Identify Microstructure and Mechanical Behavior of Aluminum Hybrid Nano Composite Prepared by Casting Technique

This introductory paper is the research content of the paper "Identify Microstructure and Mechanical Behavior of Aluminum Hybrid Nano Composite Prepared by Casting Technique" published by Jordan Journal of Mechanical and Industrial Engineering.

Figure 1. Various matrix and strengthening materials are utilized for MMC production[25].
Figure 1. Various matrix and strengthening materials are utilized for MMC production[25].

1. Overview:

  • Title: Identify Microstructure and Mechanical Behavior of Aluminum Hybrid Nano Composite Prepared by Casting Technique
  • Author: Khaldun Aldawoudi, Ayad Mohammed Nattah, Nabaa Sattar Radhi, Zainab S. Al-Khafaji, Manar Khaleel Ibrahim
  • Publication Year: 2025
  • Published Journal/Society: Jordan Journal of Mechanical and Industrial Engineering
  • Keywords: Aluminum Matrix Composites (AMCs), Fe2O3, SiO2 hybrid particles, stir casting method, reinforcement, and Brinell hardness.

2. Abstract

The development of Aluminum-based composite metallic matrices (AMMCs) has become one of the main requirements for engineering applications due to their low weight, high strength, and superior mechanical characteristics. In this work, the effect of adding 1.25 wt% SiO2, 1.25 wt% Fe2O3, or a mixture of 1.25 wt% SiO2 and 1.25 wt% Fe2O3 hybrid particles on the hardness and compressive strength of an aluminum matrix composite fabricated by stir casting will be studied. A scanning electron microscope was utilized to investigate the microstructure of the specimens. Measurements of hardness and compressive strength characteristics revealed an improvement with increasing reinforcement weight percentage. Results for specimens of reinforced aluminum with 1.25 SiO2, 1.25 Fe2O3, or a mixture of 1.25 SiO2 and 1.25 Fe2O3 wt% particles indicated that the increment percentage of Brinell hardness was, respectively, 25.5%, 6.8%, and 19.3%. Finally, with an increasing percentage of iron or silicon oxide, the yield point and young modulus significantly decreased, even reaching the minimum magnitude at the composite containing 1.25% Fe2O3 and 1.25% SiO2.

3. Research Background:

Background of the research topic:

A "composite" is a material system that consists of a distinct component (the reinforcement) dispersed in a continuous phase (the matrix) [1]-[9]. The literature has extensively examined metal matrix composites, particularly aluminum matrix composites (AMCs). [15], [16].

Status of previous research:

The literature has extensively examined metal matrix composites, particularly aluminum matrix composites (AMCs). Silicon carbide, alumina oxide, tungsten carbide, and titanium carbide are widely recognized as the most frequently utilized materials for reinforcing aluminum composites[21].

Need for research:

Previous research explored single-particle reinforcement. This study needs synergistic effects of hybrid nano-sized reinforcements.

4. Research purpose and research question:

Research purpose:

This research aims to fabricate, identify, and characterize the mechanical behavior and hardness of (AMC) reinforced with nano Hematite, nano silicon oxide, hybrid nano Hematite, and nano silicon oxide.

Core research:

Exploring the synergistic effects of hybrid nano-sized reinforcements, specifically SiO2 and Fe2O3 particles, within an aluminum matrix composite (AMC).

5. Research methodology

The research employed a stir casting technique, specifically a two-step stir-casting procedure, to fabricate aluminum matrix composites.

  1. Specimen Preparation: High-purity aluminum wires were used as the matrix material. Reinforcing materials (SiO2, Fe2O3, or a mixture) were added at 1.25 wt% each (Table 2). The aluminum was melted in a furnace, and the temperature was controlled using a thermocouple. A mechanical stirrer was used to mix the molten aluminum and the preheated reinforcement particles.
  2. Preheating of Reinforcement: Reinforcement particles were preheated to 300°C for 2 hours to improve wettability and remove moisture.
  3. Two-Step Stirring: A two-step stirring process. The first stir at the semi-solid state(620°C). The second stir above the liquidus temperature of 750°C.
  4. Casting: The molten composite was poured into a preheated steel mold for solidification.
  5. Heat Treatment: Cast samples were heat-treated at 350°C for 5 hours for homogenization and to relieve thermal stresses.
  6. Microstructural Analysis: Scanning Electron Microscopy (SEM) was used to examine the microstructure (Figure 2). X-ray Diffraction (XRD) was used to identify the phases present (Figure 3).
  7. Mechanical Testing:
    • Brinell Hardness Test: Performed according to ASTM E10-15a, using a 5mm ball indenter and 31.25 Kg force (Figure 4).
    • Compression Test: Conducted on cylindrical samples (12 mm diameter, 24 mm height) according to ASTM standard (L=2D) (Figure 5).
      -Wear Test: using the wear tester equipment model MT-4003, version 10.0, which operates on the pin-on-disk idea. (Figure 7).

6. Key research results:

Key research results and presented data analysis:

  1. Microstructure: SEM images (Figure 2) show the distribution of nanoparticles within the aluminum matrix. XRD analysis (Figure 3) confirmed the presence of Al, SiO2, and Fe2O3 phases.
  2. Brinell Hardness: The addition of nanoparticles increased hardness. The Brinell hardness shows the increment percentage at (25.5%), (6.8%) and (19.3%) for aluminum reinforced with (1.25 SiO2, 1.25 Fe2O3 and 1.25 SiO2- 1.25 Fe2O3)wt. % of particle specimens respectively (Figure 4).
  3. Compressive Strength: The Al+ 1.25% Fe2O3 specimen showed a maximum increase of 165% compared with the pure aluminum. (Figure 5).
  4. Young's Modulus: Decreasing Young modulus value with increasing reinforcement percentage was (47 Gpa) for Al+(1.25 SiO2+1.25 Fe2O3) (Figure 6).
  5. Wear Rate: The wear rate is reduced by (46.4) % in aluminum reinforced by 1.25% Fe2O3. (Figure 7)
Figure 2. SEM a) 1.25 wt%Fe2O3, b) 1.25 wt%SiO2, c)1.25 wt%Fe2O3+1.25 wt%SiO2.
Figure 2. SEM a) 1.25 wt%Fe2O3, b) 1.25 wt%SiO2, c)1.25 wt%Fe2O3+1.25 wt%SiO2.
Figure 3. XRD pattern of a: Al-(1.25 wt.%) Fe2O3 b: Al-(1.25 wt.%) SiO2.
Figure 3. XRD pattern of a: Al-(1.25 wt.%) Fe2O3 b: Al-(1.25 wt.%) SiO2.
Figure 4. The Brinell hardness magnitudefordifferent Al alloys.
Figure 4. The Brinell hardness magnitudefordifferent Al alloys.
Figure 5: Compressive strength magnitude of different Al alloys.
Figure 5: Compressive strength magnitude of different Al alloys.
Figure 6: Shows the Young modulus vs Al percentage.
Figure 6: Shows the Young modulus vs Al percentage.

List of figure names:

  • Figure 1. Various matrix and strengthening materials are utilized for MMC production[25].
  • Figure 2. SEM a) 1.25 wt%Fe2O3, b) 1.25 wt%SiO2, c)1.25 wt%Fe2O3+1.25 wt%SiO2.
  • Figure 3. XRD pattern of a: Al-(1.25 wt.%) Fe2O3 b: Al-(1.25 wt.%) SiO2.
  • Figure 4. The Brinell hardness magnitudefordifferent Al alloys.
  • Figure 5: Compressive strength magnitude of different Al alloys.
  • Figure 6: Shows the Young modulus vs Al percentage.
  • Figure 7: At steady state, the wear rate for Al specimens at (time=20 min.).

7. Conclusion:

Summary of key findings:

  1. SEM and XRD results show the nanoparticles impeded in the aluminum matrix and shifting the peaks of the XRD pattern.
  2. The finding illustrated that at 10 N, the highest wear rate is in the Al sample, and the wear rate is reduced by (46.4) % in aluminum reinforced by 1.25% Fe2O3.
  3. The percentage increment of Brinell hardness is (25.5%), (6.8%) and (19.3%) for aluminum reinforced with 1.25 SiO2, 1.25 Fe2O3, and (1.25 SiO2, 1.25 Fe2O3) wt.% particles specimens, respectively.
  4. The maximum improvement for the Al+1.25 Fe2O3 specimen was recorded at 26.5% in compressive strength.
  5. The young modulus values decrease with an increasing reinforcement percentage.

Possible areas for future expansion research:

Further optimization of stir-casting parameters is recommended to enhance particle wettability and minimize agglomeration. Exploring different weight percentages and hybrid reinforcement combinations. Fatigue testing and long-term environmental exposure studies.

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9. Copyright:

  • This material is a paper by "Khaldun Aldawoudi, Ayad Mohammed Nattah, Nabaa Sattar Radhi, Zainab S. Al-Khafaji, Manar Khaleel Ibrahim": Based on "Identify Microstructure and Mechanical Behavior of Aluminum Hybrid Nano Composite Prepared by Casting Technique".
  • Source of paper: https://doi.org/10.59038/jjmie/190112

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