In the present work, mechanical, tribological, and electrochemical behaviors of Al Alloy 6061–(0–10) % B4C–(0.25–1.2) % graphene nanoplatelets (GNPs) composites, prepared by a combination of solution mixing and powder metallurgy, were investigated. Properties such as hardness, compressive strength, wear rates, and coefficient of friction (COF) were used to investigate the effects of GNPs on mechanical and self-lubricating tribological behavior. The corrosion resistance of composites was investigated using potentiodynamic polarization and electrochemical impedance techniques. Scanning electron microscopy, energy-dispersive X-ray spectroscopy (EDS), and EDS mapping were employed to study the distribution, the fracture profile, and wear mechanism. The AA 6061–10% B4C–0.6% GNPs composites exhibited sharp increase in hardness and compressive strength and significant decrease in wear rates and COF. However, for GNPs contents exceeding over 0.6 wt%, mechanical properties and wear performances deteriorated. Pulling out of sheared pultruded GNPs was observed during the fracture of composites. Worn surfaces of GNPs-containing composites showed the smeared graphene layer with some macro-cracks exhibiting delamination wear. It was found that the corrosion inhibition efficiency of GNPs was more pronounced in H3BO3 environment than in NaCl solution.

A systematic characterization of a less known Al, Fe, Mn, and Si phase in a SiC particulate-reinforced 2014Al composite (SiCp/2014Al) was performed. In addition to the expected CuAl2 phase, the Al, Fe, Mn, and Si phase was formed as either an adhesion (>1 µm) onto SiC in the as-cast composite, or as a precipitate (<100 nm) in the matrix after hot extrusion. The structure of the phase was identified as cubic by both X-ray diffraction and selected area electron diffraction (SAED). The SAED pattern also indicated that the structure belongs to the Pm$\bar{3}$ space group instead of Im$\bar{3}$. The thermodynamic phase diagram was calculated, confirming the presence of an α-AlFeMn or α-AlFeSi phase in the Al–Fe–Mn and Al–Fe–Si ternary systems, respectively, within the Fe, Mn, and Si content range corresponding to 2014Al. Wavelength-dispersive spectroscopy analysis indicated that the composition of the phase is close to Al12(Fe, Mn)3Si2, in which the Mn/Fe ratio is in the range of 0.6–1.4. The determined Mn/Fe ratio corresponds to the nominal composition of Mn and Fe in the alloy.

For thixoforming, it is necessary to have a good microstructure of fine, uniform, and globular grains in a semisolid range. In this study, the nano-Al2O3(Al2O3np)/Al7075 composites with a high solid fraction were fabricated by specially made Al2O3np containing Mg powders and semisolid ultrasonic vibration (SSUV) process. The influence of SSUV technology on primary α-Al grain and second phase in the composites was investigated. Microstructural studies revealed that a good semisolid slurry with an average grain size of 73 μm, a shape factor of 0.84, and a solid fraction of 0.715 could be obtained. Also, it could be shown that SSUV affected largely the size and type of the second phase as well as growth and nucleation of the primary α-Al grain. TEM analysis revealed that there are well-defined crystallographic orientation relationships between the second phases and α-Al, suggesting enhanced heterogeneous nucleation in Al7075 alloys. Moreover, mechanisms involved in the development of microstructure were discussed.

This research focuses on the microstructural characterization of nickel matrix composites reinforced by carbon nanotubes (CNTs). The nanocomposites were produced by a conventional powder metallurgy process and the dispersion of CNTs and mixture with nickel powders was performed in a single step by ultrasonication. Microstructural characterization of Ni–CNT nanocomposites was performed by scanning and transmission electron microscopy, electron backscattered diffraction, high-resolution transmission electron microscopy, selected area electron diffraction, and fast Fourier transform analyses. This characterization revealed CNTs embedded in the nickel grains and mainly presented as clusters at the grain boundaries. CNTs hinder recrystallization during sintering, and dislocation cells and subgrains form as a result of the recovery process.

Graphite flakes (Gf)/Si/Al composites have been fabricated with different volume fraction of graphite by vacuum gas pressure infiltration. In the composites, the addition of Si played a role of spacing apart graphite layers, which can produce voids between layers for the infiltration of molten aluminum. Microstructural characterization indicated that the reinforcements were fairly distributed in the Al and a clean interface lacking of Al3C4 phase was formed between Al and Gf. With the increase of Gf from 39 to 81 vol%, the longitudinal thermal conductivity (TC) of composites increased from 294 to 390 W/m K, but the open porosity increased from 1.85 to 6.03%. Besides, a joint M1–M2 prediction model was established, which considered that the microstructure of composites lies in between two models: (M1) a layered structure in binary metal-particle composites and (M2) ternary composites that oriented flakes randomly distributed in metal-particle confirmed a better theoretical prediction of TC.

This research focuses on characterization of the impact of dispersion methods on aluminum-carbon nanotubes (Al-CNTs) nanocomposite structure. Nanocomposites were produced by a conventional powder metallurgy process after the dispersion of the CNTs on the Al powders, using two approaches: (1) the dispersion of CNTs and mixture with Al powders were performed in a single step by ultrasonication; and (2) the CNTs were previously untangled by ultrasonication and then mixed with Al powders by ball milling. Microstructural characterization of Al-CNT nanocomposites was performed by optical microscopy, scanning and transmission electron microscopy, electron backscatter diffraction, and high-resolution transmission electron microscopy (HRTEM). Microstructural characterization revealed that the use of ball milling for mixing CNTs with Al powders promoted the formation of CNT clusters of reduced size, more uniformly dispersed in the matrix, and a nanocomposite of smaller grain size. However, the results of HRTEM and Raman spectroscopy show that ball milling causes higher damage to the CNT structure. The strengthening effect of the CNT is attested by the increase in hardness and tensile strength of the nanocomposites.

Aluminum matrix composite with 10 wt% of MoO3 particulate reinforcement was synthesized through powder metallurgy technique. The cold upsetting studies of the composites were investigated based on Taguchi L9 orthogonal array experimental design to evaluate the significance of compaction pressure, sintering temperature, and sintering time on strength coefficient. The combination of 350 MPa pressure, 600 °C temperature, and 90 minutes sintering time was identified as the optimum blend for maximum strength coefficient using the main effect plot. From the analysis of variance, compaction pressure and sintering temperature were identified as highly contributing parameters on strength coefficient. Further, a confirmation test was also conducted with the optimum parameter for validation of the Taguchi results. X-ray diffraction and scanning electron microscopy were used to confirm the presence of MoO3 and its uniform distribution over the aluminum matrix.

Nanosized Al2O3 (Al2O3np) reinforced Al7075 composites were fabricated by specially made Al2O3np containing Mg powder and subtype multifrequency ultrasonic vibration. Compared to traditional techniques, Al2O3np was effectively dispersed in the matrix by the novel method. Microstructural studies showed that the addition of Al2O3np caused the grain refinement and that the resultant microstructures of composites depended on the dominant size and degree of Al2O3np clustering. The grain refinement could be mainly attributed to particle pushing mechanisms. Compared to the matrix alloy, the ultimate tensile and compressive strength of the as-cast composite with 1.5 wt% Al2O3np fabricated at 800 °C were increased by 59.6% and 42.6%, respectively. Transmission electron microscope analysis showed that high density dislocations and clear interfaces between particles and matrix were present in the grains, suggesting that the superior improvement of mechanical properties can be attributed to dislocation-type strengthening of matrix alloy and load transfer from matrix to hard nanoparticles.

Aluminum metal matrix hybrid composites were synthesized through powder metallurgy route from ball milled powders to yield the compositions: Al + 0% TiO2, Al + 2.5% TiO2, Al + 2.5% TiO2 + 2% Gr, and Al + 2.5% TiO2 + 4% Gr. The densification and deformation properties of sintered Al–TiO2–Gr composites during cold upsetting were investigated experimentally. The powder preforms are compacted using suitable punch and die in 40 kN hydraulic press and the initial percentage theoretical density was maintained as 85%. Sintering was done in an electric muffle furnace at the temperature of 590 °C for a period of 3 h. The sintered preforms were subjected to incremental compressive loading of 10 kN until cracks were found at the free surface. The true axial stress (σz), true hoop stress (σθ), true hydrostatic stress (σm), and true effective stress (σeff) were calculated for all the preforms and all these stresses are correlated with the true axial strain (εz). The densification behaviors of the composites were studied against true axial strain (εz) and lateral strain. Better densification and deformation property were obtained for pure aluminum preforms compared with other composite preforms. Addition of TiO2 to the pure Al and Gr reinforcements increases the strength coefficient of the Al–TiO2 composite.

In this paper, a modeling method was introduced for SiC particle reinforced aluminum matrix composite. Micro-indentation technique was used to study the micro properties of both SiC particles and aluminum matrix with Micro-Compression-Tester. Mechanical properties like Young's modulus and hardness were calculated using Oliver and Pharr method. After repeated experiments, the average Young's modulus and the hardness of matrix and particle were calculated as 76.8 and 334.7 GPa, 1.58 and 32.56 GPa, respectively. During the indentation experiments on particle, the phenomenon of particle acting as “second indenter” was detected from the recorded P–h curves. Besides, the material elastic–plastic properties of matrix were analyzed using inverse method. Based on the micro material properties from indentation, the indentation processing of particle as second indenter has been simulated. Also, the simulation model at micro scale has been established by using such material properties for further investigation.