Search Results (150)

Silica/alumina composite particles were synthesized via the sol–gel method to promote fine dispersion and homogenous mixing. Aluminum chloride hydroxide served as the alumina precursor, while amorphous silica, obtained from rice husk, was directly incorporated into the alumina sol. Following synthesis, the material was calcined at 1000 °C, yielding an α-cristobalite form of silica and corundum-phase alumina. These hybrid particles were introduced into polymer composites at reinforcement levels of 1 wt.%, 3 wt.%, and 5 wt.%. Mechanical behavior was evaluated through three-point bending tests, Shore D hardness measurements, and controlled-energy impact testing. Among the formulations, the 3 wt.% composite exhibited optimal performance, displaying the highest flexural modulus and strength, along with enhanced impact resistance. Hardness increased with rising particle content. Fractographic analysis revealed that the 3 wt.% loading produced a notably rougher fracture surface, correlating with improved energy absorption. In contrast, the 5 wt.% composite, although harder than the matrix and other composites, exhibited diminished toughness due to particle agglomeration. Full article

To elucidate the key material parameters governing the tribological performance of ceramic composites under dry sliding against steel, this study presents a comprehensive comparative assessment of the microstructural characteristics, mechanical performance, and tribological behavior of two alumina–zirconia (Al₂O₃–ZrO₂) ceramic composites, each reinforced with a 42 vol.% carbide phase: zirconium carbide (ZrC) and tungsten carbide (WC). Specifically, tungsten carbide (WC) was selected for its exceptional bulk mechanical properties, while zirconium carbide (ZrC) was chosen to contrast its potentially different interfacial reactivity against a steel counterface. ZrC and WC were selected as reinforcing phases due to their high hardness and distinct chemical and interfacial properties, which were expected to critically affect the wear and friction behavior of the composites under demanding conditions. Specimens were consolidated via spark plasma sintering (SPS). The investigation encompassed macro- and nanoscale hardness measurements (Vickers hardness HV₁, HV₁₀; nanoindentation hardness H), elastic modulus (E), fracture toughness (K_IC), coefficient of friction (COF), and specific wear rate (W_s) under unlubricated reciprocating sliding against 100Cr6 steel at normal loads of 10 N and 25 N. The Al₂O₃–ZrO₂–WC composite exhibited an ultrafine-grained microstructure and markedly enhanced mechanical properties (HV₁₀ ≈ 20.9 GPa; H ≈ 33.6 GPa; K_IC ≈ 4.7 MPa·m^½) relative to the coarse-grained Al₂O₃–ZrO₂–ZrC counterpart (HV₁₀ ≈ 16.6 GPa; H ≈ 27.0 GPa; K_IC ≈ 3.2 MPa·m^½). Paradoxically, the ZrC-reinforced composite demonstrated superior tribological performance, with a low and load-independent specific wear rate (W_s ≈ 1.2 × 10⁻⁹ mm³/Nm) and a stable steady-state COF of approximately 0.46. Conversely, the WC-reinforced system exhibited significantly elevated wear volumes—particularly under the 25 N regime—and a higher, more fluctuating COF. Scanning electron microscopy coupled with energy-dispersive X-ray spectroscopy (SEM–EDX) of the wear tracks revealed the formation of a continuous, iron-enriched tribofilm on the ZrC composite, derived from counterface material transfer, whereas the WC composite surface displayed only sparse tribofilm development. These findings underscore that, in steel-paired tribological applications of Al₂O₃–ZrO₂–based composites, the efficacy of interfacial tribolayer generation can supersede intrinsic bulk mechanical attributes as the dominant factor governing wear resistance. Full article

In recent times, fiber reinforced polymer composite materials have become more popular due to their remarkable features such as high specific strength, high stiffness and durability. Particularly, Carbon Fiber Reinforced Polymer (CFRP) composites are one of the most prominent materials used in the field of transportation and building engineering, replacing conventional materials due to their attractive properties as mentioned. In this work, a CFRP laminate is fabricated with carbon fiber mats and epoxy by a hand layup technique. Alumina (Al₂O₃) micro particles are used as a filler material, mixed with epoxy at different weight fractions of 0% to 4% during the fabrication of CFRP laminates. The important objective of the study is to investigate the influence of alumina micro particles on the mechanical performance of the laminates through characterization for various physical and mechanical properties. It is revealed from the results of study that the mass density of the laminates steadily increased with the quantity of alumina micro particles added and subsequently, the porosity of the laminates is reduced significantly. The SEM micrograph confirmed the constituents of the laminate and uniform distribution of Al₂O₃ micro particles with no significant agglomeration. The hardness of the CFRP laminates increased significantly for about 60% with an increase in weight % of Al₂O₃ from 0% to 4%, whereas the water gain % gradually drops from 0 to 2%, after which a substantial rise is observed for 3 to 4%. The improved interlocking due to the addition of filler material reduced the voids in the interfaces and thereby resist the absorption of water and in turn reduced the plasticity of the resin too. Tensile, flexural and inter-laminar shear strengths of the CFRP laminate were improved appreciably with the addition of alumina particles through extended grain boundary and enhanced interfacial bonding between the fibers, epoxy and alumina particles, except at 1 and 3 wt.% of Al₂O₃, which may be due to the pooling of alumina particles within the matrix. Inclusion of hard alumina particles resulted in a significant drop in impact strength due to appreciable reduction in softness of the core region of the laminates. Full article

This study explores the use of Polypropylene (PP) as a cost-effective matrix in composite materials, employing marble dust (MD) as a readily available filler. PP’s affordability and suitable strength make it ideal for various applications. MD, composed of CaCO₃, alumina, and silica, enhances mechanical strength and is commonly used in construction applications like concrete. Composite specimens were fabricated using the injection molding technique, and their mechanical properties (tensile, flexural, and compressive strength) were analyzed following ASTM standards. Tribological properties were assessed through a pin-on-disc apparatus with varying MD proportions. SEM and EDS analyses visually inspected the fracture types and filler distribution in the composites. Full article

Multi-principal element alloys (MPEAs) exhibit distinct characteristics compared to conventional single-principal element-based metallic materials, primarily due to their unique design, resulting in intricate microstructural features. Currently, a comprehensive understanding of the fabrication processes, compositional design, and microstructural influence on the tribological and corrosion behavior of multi-component alloys remains limited. While the hardness of MPEAs generally correlates positively with wear resistance, with higher hardness typically associated with improved wear resistance and reduced wear rates, quantitative relationships between these properties are not well established. In this study, the Al₁₀Cr₁₇Fe₂₀NiV₄ alloy was selected as a model system. A homogeneous Al₁₀Cr₁₇Fe₂₀NiV₄ alloy was successfully synthesized via mechanical alloying followed by spark plasma sintering (SPS). To further investigate the correlation between hardness and wear rate, varying concentrations of alumina nanoparticles were incorporated into the alloy matrix as a reinforcing phase. The results revealed that the Al₁₀Cr₁₇Fe₂₀NiV₄ alloy exhibited a single-phase face-centered cubic (FCC) structure, which was maintained with the addition of alumina nanoparticles. The hardness of the Al₁₀Cr₁₇Fe₂₀NiV₄ alloy without nano-alumina was 727 HV, with a corresponding wear rate of 2.9 × 10⁻⁴ mm³·N⁻¹·m⁻¹. The incorporation of nano-alumina increased the hardness to 823 HV, and significantly reduced the wear rate to 1.6 × 10⁻⁴ mm³·N⁻¹·m⁻¹, representing a 45% reduction. The Al₂O₃ nanoparticles effectively mitigated alloy wear through crack passivation and matrix strengthening; however, excessive addition reversed this effect due to the agglomeration-induced brittleness and thermal mismatch. The quantitative relationship between hardness (HV) and wear rate (W) was determined as W = 2348 e^(−0.006HV). Such carefully bounded empirical relationships, as demonstrated in studies of cold-formed materials and dental enamel, remain valuable tools in applied research when accompanied by explicit scope limitations. Full article

Foam-formed cellulose biocomposites provide a promising, innovative approach to creating lightweight and eco-friendly materials for utilization in packaging and insulation. This study investigates the production and characterization of temperature-resistant, mechanically stable cellulose fiber (CF) composite foams reinforced with alumina nanofibers (ANFs). To evaluate the impact of ANFs on rheology and drainage, CF suspensions were prepared at a concentration of 20 g/kg, with ANFs added at 2 wt% and 5 wt%. All foams exhibited shear-thinning behavior, with variations in flow characteristics influenced by ANF consistency and particle–bubble interactions. ANFs were integrated into the dry CF foam structure using two methods: (i) immersion in an ANF water suspension, and (ii) direct injection of the suspension into the foam matrix. Mechanical and thermal analyses of the dried CF foams with 2% ANFs demonstrated significant improvements in strength and thermal stability. Incorporating ANFs into CF-based foams enhances their rheological properties, improves mechanical and thermal performance, and reduces combustion rates. These results highlight the potential of ANF-reinforced CF foams for use in industries requiring biodegradable insulation and packaging materials. Full article

This study incorporated silane coupling agent KH550-modified nano-alumina (KH550-Al₂O₃) into vinyl ester resin (VER) for modification. The effect of KH550-Al₂O₃ on the flexural properties of VER and basalt fiber-reinforced vinyl ester resin (BF/VER) composites was investigated. In addition, dynamic mechanical analysis (DMA) and long-term elevated temperature aging of the composites were performed. The surface functionalization of KH550-Al₂O₃ was confirmed by Fourier transform infrared spectroscopy (FTIR), thermogravimetric analysis (TGA), and energy-dispersive X-ray spectroscopy (EDS). It was revealed by scanning electron microscopy (SEM) that the aggregation of KH550-Al₂O₃ had been reduced within the VER matrix, the resin was effectively enhanced, and the fiber–matrix interfacial bonding was improved. Based on the experimental results, the optimal filler loading of KH550-Al₂O₃ was 1.5 wt%. Compared with the control group, the resin matrix exhibited 18.1% and 22.7% improvements in flexural strength and modulus, respectively, while the composite showed increases of 9.3% and 7.6% in these properties. At 30 °C, the storage modulus of the composites increased by 11.5%, with the glass transition temperature rising from 111.0 °C to 112.5 °C. After 60 days of thermal aging at 120 °C, the retained flexural strength and modulus were 64.3% and 87.4%, respectively. Full article

Mullite, 3Al₂O₃·2SiO₂, is a material with excellent thermal and mechanical properties. Two types of waste sand, rich in impurities, were employed as precursors for mullite ceramic synthesis. Two different synthesis routes were used: (i) solid-state reactions involving a sand and bauxite mixture, and (ii) precipitation synthesis, where alumina was deposited on sand particle surfaces; the sintering process was performed at temperatures ranging from 1300 °C to 1400 °C. Mullite was obtained as the main phase when the ceramics were obtained by solid-state reactions opposite to the second method, in which a composite ceramic with a specific microstructure, i.e., sand particles embedded in a matrix formed by alumina crystals, was assessed by electronic microscopy. The main properties, i.e., the apparent density, open porosity, compressive strength and thermal expansion coefficient (CTE) of the obtained materials were influenced by the composition and microstructure as well as the sintering temperature. The ceramics in which mullite was the main phase had slightly lower CTE’s and did not exhibit any phase transition in the 20–900 °C range. The results presented in this article highlight the importance of the synthesis route correlated with the nature of the precursors, the type and amount of impurities and the sintering temperature. Full article

The spark plasma sintering (SPS) technology was applied to develop alumina matrix composites (Al₂O₃MCs) with different nickel-aluminium (NiAl) particle contents of 5–20 wt.% to understand a correlation between their NiAl particle contents and their microstructures, fracture, hardness, friction, and wear. The incorporation of NiAl particles suppressed micrograins and micropores in the microstructures of the Al₂O₃MCs, which resulted in their improved fracture resistance. Increasing the NiAl particle content from 0 to 20 wt.% gave rise to a 23.9% decrease in the hardness of the Al₂O₃MCs. The Al₂O₃MCs had 18.2% and 13.3% decreases in their friction coefficients and 68.3% and 81.3% decreases in their specific wear rates under the normal loads of 2 and 6 N, respectively, with an increased NiAl particle content from 0 to 20 wt.% thanks to their decreased fatigue wear. The SPS Al₂O₃MCs with NiAl particles had promising tribological performance for rotating gas turbine components. Full article

Niobium–graphene oxide–zirconia-toughened alumina (ZTA) composites were produced by wet mixing and spark plasma sintering. The microstructure and mechanical properties of this novel composite have been studied. The results show that niobium particles are homogeneously dispersed in the ZTA matrix. Raman spectroscopy confirmed the thermal reduction in graphene oxide during sintering. The presence of ductile metal and graphene flakes leads to an increase in the crack resistance value of the ZTA matrix. The developed composites demonstrate a fracture toughness of 16 MPa∙m^1/2, which is three times higher than ZTA ceramic composites. The high toughness values found in this new composite are a consequence of the strong interaction between the simultaneous action of several toughening mechanisms, specifically involving crack trapping, crack blunting, crack renucleation, and the bridging mechanisms of the metallic and graphene particles. Moreover, this increase has also occurred due to the enhancement of the transformability of zirconia in ceramic–metal composites. Full article

Alumina is one of the most studied and used ceramic materials, but increasing its fracture toughness is still a challenge for many specific impact applications. Adding a second phase with a low coefficient of thermal expansion (CTE) to an alumina matrix can enhance the matrix’s mechanical properties, reduce its sintering temperature, and increase its toughness by generating compressive stresses on the alumina particle surface. In this study, nanostructured alumina/eucryptite composites were prepared to achieve enhanced toughness. First, eucryptite (Li₂O·Al₂O₃·2SiO₂) nanoparticles were successfully synthesised via colloidal heterocoagulation. These nanoparticles were then used to reinforce alumina matrices through slip casting followed by conventional sintering. Complete crystallisation of eucryptite was achieved at 850 °C with a CTE of 0.46 × 10 ⁻⁶ °C ⁻¹. Transmission electron microscopy analysis revealed that the average particle size was 28.5 ± 14.5 nm. To achieve a relative density of 95.3%, the composite containing 5 vol.% eucryptite required sintering for 1 h at 1400 °C whereas pure alumina required 2 h at 1600 °C. This reduction in sintering temperature (by up to 200 °C) helped to improve the fracture toughness, with the alumina grain size decreasing from 2.3 to 0.9 µm. The advantages of the new composite are the more economically viable and environmentally friendly way of producing the lithium aluminosilicate nanoparticles, compared to the production of ceramic frits at high temperatures (~1500 °C). Full article

Thermally conductive composites were prepared based on epoxidized natural rubber (ENR) filled with alumina, silica, and hybrid alumina and silica. The thermal conductivity and mechanical properties were assessed. It was observed that the interactions of polar functional groups in the fillers and epoxy group in ENR supported a fine dispersion of filler in the ENR matrix. The mechanical properties were improved with alumina, silica, and hybrid alumina/silica loadings. The ENR/Silica composite at 50 phr of silica provided the highest 60 shore A hardness, a maximum 100% modulus up to 0.37 MPa, and the highest tensile strength of 27.3 MPa, while ENR/Alumina with 50 phr alumina gave the best thermal conductivity. The hybrid alumina/silica filler at 25/25 phr significantly improved the mechanical properties and thermal conductivity in an ENR composite. That is, the thermal conductivity of the ENR/Hybrid filler was 2.23 W/mK, much higher than that of gum ENR (1.16 W/mK). The experimental results were further analyzed using ANOVA and it was found that the ENR/Hybrid filler showed significant increases in mechanical and thermal properties compared to gum ENR. Moreover, silica in the hybrid composites contributed to higher strength when compared to both gum ENR and ENR/Alumina composites. The hybrid filler system also favors process ability with energy savings. As a result, ENR filled with hybrid alumina/silica is an alternative thermally conductive elastomeric material to expensive silicone rubber, and it could have commercial applications in the fabrication of electronic devices, solar energy conversion, rechargeable batteries, and sensors. Full article

Aluminium metal matrix composites (AMMCs) using alumina (Al₂O₃) and silicon carbide (SiC) as reinforcement elements are gaining significant interest in various applications because of their excellent properties. In this study, Al₂O₃/SiC with compositions (0.5 wt.%, 1.5 wt.%, and 2.5 wt.% for each) were used as reinforcement elements in an aluminium alloy (AA2024-T6). The samples prepared were AA2024-T6 + (0.5Al₂O₃/0.5SiC), AA2024-T6 + (1.5Al₂O₃/1.5SiC), and AA2024-T6 + (2.5Al₂O₃/2.5SiC) using a stir-casting technique. The experimental study included density calculation mechanical properties, such as tensile strength, compressive strength and hardness. The study also included a microstructure examination of the fracture surface of the tensile specimens. The results showed that incorporating Al₂O₃/SiC as reinforcement materials into aluminium AA2024-T6 significantly improved its properties. Hence, increasing the reinforcement with compositions of 2.5Al₂O₃/2.5SiC into AA2024-T6 showed a drop in density and increased mechanical properties, such as ultimate tensile strength, compressive strength and hardness, compared to the base alloy (AA2024-T6). Furthermore, the scanning electron microscopy analysis revealed the uniform distribution of the reinforcement particles resulting in strong bonding with the matrix. The findings suggest that Al₂O₃/SiC reinforced with AA2024-T6 can be used in applications where a combination of lightweight and high strength is needed. Full article

The aim of this study is to provide tailored alumina particles suitable for reinforcing the metal matrix film. The sol–gel method was chosen to prepare particles of submicron size and to control crystal structure by calcination. In this study, copper-based metal matrix composite (MMC) films are developed on brass substrates with different electrodeposition times and alumina concentrations. Scanning electron microscopy (FE-SEM) with energy-dispersive spectroscopy (EDS), TEM, and X-ray diffraction (XRD) were used to characterize the reinforcing phase. The MMC Cu-Al₂O₃ films were synthesized electrochemically using the co-electrodeposition method. Microstructural and topographical analyses of pure (alumina-free) Cu films and the Cu films with incorporated Al₂O₃ particles were performed using FE-SEM/EDS and AFM, respectively. Hardness and adhesion resistance were investigated using the Vickers microindentation test and evaluated by applying the Chen–Gao (C-G) mathematical model. The sessile drop method was used for measuring contact angles for water. The microhardness and adhesion of the MMC Cu-Al₂O₃ films are improved when Al₂O₃ is added. The concentration of alumina particles in the electrolyte correlates with an increase in absolute film hardness in the way that 1.0 wt.% of alumina in electrolytes results in a 9.96% increase compared to the pure copper film, and the improvement is maximal in the film obtained from electrolytes containing 3.0 wt.% alumina giving the film 2.128 GPa, a 134% hardness value of that of the pure copper film. The surface roughness of the MMC film increased from 2.8 to 6.9 times compared to the Cu film without particles. The decrease in the water contact angle of Cu films with incorporated alumina particles relative to the pure Cu films was from 84.94° to 58.78°. Full article

The miniaturization and high-power density of modern electronic devices pose significant thermal management issues, particularly affecting their performance and lifetime. Ladder-like polysilsesquioxanes (LPSQs) offer a promising solution due to their remarkable thermal, mechanical, and chemical properties. By incorporating thermally conductive fillers, LPSQ composites can achieve high thermal conductivity (TC), making them ideal for thermal management in advanced electronic applications. In this study, LPSQ-based nanocomposites containing functionalized alumina nanoparticles were prepared by solution casting and UV curing, and the effects of varying amounts of Irgacure-184 photoinitiator on their structural and thermal properties were investigated. Three sets of samples were prepared with a fixed amount of LPSQs, 80 wt.% of nanoparticles, and 1, 5, or 10 wt.% of photoinitiator with respect to the matrix. TC was evaluated from the measured values of heat capacity, density, and thermal diffusivity. TC values increased by 60%, 71.2%, and 93.1% for the three samples, respectively, compared to the neat matrix. Results indicate that an intermediate amount of photoinitiator (5%) preserved LPSQs’ structural integrity, namely the presence of long linear silsesquioxane chains, and provided good filler dispersion and distribution, high polymerization degree, thermal stability, and high TC. Full article