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Aluminum and its alloys have numerous applications in manufacturing, aerospace, and automotive industries. At elevated temperatures, they start to fail in fulfilling their roles and functions. Aluminum-based metal matrix composites (MMCs) are good alternatives for metal and alloys due to their excellent properties. However, the conventional machini...
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... was equipped with a pointed diamond probe with a scanning length of 5 mm. The experiments were planned as per full factorial design, as demonstrated in Table 2. ...
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... was equipped with a pointed diamond probe with a scanning length of 5 mm. The experiments were planned as per full factorial design, as demonstrated in Table 2. ...
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Citations
... In contrast, helical chips were produced at a higher feed rate and cutting speed. The two-degree model accurately predicted feed force, cutting force, and surface roughness with a lower error range (3%−9%) [23]. Khanna et al. machined an AZ91/SiC particulate magnesium matrix composite and analyzed the surface roughness and chip breakability index through a full factorial experimental design. ...
Machinability analyses of metal matrix composites are essential for manufacturing industries. The current study is focused on the mathematical modeling of the machinability of an in-situ synthesized RZ5-8 wt.% TiB2 composite using the Taguchi design statistical tools and analysis of variance (ANOVA). Taguchi's method indicates that the feed rate is the most influential parameter, followed by the depth of cut and cutting speed in determining the cutting force and surface roughness during the machining of the RZ5/8 wt.% TiB2 composite. A regression analysis of the experimental data was carried out using ANOVA, and regression equations were established to estimate cutting force and surface roughness under different parametric conditions. The regression model was validated for other test conditions and the maximum deviation observed was ±10%. Main effects plots and response surface plots were developed to analyze the machining parameters' individual and combined effects on the RZ5/8 wt.% TiB2 composite's machinability. The chip morphology and tool wear of the RZ5/8 wt.% TiB2 composite were analyzed using FESEM under different machining conditions.
... The crucible containing a solid metal mixture of aluminium and copper was kept inside an induction furnace and then heated to a temperature of 800°C for one full hour. Then, hexachloroethane (C 2 Cl 6 ) tablets were added to serve the purpose of degassing the mixture, thereby removing any and all dissolved atmospheric gases [18][19][20]. Now, the mixture of K 2 TiF 6, KBF 4 salts, and cryolite (Na 3 AlF 6 ) are gently added to the molten aluminium-copper alloy. ...
This paper examines the turning processTurning process for an Al-4.5%Cu/TiB2/3p MMC compositeComposite on an HMT lathe machine. An attempt has been made to explore the machining characteristics such as cutting force of the in situIn situ MMC composite by varying the machining input parameters to include cutting speed, depth of cut, and feed rate. To have an enhanced understanding of the mechanism behind the turning operation, a three-dimensional finite element simulation modelFinite element modelling (FEM) was developed for the estimation of cutting force by replicating the process of turning using the software code ANSYS 19.1. In this research study, the Johnson–Cook material and failure model was used for deformation of the constitutive material using finite element (FE) simulation modellingFinite element modelling (FEM) while considering the ductile nature of the Al-4.5%Cu/TiB2/3p compositeComposite. In this study, several simulation models were developed with varying cutting parameters and finite elementFinite element modelling (FEM)(FE) mesh sizeMesh size. The cutting forces were estimated by conducting both numerical simulation modelling and turning experiments of the chosen aluminum alloyAluminum alloy metal matrix compositeComposite [Al-4.5%Cu/TiB2/3p], and contrasts are drawn between the results obtained from using these two methods. The simulation models for the different cutting parameters and conditions exhibited near-similar chip morphology and cutting forces as was obtained through the turning operation. Further, as the mesh of the chip was refined, the cutting force was observed to be in good agreement with the experimental value.
... These materials are often made up of a continuous phase, which serves as the matrix and a dispersed phase, which serves as the reinforcement. Metal-matrix composites (MMCs), polymer-matrix composites (PMCs), ceramic-matrix composites (CMCs), and even intermetallic-matrix composites (IMCs) are the four main categories of composites that have been developed and put forth based in essence on the matrix material used [14][15][16][17][18]. The family of metal-matrix composites provide a healthy combination of properties to include low weight, high strength, adequate fatigue resistance, acceptable corrosion resistance, good wear resistance, and high stiffness. ...
An aluminum alloyAluminum alloy, i.e., aluminium-silicon alloy reinforced with particulates of titanium diborideTitanium diboride particulates (TiB2) and in situ processed metal-matrix composites can safely be categorized to be an advanced material that has shown much promise for selection and use in the industries spanning structural, automotive, aerospace, and both performance-critical and non-performance-critical end products. This is essentially because of its high strength-to-weight [σ/ρ] ratio and good-to-excellent wearWear resistance characteristics. These composites tend to exhibit superior wearWear resistance coupled with good fatigue strength in comparison with the monolithic counterpart at both room temperature and at elevated temperatures. An exothermic reaction between the hexafluorotitanate (K2TiF6) salt, potassium borofluoride (KBF4) salt, and molten aluminum-silicon (Al-Si) alloy results in the production of the TiB2 particulatesTitanium diboride particulates which is present as the reinforcing phase in the soft aluminum alloyAluminum alloy metal matrix. Two volume fractions of the TiB2 particulateTitanium diboride particulatesreinforcementReinforcement, i.e., 3 weight pct. and 6 weight pct. were considered for synthesizing test specimens of the composite material. The presence of both titanium and boron in the reinforcing TiB particlesTitanium diboride particulatesB was confirmed using energy-dispersive X-ray analysis. Study of microstructure of the in situ processed composite specimens revealed a near-uniform distribution of the TiB2 particulatesTitanium diboride particulates in the aluminum alloyAluminum alloy [Al-Si alloy] metal matrix. Mechanical properties and dry sliding wearWear behavior of the as-synthesized composite materials were studied using a pin-on-disk tribometer. The coefficient of friction (COF) and wearWear rate were studied with precision under various conditions. The intrinsic mechanisms governing wearWear and elemental analysis of the wearWear surfaces of the composite test specimens were established following examination in a scanning electron microscope.
... The emerging field of metal matrix composites (MMCs) can spearhead this revolution from a materials science perspective while becoming a significant contributor to this cause. Moreover, with both the present and future consumers more interested in climate-friendly material and related technologies and concurrently the Governments pushing for reforms, it is high time that industry should focus on this field by assuring adequate Research and Development [3][4][5][6]. Moreover, improved global awareness of such materials has resulted in a sudden increase in the demand for introducing sustainable and climate-friendly green composite technologies [7,8]. ...
Globally, there has been a noticeable wave to gradually shift to green materials for the purpose of sustainable and climate-friendly development. The emergence of metal matrix compositesMetal matrix composites contributed in a small way to this revolution. In this technical manuscript, the potential for metal matrix composites (MMCs) to aid in achieving sustainable and eco-friendly development goals is presented and briefly highlighted. The family of metal matrix compositesMetal matrix composites is gaining increased attention among the scientific research community and industrial community for selection and use in applications due in essence to their advantages of being eco-friendly and sustainable coupled with an acceptable combination of physical propertiesProperties and mechanical propertiesProperties. The sustainable development goals can be made possible by applying the technologyTechnology development specific to metal matrix composites to both recyclable materials and materials having lightweight. This would result in replacing the existing material with metal matrix composite having fewer energy inputs for manufacturingManufacturing while concurrently offering better characteristics. A short overview of the interest of the end-user in climate-friendly materials and related technologies is presented.
... The properties of composites are significantly different from that of the matrix material as the composite comprises the additional insoluble phases [5]. Aluminum matrix composites are a popular choice for automobile and aerospace industries due to their outstanding properties such as low density, good wear resistance, thermal stability, low density, high strength and stiffness, and high damping capacity [6][7][8][9]. They are best known for their weight-saving properties, which include high strength-to-weight ratio and can withstand high temperatures [10][11][12]. ...
In today's technological and scientific era, new generation materials are intended to achieve the demands of several engineering industries. The researchers are now turning their attention towards new age composite materials from monolithic materials which can be attributed to the increased and exceptional capabilities of these materials. Aluminium-based hybrid metal matrix compositesHybrid metal-matrix composites have a tremendous potential and can be used for many technical applications that can meet the growing need for enhanced properties such as better toughness, corrosion resistance, and high strength. Aluminium-based metal matrix composites are at the top of the list of composites for a variety of applications in automotive, aircraft, and marine industries owing to their high strength-to-weight ratio, better toughness, high wear resistance, and hardness. This literature review highlights the various aspects pertinent to hybrid reinforcement in composites where aluminium was employed as the integral matrix material. While different fabrication techniques and processing routes were also studied by means of mechanical characterization, property enhancements with further augmentation in mechanical and thermalThermal behavior properties resulting in lower wear rates, and better microstructuresMicrostructure. The comparison between various reinforcementsReinforcements, such as nitrides, borides, carbides, oxides, etc. has been evaluated, aiming to climax the properties and obtain the best results for diverse technical applications. The aluminium-based hybrid metal matrix composites’Hybrid metal-matrix composites future capabilities and scope are also covered at the conclusion of this article.
... It is attributed to the increase in machining temperature with higher cutting speed, irrespective of machining conditions. Thermal softening of workpiece material is a possible reason for lower feed forces, which is also consistent with earlier reported results [34,35]. DM showed highest feed force of 111 N among all four machining conditions at a feed of 0.16 mm/rev, whereas machining using GCF showed significant reduction as feed force is 84 N at same feed (Fig. 8a). ...
Metal cutting causes severe friction and heat generation in the machining zone. Previously, petroleum-based cutting fluids were applied for reducing friction and machining temperature at the machining zone. Nowadays, nano-cutting fluids are preferred owing to their higher thermal conductivity and better lubricating ability. However, during machining of hard materials (hardness, ≥50 HRC), the effectiveness of these nano-cutting fluids is limited, as they rarely reach to the cutting edge of cutting tool because of high normal stresses. In this regard, the combination of rake face micro-textured cutting tool with indigenously synthesized nano-green cutting fluids under in-house developed minimum quantity cutting fluid (MQCF) environment is accomplished for hard machining experiments. For comparison, hard machining experiments are also performed under dry machining, green cutting fluid and nano-green cutting fluid (NGCF) with untextured cutting tools. Detailed analysis shows significant improvement in hard machining performance using combination of micro-textured tools with NGCF corresponding to forces, chip-tool interface friction, workpiece surface roughness and chip morphology. It is attributed to better infiltration of NGCF in-between chip-tool interface by virtue of micro-textures present on the cutting tool rake face. Further, the proposed analytical model captures the effect of textures on the tool surface in the same way as reduced contact tools. It is in a good agreement with corresponding experimental cutting forces.
... Ramkumar et al. [20] studied the problem pertaining to efficiency of turning cycles by measuring the cutting forces and tool wear on the cutting edge. Jimmy et al. [21] synthesized Al-Si-TiB2 composites and analyzed the performance characteristics of cutting forces and surface roughness. Basavarajappa et al. [22] synthesized 15 wt.% reinforced Al 2219 composite and 15-3 wt.% graphite reinforced A1 2219 hybrid composite. ...
Reinforced aluminum composites are the basic class of materials for aviation and transport industries. The machinability of these composites is still an issue due to the presence of hard fillers. The current research is aimed to investigate the drilling topographies of AA7075/TiB2 composites. The samples were prepared with 0, 3, 6, 9 and 12 wt.% of fillers and experiments were conducted by varying the cutting speed, feed, depth of cut and tool nose radius. The machining forces and surface topographies, the structure of the cutting tool and chip patterns were examined. The maximum cutting force was recorded upon increase in cutting speed because of thermal softening, loss of strength discontinuity and reduction of the built-up-edge. The increased plastic deformation with higher cutting speed resulted in the excess metal chip. In addition, the increase in cutting speed improved the surface roughness due to decrease in material movement. The cutting force was decreased upon high loading of TiB2 due to the deterioration of chips caused by fillers. Further introduction of TiB2 particles above 12 wt.% weakened the composite; however, due to the impact of the microcutting action of the fillers, the surface roughness was improved.
... The composites progressed as a groundbreaking material for engineering components throughout the middle of the twentieth century offering new possibilities for advanced technology. Usually, any material consisting of two or more components with different properties and distinct boundaries between the components can be stated as a composite material [24][25][26][27][28][29][30][31]. Cotton-polymer are reportedly the first state reinforced plastics that utilizes radar aircraft carriers, the very first example was the East Trabant car in 1950, the frame was made of polyester tightened with cotton threads [32]. ...
Plant base cellulose nanofibers with diameter 20–50 nm are obtained by Agave gigantea through the steam explosion method. These nanofibers used as a reinforcement to making composites at different percentages (10%, 15%, and 20%) with epoxy LY556 & hardener HY951 used as a matrix at a 10:1 ratio. Thermoset polymer is used as a matrix although it has a great strength-to-weight ratio, and performance, and good thermal properties. Preparation of composite used hand-lay-up method with random orientation of fibers, examining the mechanical properties of nanofiber-reinforced polymer matrix composites like tensile testing, impact testing, and hardness of the composites. The percentage of nanofibers has greatly influenced the mechanical properties of the material. The significant enhancement of mechanical characteristics was observed as the result of addition of nanofibers as a reinforcement in composites. Finding the percentage of absorption of moisture for the different samples at the same period and the rate of water absorption depend on the percentage of fiber used in the composite. It is directly proportional to the percentage of fibers and is the only the demerit when using plant base nanofiber as reinforcement.
... The composites progressed as a groundbreaking material for engineering components throughout the middle of the twentieth century offering new possibilities for advanced technology. Usually, any material consisting of two or more components with different properties and distinct boundaries between the components can be stated as a composite material [24][25][26][27][28][29][30][31]. Cotton-polymer are reportedly the first state reinforced plastics that utilizes radar aircraft carriers, the very first example was the East Trabant car in 1950, the frame was made of polyester tightened with cotton threads [32]. ...
The objective of this study was to develop a natural fiber-based composite with fibers extracted through a simple technique called a steam explosion. These environment friendly materials having deterioration rate greater than that of the other polymer-based materials commonly used in manufacturing industries. During this study, the cellulose nanofibers were extracted from a hemp fiber with the help of steam explosion technique. To confirm its suitably for bio-based composites structure implementations, the characteristic features and morphological properties were meticulously studied. The chemical characterization of Hemp fiber material exhibited a rise in cellulose content from 64% to 95%, due to bleach, alkali and acid therapies. Scientific evidence confirms that non-cellulosic compounds extraction such as lignin and hemicellulose that occur in acid, steam explosion and bleaching treatment, as observed in chemical properties during pre and post chemical fiber therapy. Scanning electron microscopy studies indicates that a decrease in the fiber-diameter aspect ratio and the percentage yield of nano-fiber removed by such a procedure is found to be very high compared with other conventional approaches during steam explosion with acid treatment. X-ray diffraction analysis exhibited the crystallinity of fiber contained crystalline cellulose was increased due to performed procedure. The composite developed with the reinforcement of the steam explosion process demonstrate increased mechanical properties such as hardness, tensile strength and toughness of the material used (Epoxy LY 556 and Hardener HY 951). The cellulose fiber-reinforced composites were processed after obtaining the cellulose fiber from the steam explosion process. Mechanical properties such as harness, tensile strength and toughness were significantly improved.
... Mechanical properties of the aluminum alloy-based metal matrix composites [denoted as AMCs] are significantly influenced by the conjoint and mutually interactive influences of matrixreinforcement bonding and the fabrication and processing route chosen and used to process the composite material. Ceramic reinforcement particles, such as titanium diboride (TiB 2 ), aluminum oxide or alumina (Al 2 O 3 ), titanium carbide (TiC), and silicon carbide (SiC) along with pure aluminum or an aluminum alloy, are often chosen for use in structural applications primarily because of their higher fracture toughness and good wear-resistance properties [4,5]. With the additions of titanium diboride (TiB 2 ) particles to an aluminum alloy metal matrix, the elastic modulus or stiffness of the resultant composite noticeably increases and this value is often greater than that for the composite material obtained by the addition of reinforcements like aluminum oxide (Al 2 O 3 ) and titanium carbide (TiC). ...
The primary objective of this pape is to present and discuss the appropriateness of using the stir casting process as a viabke approach for the fabrication an in-situ aluminum alloy-based metal matrix composite (MMCs). The exothermic chemical reaction that occurs between the K2TiF6 and KBF4 salts is responsible for the formation and presence of the reinforcing titanium diboride (TiB2) particles in the melted aluminum-copper alloy. Presence of these particles exerts an influence on hardness, tensile strength and even ductility of the engineered composite material. With the help of X-ray diffraction (XRD) and field emission scanning electron microscopy (FE-SEM) both the chosen aluminum alloy and the synthesized aluminum alloy composite material were characterized to facilitate a better understanding of the intrinsic morphological details and/or intrinsic features to include the size, morphology and distribution of the TiB2 reinforcement in the aluminium alloy metal matrix. For purposes of enhancing the mechanical properties of the chosen Al-4.5 pct. Cu alloy and the Al-4.5 wt.pct Cu/xTiB2 composite a T6 heat treatment sequence was used and test results of the heat treated alloy compared with results obtained for the as-cast counterpart.
