Abstract: Forging, milling, turning, grinding and shaping etc. are the various industrial manufacturing processes which generate the metal waste. Grinding is extensively used in the finishing operation. The waste generated contains significant impurities apart from the metal particles. Due to these significant impurities, it becomes difficult to process and gets usually dumped in the landfills which create environmental problems. Therefore, it becomes essential to reuse metal waste to create value added products. Powder injection molding process is used for producing the porous metal matrix framework. This paper discusses the presented design of the porous framework to be used for the liquid filter application. Different parameters are optimized to obtain the better strength framework with variable porosity. Carbon nanotubes are used as reinforcing materials to enhance the strength of the metal matrix framework.
Abstract: Partially lubricated sliding wear behaviour of a zinc-based alloy reinforced with 10wt% SiC particles has been studied as a function of applied load and solid lubricant particle size and has been compared with that of matrix alloy and conventionally used grey cast iron. The wear tests were conducted at the sliding velocities of 2.1m/sec in various partial lubricated conditions using pin on disc machine as per ASTM G-99-05. Base oil (SAE 20W-40) or mixture of the base oil with 5wt% graphite of particle sizes (7-10 µm) and (100 µm) were used for creating lubricated conditions. The matrix alloy revealed primary dendrites of a and eutectoid a + h and Î phases in the Inter dendritic regions. Similar microstructure has been depicted by the composite with an additional presence of the dispersoid SiC particles. In the case of cast iron, flakes of graphite were observed in the matrix; the latter comprised of (majority of) pearlite and (limited quantity of) ferrite. Results show a large improvement in wear resistance of the zinc-based alloy after reinforcement with SiC particles. The cast iron shows intermediate response between the matrix alloy and composite. The solid lubrication improved the wear resistance and friction behaviour of both the reinforced and base alloy. Moreover, minimum wear rate is obtained in oil+ 5wt % graphite (7-10 µm) lubricated environment for the matrix alloy and composite while for cast iron addition of solid lubricant increases the wear rate and minimum wear rate is obtained in case of oil lubricated environment. The cast iron experienced higher frictional heating than the matrix alloy and composite in all the cases especially at higher load condition. As far as friction coefficient is concerned, a mixed trend of behaviour was noted. The wear rate and frictional heating increased with load while friction coefficient was affected in an opposite manner. Test duration influenced the frictional heating and friction coefficient of the samples in a mixed manner.
Abstract: Nanostructured materials have attracted many
researchers due to their outstanding mechanical and physical
properties. For example, carbon nanotubes (CNTs) or carbon
nanofibres (CNFs) are considered to be attractive reinforcement
materials for light weight and high strength metal matrix composites.
These composites are being projected for use in structural
applications for their high specific strength as well as functional
materials for their exciting thermal and electrical characteristics. The
critical issues of CNT-reinforced MMCs include processing
techniques, nanotube dispersion, interface, strengthening mechanisms
and mechanical properties. One of the major obstacles to the effective
use of carbon nanotubes as reinforcements in metal matrix
composites is their agglomeration and poor distribution/dispersion
within the metallic matrix. In order to tap into the advantages of the
properties of CNTs (or CNFs) in composites, the high dispersion of
CNTs (or CNFs) and strong interfacial bonding are the key issues
which are still challenging. Processing techniques used for synthesis
of the composites have been studied with an objective to achieve
homogeneous distribution of carbon nanotubes in the matrix.
Modified mechanical alloying (ball milling) techniques have emerged
as promising routes for the fabrication of carbon nanotube (CNT)
reinforced metal matrix composites. In order to obtain a
homogeneous product, good control of the milling process, in
particular control of the ball movement, is essential. The control of
the ball motion during the milling leads to a reduction in grinding
energy and a more homogeneous product. Also, the critical inner
diameter of the milling container at a particular rotational speed can
be calculated. In the present work, we use conventional and modified
mechanical alloying to generate a homogenous distribution of 2 wt.
% CNT within Al powders. 99% purity Aluminium powder (Acros,
200mesh) was used along with two different types of multiwall
carbon nanotube (MWCNTs) having different aspect ratios to
produce Al-CNT composites. The composite powders were processed
into bulk material by compaction, and sintering using a cylindrical
compaction and tube furnace. Field Emission Scanning electron
microscopy (FESEM), X-Ray diffraction (XRD), Raman
spectroscopy and Vickers macro hardness tester were used to
evaluate CNT dispersion, powder morphology, CNT damage, phase
analysis, mechanical properties and crystal size determination.
Despite the success of ball milling in dispersing CNTs in Al powder,
it is often accompanied with considerable strain hardening of the Al
powder, which may have implications on the final properties of the
composite. The results show that particle size and morphology vary
with milling time. Also, by using the mixing process and sonication
before mechanical alloying and modified ball mill, dispersion of the
CNTs in Al matrix improves.
Abstract: The application of agro-industrial waste in Aluminum
Metal Matrix Composites has been getting more attention as they
can reinforce particles in metal matrix which enhance the strength
properties of the composites. In addition, by applying these agroindustrial
wastes in useful way not only save the manufacturing cost
of products but also reduce the pollutions on environment. This
paper represents a literature review on a range of industrial wastes
and their utilization in metal matrix composites. The paper describes
the synthesis methods of agro-industrial waste filled metal matrix
composite materials and their mechanical, wear, corrosion, and
physical properties. It also highlights the current application and
future potential of agro-industrial waste reinforced composites in
aerospace, automotive and other construction industries.
Abstract: The present paper concerns with the influence of fiber
packing on the transverse plastic properties of metal matrix
composites. A micromechanical modeling procedure is used to
predict the effective mechanical properties of composite materials at
large tensile and compressive deformations. Microstructure is
represented by a repeating unit cell (RUC). Two fiber arrays are
considered including ideal square fiber packing and random fiber
packing defined by random sequential algorithm. The
micromechanical modeling procedure is implemented for
graphite/aluminum metal matrix composite in which the
reinforcement behaves as elastic, isotropic solids and the matrix is
modeled as an isotropic elastic-plastic solid following the von Mises
criterion with isotropic hardening and the Ramberg-Osgood
relationship between equivalent true stress and logarithmic strain.
The deformation is increased to a considerable value to evaluate both
elastic and plastic behaviors of metal matrix composites. The yields
strength and true elastic-plastic stress are determined for
graphite/aluminum composites.