Search Results (299)

This study addresses the issue of adapting the thermal drilling process for joining dissimilar thin-walled materials—sheets made of non-ferrous metal alloys and polymer composites with a thermoplastic matrix reinforced with glass and carbon fibers—without the use of connecting elements and without disrupting the continuity of the reinforcing fibers. An extensive metallographic study was conducted on bushings formed in thin metal sheets made of EN AW 6082 T6 aluminum alloy and AZ91 magnesium alloy obtained during separate drilling procedures. Experiments were also performed where the metal sheet and composite material overlapped, using both direct and sequential drilling above the melting point of the polymer matrix, applying various process parameters. The dimensions of the resulting bushings and the suitability of their profile for joining with composites were evaluated. The results suggest the possibility of joining metals and fiber composites through thermal drilling, and suitable joining process parameters and conditions are specified. To limit composite delamination, it is advisable to make a hem flange on the reverse side of the joints. CT scans confirmed the deflection of fibers around the hole in the composite without compromising their integrity. The load-bearing capacity of the joints and the possibility of creating hybrid mechanical–adhesive joints between these materials are the subject of Part Two of this study. Full article

Powder metallurgy is an ideal technique for manufacturing metal matrix composites, owing to its capacity for near-net shape production and minimal material waste. However, a characteristic feature of the aluminum green compacts during the sintering process is the presence of natural oxide films on the surfaces of aluminum powders, which limits the application of aluminum powder metallurgy technology. To address this, we propose a sonication-assisted mixing and liquid metal sintering strategy by which aluminum powder can be easily sintered at the temperature as low as 623 K, two-thirds of the melting point of aluminum. The present investigation demonstrates that the molten gallium enhances metallurgical bonding between the aluminum particles by acting as a “bridge” between adjacent aluminum particles and disrupting the oxide film inevitably existing on the outermost layer of aluminum powder. According to the performance analysis results, when the sintering temperature is as low as two-thirds of the melting point of aluminum, the compressive strength of the Al-5Ga sample increases by 62.5% compared with that of pure aluminum. This innovation will help powder metallurgy researchers to pursue sintering at low-temperature and has a sweeping impact on a wide range of powder metallurgy applications. Full article

This study investigates the application of phononic crystal plates for automotive vibration and noise attenuation through a combined material–structure design approach. Four materials—aluminum, lead, epoxy resin, and plexiglass—were selected to construct a composite plate with a low-density matrix and high-density metallic inclusions. Finite element modeling in COMSOL Multiphysics identified organic glass–lead as the optimal configuration, balancing wide bandgap performance with low-frequency characteristics and lightweight requirements. Parametric analysis demonstrated that rectangular inclusions provide the widest bandgap under equal area conditions, and increasing their volume fraction shifts the bandgap to lower frequencies while broadening its width. The study verifies the reliability of the finite element method (FEM) and further explains the formation mechanism of the bandgap. This study proposes a phononic crystal plate structure with optimal performance: a rectangular phononic crystal plate with a length of A = 20 mm and a height of B = 10 mm serves as the matrix, and four identical rectangular inclusions each with an area of S = 16 mm² are embedded in it. The matrix material is organic glass, while the material of the inclusions is lead. The resulting optimized structure exhibits a complete Lamb wave bandgap from 6.29 to 22.03 kHz, with strong elastic wave attenuation extending over 6.00–30.00 kHz. Acoustically, it achieves sound transmission loss (STL) exceeding 130 dB within 5.85–27.91 kHz, peaking at 143.99 dB. These results verify the structure’s dual functionality in simultaneous vibration isolation and sound attenuation within the same frequency range, demonstrating the potential of phononic crystal plates for targeted noise and vibration control in automotive engines and rotating machinery. Full article

Lightweight metal matrix composites (MMCs) continue to attract significant interest due to their potential to deliver high mechanical performance at reduced weight, meeting the increasing demands of aerospace, automotive and advanced manufacturing sectors. Among these systems, aluminum-, magnesium- and titanium-based MMCs stand out for their favorable strength-to-weight ratios, corrosion resistance and versatility in processing. Although numerous studies have explored individual MMC families, the literature still lacks comparative reviews that integrate quantitative mechanical data with a broad evaluation of processing, microstructural control and application-driven performance. This review addresses these gaps by providing a comprehensive and data-driven assessment of lightweight MMCs. Recent advances in reinforcement strategies, hybrid architectures and processing routes—including friction stir processing, powder metallurgy and semi-solid techniques—are systematically examined. Emerging developments in syntactic metal foams and functionally gradient MMCs are analyzed in detail, along with practical considerations such as machinability, corrosion resistance, and high-temperature performance, integrated with AI/machine learning for predictive optimization. Overall, this work provides an integrated and critical perspective on the capabilities, limitations, and design trade-offs of lightweight MMCs, positioning them as sustainable and high-performance alternatives for extreme environments. By combining qualitative insights with quantitative meta-analyses and new experimental contributions, it offers a valuable reference for researchers and engineers seeking to optimize material selection and tailor the performance of MMCs for next-generation lightweight structures, surpassing previous reviews through holistic and innovation-driven insights. Full article

Composites based on the AlSi12 aluminum alloy reinforced with Saffil^TM fibers (Composite I) and with both Saffil^TM fibers and nickel-coated graphite flakes (Composite II) were developed using the squeeze casting method in the fabrication process. The objective of this work was to evaluate the influence of the employed reinforcements on the mechanical properties and corrosion behavior of the obtained materials. To achieve this, investigations were conducted, including SEM analysis, flexural strength testing, Brinell hardness testing, linear sweep voltammetry (LSV) and electrochemical impedance spectroscopy (EIS). Corrosion measurements were performed in a 3.5% NaCl solution at room temperature. Mechanical investigations revealed a significant increase in flexural strength and hardness for Composite I compared to the plain matrix alloy. In contrast, Composite II’s flexural strength was reduced by the weakening effect of graphite flakes. Performance under bending improved by 46% for Composite I and 25% for Composite II compared to the AlSi12. The corrosion resistance of the tested materials followed the order AlSi12 > Composite I > Composite II. The LSV and EIS results indicate that the explanation for this may be differences in the properties of the protective oxide/hydroxide layer. Furthermore, SEM images showed a weak bond between nickel and graphite. Full article

The use of aluminum alloys in aerospace is limited by their poor weldability, making many incompatible with additive manufacturing (AM) processes like powder bed fusion—laser beam metal (PBF-LB/M), known as well as laser powder bed fusion. This incompatibility hinders the fabrication of complex, lightweight components. To overcome this, Aluminum Metal Matrix Composites (AMMCs) are formed by mechanically alloying the non-processable Al6082 base alloy with ceramic reinforcements; subsequently, Titanium Carbide (TiC) and Silicon Carbide (SiC) particles are developed. This approach induces microstructural changes necessary for AM compatibility. The influence of varying reinforcement contents (1–5 wt.%) on powder homogeneity, microstructural evolution (via Energy Dispersive X-ray Spectroscopy and Electron Backscatter Diffraction), processability, and mechanical properties is systematically studied. The key finding is that metallurgical modification is a robust solution. TiC addition at 2 wt.% and 5 wt.% completely eliminated solidification cracking, achieving high processability. SiC substantially reduced cracking compared to the base alloy. These results demonstrate the potential of AMMCs to successfully translate conventional, non-weldable aluminum alloys into the realm of advanced additive manufacturing. Full article

In the present study, aluminum matrix composites (AMCs) were fabricated by friction stir processing (FSP) using Ni-Cu particles. Ni-Cu particles were added to the Al matrix in two ways. First, without any treatment and in the form of a mixture of as-received powders. Second, treated through mechanical alloying to form Monel solid-solution particles. The particles were added to a groove to be processed by the FSP tool to produce a local AMC. To investigate the kinetics of intermetallic compounds (IMCs) growth in reinforcement particles, the produced AMCs were annealed at 500 °C for 2 h. To characterize the reinforcing particles, several analyses were performed on the samples. Field-emission scanning electron microscopy (FE-SEM) was used to study the size, morphology, and IMC thickness. TEM was performed to characterize the IMCs through high-resolution chemical analyses. Tensile testing was used to understand the mechanical properties and fracture behavior of AMCs. Tensile testing revealed a noticeable improvement in strength for the as-mixed sample, with a UTS of 90.3 MPa, approximately 22% higher than that of the base aluminum. In contrast, the mechanical alloying sample with annealing heat treatment exhibited a severe drop in ductility, with elongation decreasing from 17.98% in the as-mixed sample to 1.52%. The results showed that heat treatment thickened the IMC layer around the reinforcing particles formed during the FSP process with as-mixed particles. In the AMC reinforced with mechanically alloyed Ni-Cu powders, IMC formation during FSP was significantly suppressed compared to that of as-mixed particles, despite the finer size resulting from milling. Additionally, the heat treatment resulted in only a slight increase in IMC thickness. The IMC layer thickness after heat treatment in both the mechanically alloyed sample and the as-mixed sample was approximately 2 µm and 20–40 µm, respectively. The reason behind this difference and its effect on the fracture behavior of the composite were elaborated in this study, giving insights into metal-matrix production with controlled reaction. Full article

Overcoming the strength–ductility trade-off in conventional aluminum matrix composites (AMCs) remains a significant challenge. This study employs dual-scale hybrid reinforcement particles comprising micron-sized Cu and nano-sized Ti, alongside bimodal micro-sized pure Al powders as matrix fillers. The AMCs were fabricated through ball milling (BM) combined with multi-pass friction stir processing (FSP). The homogenously distributed hybrid reinforcement particles generate an integrated composite region consisting of both coarse-grained (CG) and fine-grained (FG) structures, demonstrating enhanced material characteristics. The interwoven network of coarse- and fine-crystalline domains constructs a heterogeneous architecture that enables simultaneous improvement in both strength and ductility properties. The micron-Cu acts as a skeletal support within the matrix, enhancing load transfer efficiency and effectively hindering dislocation motion. The nano-Ti and in situ intermetallics facilitate grain refinement via the pinning effect and promote heterogeneous nucleation, which contributes to stress dispersion and dislocation obstruction. The addition of dual-scale micron-sized pure Al powder particles promotes the formation of the heterogeneous architecture, which enhances the balancing of strength and ductility in the composite. Following compositing (Al₁₀-5Cu-10Ti-10Al₂₀), the alloy exhibits an ultimate tensile strength (UST) of 267 MPa, a hardness of 98 HV, and an elongation of 16.7%, representing increases of 193.4%, 226.7%, and 9.9%, respectively, relative to the base metal. Full article

This research investigated the influence of volume fraction (30 vol.% and 40 vol.%) and particle size α-Al₂O₃ on the physical and mechanical properties of AlMg7 composites manufactured by the squeeze casting technique. The aim of the study was to characterize the microstructure, hardness, density, tensile strength (σmax), compressive strength (σcmax), and impact strength, with a discussion of the mechanisms of destruction. The obtained materials exhibited very low porosity (below 2%), confirming the high efficiency of the ceramic preforms infiltration process. It was found that both hardness and tensile strength increase with decreasing size of the reinforcing particles. The highest growth in hardness at 113% was observed for the composite with 40 vol.% of F1200 particles, while the highest tensile strength, 341 MPa, was noted for materials with 30 vol.% of the same fraction of α-Al₂O₃ particles. In the case of compressive strength, the opposite relationship was observed, where an increase in volume fraction to 40% resulted in a significant rise in σcmax to 522 MPa. The tests also indicated that an increase in the proportion of the brittle ceramic phase radically reduces the impact strength of composites compared to the matrix, which is typical for composite materials with a metallic matrix. Microstructure analysis of the fractures revealed that the mechanism of destruction depends on the type of load and the size and proportion of particles, which is reflected in the transition from transcrystalline cracking to delamination at the phase boundary. The results confirm that the strengthening processes of composites depend on the effective transfer of stresses at the microscopic level. Full article

ZrO₂-MgO-Al₂O₃ ceramics, despite a long history of research, still attract the attention of researchers due to the high potential of their applications as refractories and matrices for metal ceramics. A unique composition combining high strength and temperature stability is particularly in demand. In this paper, a comprehensive study of ceramics of the composition (90−x)·ZrO₂-10·MgO-x·Al₂O₃ (x = 10–80 wt.%) obtained by solid-phase sintering with preliminary annealing is carried out. Preliminary annealing was used for the possible formation of metastable phases with outstanding mechanical properties. Using the X-ray diffraction method, it was found that most of the samples consist of monoclinic zirconium oxide, magnesium–aluminum spinel, and corundum phases. The exception is the sample with x = 10 wt.%, in which the main phase was a cubic modification of zirconium oxide. By formation this type of ZrO₂ polymorph in the composition hardness and flexural strength significantly increased from 400 to 1380 and 50 to 210 MPa, respectively. The total porosity of ceramics under study lies in the range 6–28%. Using the scanning electron microscopy method, it was found that the phase composition significantly affects the morphology of the microstructure of the sintered bodies. Thus, for sintered ceramics with a high corundum content, the microstructure is characterized by high porosity and a large grain size. For the first time, by applying preliminary annealing, a new type of ternary ceramic ZrO₂-MgO-Al₂O₃ was sintered with potentially outstanding mechanical properties. The presence of a stabilized zirconium oxide phase, stresses in the crystal lattice of the matrix phase, and the formation of cracks in the microstructure are the main factors influencing shrinkage, porosity, microhardness, and biaxial flexural strength. Full article

Aluminum metal matrix composites (AMMCs) were obtained using the stir-casting method, adding 0.15, 0.25, and 0.50 in vol.% of ZrO₂. Microstructural observations made using scanning electron microscopy (SEM) indicated that oxide addition modified grain size. X-ray diffraction analyses revealed that mainly ZrAl₃ and Al₂O₃ phases had formed. Hardness evaluation indicated a maximum value of 63 HV for the zirconia-reinforced samples, representing an increase of approximately 70% compared with pure aluminum. This hardness increase was mainly attributed to the zirconia distribution in the aluminum matrix promoting lattice distortion, which promoted the inhibition of dislocation mobility. Wear tests indicated that the samples with 0.50 vol.% of ZrO₂ added presented the lowest wear rate because of the hardness they acquired. The results are discussed considering composite strengthening due to ZrO₂ addition and the thermal treatment applied (cooling rate). Full article

Aluminium metal matrix composites (AMMCs) incorporate aluminium alloys reinforced with fibres (continuous/discontinuous), whiskers, or particulate. These materials were engineered as advanced solutions for demanding sectors including construction, aerospace, automotive, and marine. Micro- and nano-scale reinforcing particles typically enable attainment of exceptional combined properties, including reduced density with ultra-high strength, enhanced fatigue strength, superior creep resistance, high specific strength, and specific stiffness. Microstructural, mechanical, and tribological characterizations were performed, evaluating input parameters like reinforcement weight percentage, applied normal load, sliding speed, and sliding distance. Fabricated nanocomposites underwent tribometer testing to quantify abrasive and erosive wear behaviour. Multiple investigations employed the Taguchi technique with regression modelling. Analysis of variance (ANOVA) assessed the influence of varied test constraints. Applied load constituted the most significant factor affecting the physical/statistical attributes of nanocomposites. Sliding velocity critically governed the coefficient of friction (COF), becoming highly significant for minimizing COF and wear loss. In this review, the reinforcement homogeneity, fractural behaviour, and worn surface morphology of AMMCswere examined. Full article

The increasing demand for lightweight and high-performance brake rotors has led to the exploration of aluminum–metal matrix composites (Al-MMCs) as alternatives to conventional cast iron rotors. This study evaluated the tribological performance of squeeze-cast Al-MMC brake rotors using an AK Master dynamometer test and compared it with that of conventional gray cast iron (GCI) rotors. The Al-MMC rotors demonstrated stable coefficients of friction (CoFs) with reduced wear rates, compared to the GCI rotors. Surface analysis identified the predominant wear mechanisms, including abrasive and oxidative wear. The Al-MMC rotors exhibited sensitivity to pressure and speed, with a CoF range of 0.35–0.47 that decreased at higher pressures and speeds, whereas the GCI rotors maintained a stable CoF range of 0.38–0.44. At elevated temperatures, the GCI rotors displayed superior thermal stability and fade resistance compared to the Al-MMCs, which experienced a 40–60% loss in CoF. Wear analysis indicated material transfer from brake pads to Al-MMC rotors, resulting in protective tribofilm formation, whereas GCI rotors exhibited conventional abrasive wear. These findings highlight the potential of squeeze-cast Al-MMCs for automotive braking applications, offering advantages in weight reduction and wear resistance, but also suggest the need for further material optimization to enhance high-temperature performance and friction stability. Full article

The formation of metal–polymer composites by 3D printing PLA and PETG onto EN AW-5182 H111 aluminum substrates without the use of adhesives was investigated. Four surface treatments were evaluated on the metal substrate (fine sanding, coarse sanding, abrasive blasting, and acid etching), over which a polymer primer—prepared from PLA and PETG solutions—was applied. Subsequently, test specimens were fabricated using the same polymer through material extrusion (MEX) with filaments. Adhesion strength between the printed polymer and the metal substrate was assessed through perpendicular tensile, lap shear, and three-point bending tests. The 16-condition experimental matrix combined surface treatment, primer thickness, and bed temperature and was replicated for each test. Peak tensile and shear strengths confirmed the effectiveness of the proposed strategy, with PETG consistently showing a higher interfacial performance than PLA. ANOVA analysis identifies primer layer thickness (p = 0.023) and loading type (p = 0.031) as statistically significant variables. The results suggest that either abrasive or acid pretreatment, combined with a primer thickness ≥ 80 µm and moderate bed temperatures (65 °C for PLA and 90 °C for PETG), enables the fabrication of robust metal–polymer joints, which are particularly resistant to shear stress and suitable for industrial applications. Full article

Difficult, extreme operating conditions of parabolic antennas under precipitation and sub-zero temperatures require the creation of effective heating systems. The purpose of the research is to develop a multilayer coating containing two metal-ceramic layers, epoxy composite layers, carbon fabric, and an outer layer of basalt fabric, which allows for effective heating of the antenna, and to study the properties of this coating. The multilayer coating was formed on an aluminum base that was subjected to abrasive jet processing. The first and second metal-ceramic layers, Al₂O₃ + 5% Al, which were applied by high-speed multi-chamber cumulative detonation spraying (CDS), respectively, provide maximum adhesion strength to the aluminum base and high adhesion strength to the third layer of the epoxy composite containing Al₂O₃. On this not-yet-polymerized layer of epoxy composite containing Al₂O₃, a layer of carbon fabric (impregnated with epoxy resin) was formed, which serves as a resistive heating element. On top of this carbon fabric, a layer of epoxy composite containing Cr₂O₃ and SiO₂ was applied. Next, basalt fabric was applied to this still-not-yet-polymerized layer. Then, the resulting layered coating was compacted and dried. To study this multilayer coating, X-ray analysis, light and raster scanning microscopy, and transmission electron microscopy were used. The thickness of the coating layers and microhardness were measured on transverse microsections. The adhesion strength of the metal-ceramic coating layers to the aluminum base was determined by both bending testing and peeling using the adhesive method. It was established that CDS provides the formation of metal-ceramic layers with a maximum fraction of lamellae and a microhardness of 7900–10,520 MPa. In these metal-ceramic layers, a dispersed subgrain structure, a uniform distribution of nanoparticles, and a gradient-free level of dislocation density are observed. Such a structure prevents the formation of local concentrators of internal stresses, thereby increasing the level of dispersion and substructural strengthening of the metal-ceramic layers’ material. The formation of materials with a nanostructure increases their strength and crack resistance. The effectiveness of using aluminum, chromium, and silicon oxides as nanofillers in epoxy composite layers was demonstrated. The presence of structures near the surface of these nanofillers, which differ from the properties of the epoxy matrix in the coating, was established. Such zones, specifically the outer surface layers (OSL), significantly affect the properties of the epoxy composite. The results of industrial tests showed the high performance of the multilayer coating during antenna heating. Full article