and sintering temperature on yield

stress and hardness [185].

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Fig. 12. Effect of Al2O3s particle content and sintering temperature on yield stress and hardness [185].

From the figures above, it is observed that as the amount of reinforcements and sintering temperature increased the yield and hardness increased to an optimum point and suddenly decreased due to high content of alumna and increase in tem-perature. Ghasali et al. (2017) manufactured Al-15% TiC through MWS, SPS and traditional sintering techniques. A temperature of 7000C for traditional sintering, 6000C for MWS and 4000C for SPS were employed in the heating process. They reported that the best method was SPS having produced a hardness of 253 HV and bending strength of 291 MPa [186]. Rahimian et al. (2009) investigated the influence of size of par-ticle, sintering time and temperature on mechanical properties of PM Al-Al2O3 composite and it was reported that as the size of particle was minimized, sintering time and temperature increased hardness increased. It was concluded that the best hardness (76HB) and strength (318 MPa) were achieved at 3 µm, 600oC and 45 minutes as shown in Fig. 13 and Fig. 14 [187].

Fig. 13. Effect of Al2O3 size, sintering temperature and time on yield strength and hardness of AMC [187].

Fig. 14. Effect of Al2O3 size, sintering temperature and time on yield strength and hardness of AMC [187].

Wagih (2015) studied the effect of milling time on mechanical properties by introducing alumina into Al and Al-10wt% Mg via mechanical alloying. The blend was milled for 20 hours at 250 rpm. The higher milling time, 20 hr led to breaking down of both the matrix and the reinforcement into nano particles. The finding indicated that milling time of 20 hour improved the micro hardness of the nanocomposite due to grain refine-ment and homogeneous distribution of the Al2O3 within the matrix [188]. Canakci, Varol and Ertok (2012) investigated the impact of alumina on Al produced by mechanical alloying. Al and alumina of 37 μm and 13 μm were used as materials. The authors discovered that the hardness value increased by in-creasing the milling time and the amount of reinforcement. More so, raising the content of alumina influenced both micro-structural and morphological properties of AMC [189]. Raju (2015) observed the effect of nano alumina on mechanical properties of AMC produced powder and liquid metallurgy. The finding revealed that as the content of the alumina in-creased the hardness increased similarly if the amount of alu-mina increased the tensile strength was increased up to 1.5% of Al2O3 thereafter tensile strength will decrease [190]. While studying the impact of alumna on the hardness of Al-Zn-Mg-Cu-Ni-Co matrix produced through PM, Naeem and Mo-hammed (2015) reported an increase in hardness of the matrix with ageing at T6 temper and the maximum hardness was reached at retrogression and reageing of 120oC for one day +180oC for 1800 s + 120oC for one day [191]. Liu et al. (2012) investigated the impact of ball-milling time on CNT/Al com-posite reported that as milling time increased the tensile and yield strengths of the composite increased reaching optimum values at 6 hrs. This is attributed to homogeneous distribution of the CNT in the Al. However, an increase in time above 6 hrs reduced the mechanical properties and the elongation [192]. Dash, Murty and Aamanchi (2015) fabricated laminate nano composite by reinforcing glass/epoxy with Al-Cu-Al2O3 parti-cle via MA. SPS and conventional sintering sintered the green compact. The results indicated that an increase in the amount of Al-Cu-Al2O3 increased the hardness, yield strength and compression of the composite, SPS composite revealed better mechanical properties [193]. Chen et al. (2018) reinforced AA 6061 with B4C via PM. The sample having 30% B4C was ex-truded, rolled and sintered by hot pressing. The results indi-cated uniform dispersion of B4C within the 6061 Al and the composite composed of Al2O3, B4C and Al. The yield and ul-timate tensile strengths increased with increase in the defor-mation and decrease due to breakage of sizeable B4C and stress intensity within the site between 6061 Al and B4C [194]. Sadeghi et al. (2018) combined SPS and friction stir process to produce a binary composite. Alumina of micro and nano size were added to elemental Al. A load of 50 MPa and a tempera-ture of 550oC at 5 min/oC were applied to the green compact. The duration for heating was less than 25 minutes. They re-ported increase in hardness as rotational speed, velocity, pressing load and heat input increased. They concluded that the variation in hardness was due to nano alumina particles acting as recrystallization inducers [195].

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5 MECHANICAL PROPERTIES OF HYBRID REINFORCED

COMPOSITE

Bilal, Shaikh, and Arif (2018) fabricated the aluminum hybrid composites by adding SiC and fly ash to Al using powder metallurgy method. The result showed that hardness as well as wear resistance were increased due to increase in the amount fly ash and SiC [196]. Kumar et al. (2016) incorporated SiC and B4C into Al metal matrix via PM route. Three various hybrid composite samples were studied and it was observed that as the concentration of the reinforcements increased the hardness increased and that as the amount of SiC decreased the hardness decreased. The highest hardness was obtained at 90%Al 3%SiC 7% B4C 32.7 HB [197]. Karabulut, Gökmen, and Çinic (2016) reinforced aluminum alloy 7039 with SiC, Al2O3

and B4C to look into the effect of reinforcements on the alloy. Three samples having 10% of the reinforcements were pre-pared via PM coupled with hot extrusion. The finding re-vealed homogeneous distribution of the particles in the matrix and there was proper wetting between the matrix and the re-inforcements that led to increased hardness, bending strength and elongation. They concluded that alumna gave the highest mechanical properties in relation to SiC and B4C [198]. Swaminathan et al. (2016) examined the effect of compacting load and microwave sintering on Al reinforced with SiC/ Al2O3/Fly ash via powder metallurgy. The samples were pressed at different pressing force from 4 ton to 8 ton and sin-tering was performed through conventional and microwave sintering 5600C for 2.5 hrs and 5600C for ½ hr. respectively. The outcome revealed that as the compacting load and tem-perature increased the hardness as well as the densification increased. Also, MWS gave better hardness and densification than conventional sintering [199]. Alalkawai, Azid and Alja-wad (2019) introduced nano particles of Fe2O3 and Al2O3 into Al of size 60 µm via PM to study mechanical and other proper-ties of the hybrid composite. They reported important im-provement on the hardness and compressive strength of the composite by increasing the amount of the reinforcing parti-cles and using nano size of 30 nm and 14-20 nm of Fe2O3 and Al2O3 respectively. The optimum compressive strength 152 MPa and hardness 47 HV were achieved at 2% Al2O3 and 1.5% Fe2O3 representing 30% and 18.5% increase when compared with strength and hardness of the elemental aluminum [200] . Kumar et al (2018) studied the effect of Al2O3/SiC on pure Al fabricated through PM. The amount of SiC was varied from 0-8% while that Al2O3 was kept constant at 4%. The mixed sam-ple was compacted in a UTM under a pressure of 300 MPa, sintered at fixed temperature of 400c and time 45 min for hardness testing while for compressive testing the applied loads were varied. The result indicated increasing the amount of SiC increased the hardness and the compressive strength of the composite. However, compression strength decreased with a decrease in compaction load [201].

TABLE 9

MATERIAL PROPERTIES OF SELECTED COMPOSITES

Nanocomposite UTS (MPa) Hardness MOM Ref.

Al 100.46 72. 3 HRB

Al-0.5 Al2O3 120.01 78.2 HRB

Al-1.0 Al2O3 138.01 81.5 HRB

Al-1.5 Al2O3 177.43 89.7 HRB

Al-2.0 Al2O3 152.25 94.4 HRB PM [190]

Al-SiC 145 51 BHN

Al-0.5SiC 220 65 BHN

Al-2.5SiC 257 72 BHN

Al-4.5SiC 240 76 BHN PM [202]

AA7075 574 192 HV

AA7075-1SiC 634 198 HV

AA7075-5SiC 547 199 HV [203]

A 356 128 52 BHN

A 356-1.5 Al2O3 184 71 BHN PM [204]

Al 95 15 BHN

Al-0.5MCNTSiC 219.88 42 BHN

Al-1MCNTSiC 232.50 47 BHN

Al-1.5MCNTSiC 246.41 49 BHN PM [178]

Al5058 235 55 BHN

Al5083-1%SiC 247 60 BHN

Al5083-2%SiC 262 68 BHN

Al5083-3%SiC 270 78 BHN UAC [205]

Micro Composite UTS (MPa) Hardness MOM Ref.

A356.2 alloy 263 68 BHN

A356.2/2%RHA/2%SiC 296 74 BHN

A356.2/4%RHA/4%SiC 310 83 BHN

A356.2/6%RHA/6%SiC 333 96 BHN SC [206]

A356.2/8%RHA/8%SiC 356 104 BHN

Al 6061 184 60 BHN

Al 6061 10% Al2O3/SiC 270 85 BHN

Al 6061 15% Al2O3/SiC 359 105 BHN

Al 6061 20% Al2O3/SiC 415 122 BHN SC [207]

Al3.38%Zn 0%FA.8%

Al2O3

93.38 47.39 BHN

Al3.38%Zn 4%FA.8%

Al2O3

100.07 51.25 BHN

Al3.38%Zn 8%FA.8%

Al2O3

113.81 58.26 BHN

Al3.38%Zn 12%FA.8%

Al2O3

133.74 65.37 BHN SC [208]

AALM4 130.5 52.5 HV

AALM4 5% Al2O3/SiC 137.2 67.5 HV

AALM4 10% Al2O3/SiC 145.6 135.5 HV

AALM4 12% Al2O3/SiC 161.6 157.5 HV SC [209]

IJOART



TABLE 10

MATERIAL PROPERTIES OF SELECTED COMPOSITES

A 7075

1%Gr/2%BA 259 87.3 BHN

A 7075

3%Gr/4%BA

283.4 94.2 BHN

A 7075

5%Gr/6%BA

299.4 99.6 BHN SC [210]

Al 5058 228

Al5083-3%SiC 237

Al5083-5%SiC 247

Al5083-8%SiC 262 78 BHN

Al5083-10%SiC 270 78 BHN UAC [205]

Al 77 36 HB

Al 5%CuTi 100 52 HB

Al 5%CuTi 136 68 HB

Al 5%CuTi 170 88 HB MWS [211]

Al-10%ZrB2 200 22 HV

Al-10%ZrB2 248 42 HV

Al-

19%ZrB2/1%Co

275 54 HV

Al-

20%ZrB2/1%Co

350 63 HV MWS [212]

Al-10 wt%B4C 240 78 HV

Al-10 wt% B4C -

1wt%Co

270 82 HV

Al-15 wt% B4C -

1.5wt%Co

300 110 HV

Al-20 wt% B4C -

2wt%Co

330 112 HV MWS [213]

Al-15 wt% B4C -

1.5wt%Co

281 ±

15

82 ± 15 HV MWS [214]

Al-15 wt% B4C -

1.5wt%Co

438 ±

31

241 ± 22HV SPS [214]

Nano/Micro

Composite

TS

(MPa)

Hardness MOM Ref.

Pure B4C 24:6 ±

0:21GPa

B4C +2% C-black 34:2 ±

0:17GPa

B4C +2% CNT 34:6 ±

0:24GPa

SPS [215]

6 APPLICATION FIELDS

AMC is a high performance material for industrial applica-tions due to appreciable properties over the unreinforced Al or its alloys [216], [217]. AMC is applied in the fabrication of dif-

ferent components in automotive, electronics, aerospace and nuclear industries [218]. The table below gives a summary of the application of various system of composites. The Fig. 15 and Fig. 16 show some parts made from AMCs.

TABLE 11

APPLICATION OF COMPOSITE SYSTEMS

Composite System Components Area

Al/SiC/Al2O3

Piston, disc brake, fastener fan

exit guide vane, rotating blade

Piston, Hydraulic actuators

Automotive, Aerospace

[219–220]

AlSi7Mg2Sr0.03/SiCp Bearings, piston Automotive [221]

Al/Gr Cutting tools, machine Automotive and manu-

facturing [222]

Al/Zr /Al/SiCW

Cu/Gr

Al/Al2O3-CF

Connecting rod, Sprockets

Current Collectors

Engine block

s

Automotive [223–224]

Automotive [223–224]

Automotive [223– [224]

Al-Al2O3

Reactor core Nuclear [225]

Fig. 15. AMC brake rotors [226].

Fig. 16. AMC single piston sliding caliper disc brake [227].

IJOART



7. CONCLUSIONS

Various manufacturing techniques such as powder metallur-gy, mechanical alloying and milling, microwave and spark plasma sintering, stir casting, spray-up and ultra-sonic assist-ed casting techniques as well as mechanical properties have been explored under this review. Both academic and industri-al researchers have displayed an important quantum of inter-est in AMCs and this has increased the literature on the me-chanical properties of the AMCs. It is seen that the hard-ness/compressive strength and tensile/ultimate tensile strengths increased with increasing the amount of reinforce-ments, sintering time, temperature, compaction load and re-duced size of the reinforcements. There is the need for re-search to fully understand the impact of reinforcement con-tents and experimental variables in order to achieve the best mechanical properties of AMCs produced via PM/MA, MWS/SPS, and SC/USA processing techniques

ACKNOWLEDGMENT

The authors want to thank to all those who contributed to-wards making this work a reality.

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