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Effect of Fabrication Methods on Mechanical Properties and Machining Parameters of Aluminium Matrix Composites-A Review
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ScienceDirect Materials Today: Proceedings 5 (2018) 22576–22580
www.materialstoday.com/proceedings
ICASE_2017
Effect of Fabrication Methods on Mechanical Properties and Machining Parameters of Aluminium Matrix Composites-A Review. J.P. Savina, B.V. Raghavendra* Department of Mechanical Engineering, JSS Academy of Technical Education, Bangalore-560060, India
Abstract
Aluminium matrix composites (AMCs) are potential material for numerous applications due to their excellent mechanical and physical properties. The stiffness, specific strength, wear, creep and fatigue properties can be enhanced by the addition of the reinforcements in to metallic matrix compared to the conventional engineering materials. Improvement in strength and stiffness has been observed in most metal systems and lowering of the coefficient of friction and the wear rates have been observed by addition of CNTs in Ni, Cu and Al based composites. This paper presents the overview of the effect of addition on various reinforcements in Aluminium highlighting their merits and demerits. Effect of different reinforcement on AMCs on the machining parameters and mechanical properties like tensile strength, strain, hardness, wear and fatigue is discussed in this paper. Major issues like agglomerating phenomenon, fiber-matrix bonding and the problems related to distribution of particles are also discussed in detail. Major applications of different AMCs are also highlighted in this review. © 2018 Elsevier Ltd. All rights reserved. Selection and/or Peer-review under responsibility ofInternational Conference on Advances in Science & Engineering ICASE - 2017. Keywords:Aluminium Matrix Composites; carbon nanotube; Processing Techniques; Machining Parameters.
* Corresponding author. Tel.:+91-848-177-6070; Fax: 0-802-861-2706 E-mail address :[email protected] 2214-7853© 2018 Elsevier Ltd. All rights reserved. Selection and/or Peer-review under responsibility ofInternational Conference on Advances in Science & Engineering ICASE - 2017.
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1. Introduction Review summarizes the research work carried out in the field of metal matrix composites (MMCs) of aluminium with carbon nanotube (CNT) and other materials. Since 1970, Carbon Nano Tube(CNT) reinforced MMC’s have been largely used in a wide array of applications such as aircraft brakes, space structures, military and commercial planes, lithium batteries, sporting goods and structural reinforcement in construction. Research in the field of carbon was revolutionized by the discovery of carbon nanotubes (CNTs) by Ijjima in 1991[1]. Carbon nanotubes have a Young’s modulus of 1TPa, making those ideal reinforcements for composite materials. It is important to understand the relevant strengthening mechanisms involved in CNT/Al composites, in order to produce optimized composites. Three major mechanisms are analysed along with experimental procedure for making CNT/Al composites. The results have shown that mechanical properties of the CNT/Al composite, including Young’s modulus, have shown improvement. The lack of metals and alloys in giving both stiffness and strength to a structure has led to the evolution of metal matrix composites. Among various MMCs, Aluminium has grabbed noteworthy attention due to its good mechanical properties, corrosion resistance, high thermal conductivity, low density and higher strength. Metal matrix composites reinforced with nanoparticles and nanotubes are increasing attention in areas such as aerospace, alternative transport, renewable energy, architectural structure and electronics in order to make lighter and stronger structures [2–5]. The carbon nanotubes having excellent chemical stability due to their seamless cylindrical graphite structure are an exceptional candidate for the reinforcement in aluminum matrix[6]. The Aluminium MMCs have gained the attention for its application in various fields. Aluminium metal matrix composites (AMMC's) with high specific stiffness and high strength could be used in longterm application in which saving weight is an important feature, such applications include aircrafts, high speed machinery, high-speed rotating shafts, and automotive engine and brake parts. 2. Processing Techniques and Effect on Mechanical Properties Wear properties are more critical for coatings and hence most of the wear studies are on Ni-CNT composite coatings formed by electro-deposition techniques [7,8].There are few studies on Cu-CNT and Al-CNT composites [9-14]. All of these studies have reported a decrease in the coefficient of friction (COF) and increase in the wear resistance with addition of CNTs to the metal matrix. The decrease in the COF has been attributed to the lubricating nature of the MWCNTs caused by the easy sliding of their walls, which are attached by weak Van-der Waals forces. The improved resistance to wear is attributed to role of CNTs as spacer’s preventing the rough surfaces of the matrix from contact with the wear pin. Deng et al., (2007) have prepared Al-CNT (1 and 2 wt.-%) composites, through different methods such as hot pressed compacts and hot extrusion (733 K, extrusion ratio of 25:1) of cold isostatic pressing [15]. High temperature processes result in Al4C3 formation at CNT/matrix interface. Al-1 wt.-%CNT composites exposed bridging and pullout in the fracture surface while Al-2 wt.-%CNT displayed interface de-bonding and agglomeration and had relative density of 99%. Kuzumaki et al., (1998) examined 100% increase in the tensile strength for the first time with the addition of 10 vol.-% CNT by the powder metallurgyroute accompanied by SPS60 and/or hot deformation [16]. He reported increased tensile strength about 129% with the addition of 5 vol.-% CNT addition. Salas et al., (2007) have reported deterioration in hardness in a shock-wave-consolidated Al5 vol.-%CNT composite. Agglomeration of CNTs in the matrix and weak interface bonding led to deterioration in the properties [17]. Morsi and Esawiet al. (2007) disperse CNTs in Al matrix by using ball milling technique. Good dispersion is achieved by Milling for up to 48 hrs of CNTs but due to cold welding lead to formation of large spheres (0.1 mm) [18,19]. L. X. Pang et al., (2007) prepared Fe3Al-CNT composites by hot-pressingwhich had revealed enhanced mechanical properties (bend strength, compressive strength and hardness) owing to uniform dispersion of CNTs [20]. The improvement in the mechanical properties was ascribed to inhibition of grain growth caused by interlocking nanotubes. Majkic et al., (2007) prepared Al-CNT composite using Spark Plasma Sintering(SPS) followed by hot extrusion of powders synthesized by a nanoscale dispersion method [21]. This method enhanced the mechanical strength by 129% by adding of 5 vol.-%CNT due to good alignment and distribution of CNTs in the
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matrix.T. Laha et al., (2008) used plasma spray processing to fabricate Al-CNT composite, elastic modulus increased by 40% and addition of CNT revealed the drastic increase in elastic recovery of the composite [22]. Bakshi et al.,(2009) produced Al-CNT composite by cold spraying method has been revealed to performheterogeneously with respect to mechanical properties and no quantification on improvement of the strength has been provided as a result of CNT addition [23]. Noguchi et al.,(2004) have reported a 350% increase in the compressive yield strength with 1/6 vol.-% CNT addition, which, is due to a very homogeneous distribution of CNTs obtained by the Nano-scale dispersion method. They also have achieved 333% increase in hardness and 184% increase in tensile strength with 6%, 5 vol.% CNT additions. Hence, it is clear that homogeneous distribution of CNTs and strong bonding with the matrix are the main means to control the mechanical properties of the MM-CNT composites[24].Meenakshi Sundaram et al.,(2015) carried out experiment for A356-CNT composites fabricated by a special reinforcement technique and compo casting route. Using Vickers scale found that hardness of the samples is increased significantly with the addition of CNTs[25]. Both coefficient of friction and wear rate were increased with addition of MWCNT reinforcements with the rise of normal load, sliding speed and vice versa but decreases by increasing the reinforcement ratio. Jinzhi Liao et al., (2005) have examined, (0.5wt.-%) CNTs reinforced aluminum matrix composites prepared by powder metallurgy technique (PBA)[26]. The experimental result explored the high tensile strength and hardness of composites with less amount of CNTs. Comparing with the pure matrix the small addition of CNTs effectively enhanced the mechanical properties. The study showed good dispersion effects with PBA and high energy ball milling technique. Bakshi et al., (2009)reported spray drying route to prepare homogeneously dispersed CNT in bulk Al-CNT nanocomposite cylinders with thickness of 5 mm[27].The fabricated nanocomposite constituted a matrix comprising CNT rich clusters and uniform dispersion of CNTs. The CNTs were distributed uniformly within the splats and pull out phenomena was noticed with a degree of alignment that could leads in strengthening. Salas et al., (2007) discovered shock wave consolidation of alternate layers of Al powder with 2 and 5 wt.-% CNT [28]. The trail resulted unsuccessful in terms of uniform distribution of CNTs in the matrix due to agglomeration of CNT’s at grain boundaries and triple points of the matrix. He noticed that the rise in the content of CNT resulted in more agglomeration. This agglomeration had direct adverse effect on the mechanical properties of the composite material. Though this fabrication method is more ease to process. Reis et al.,(2012) synthesized CNTs successfully by DC arc discharge process under argon/acetone atmosphere, in the form of CNT-Al agglomerates with other forms of carbon[29]. Conventional powder metallurgy route was used to prepare Aluminum matrix composites reinforced by these CNT-Al agglomerates. The strengthening effect of the CNT-Al agglomerates on the Aluminum matrix increased from 0 to 1.0 wt.-% in CNT-Al agglomerates concentration, hardness raised by 40% in spite of its poor dispersion. 3. Effect on Machining Parameters. Gangadharan et al.,(2011) adopted a relatively new tool to examine nonlinear and chaotic systems called Recurrence Quantification Analysis (RQA) and Recurrence Plots (RP)[30]. Powder metallurgy route was used to develop CNT reinforced Al/Al-Si composites, Al and Al-Si alloys (LM6 and LM25) to study the machining characteristics of cast and powder metallurgy. RQA technique was mainly used to examine, acquire and sense the cutting force signals. The deterministic nature of the cutting force signal for the fabricated materials was found by RQA tool. The results found were maximum for reinforced 0.5% CNTs of Al/Al-Si composites. Mahesh et al.,(2012) conducted turning experiments on machining of Al-SiC-B4C composite prepared by stir casting method[31]. Surface roughness was measured to determine the effect of machining parameters like feed rate, depth of cut and cutting speed. The optimal cutting conditions were found to be depth of cut as 0.5 mm, cutting speed as 90 m/mm and feed rate 0.1 mm/rev. The results were confirmed by ANOVA and the percentage of contribution of machining parameters was obtained. It was confirmed that the depth of cut had less impact on surface roughness. Rajaneesh et al., (2013) studied the effect of machining zinc-aluminium alloy reinforced with silicon carbide particles with Wire Electric Discharge Machining Process(WEDM)[32]. Electrical discharge machining process compare to conventional machining prevents the tool damage and generates complicated contours with superior
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finish. Material Removal Rate (MRR) was reduced as the pulse on time and applied current was increased. With increase in reinforcement percentage, surface roughness increased and material removal rate decreased. Krishnamurthy et al., (2013) used a melt stirring squeeze casting route to fabricate TiB2/Al-6063 MMCs with 40μm in mean size[33]. The machining parameters for turning operations of 5 wt.-% and 10 wt.-% were examined using Taguchi method. For higher MRR of TiB2/Al-6063 MMCs, the optimal conditions of machining parameters with depth of cut as 0.75 mm, cutting speed as 113.07 m/min and feed rate 0.15 mm/min. For lower surface finish of TiB2/Al-6063 MMCs, the optimal conditions of machining parameters with depth of cut as 0.25 mm, cutting speed as 113.07 m/min and feed rate 0.05 mm/min. The less surface roughness value was obtained for K20 compared to K10 type carbide tool. Senthilraja et al., (2015) developed empirical mathematical model about the machining parameters to reduce the surface roughness in drilling of LM25/Sic/B4C -MMC composites by employing the feedback surface methodology (RSM)[34]. The Drilling parameters are cutting speed, Depth of cut, feed rate and environmental conditions. Using empirical relation cutting condition, surface roughness in machining was evaluated. 4. Applications of Aluminium Matrix Composites Modi et al.,(1999) prepared aluminum alloy composite was by stir casting technique. The mechanical, tribological and electrochemical properties of composite makes it a potential material for automobile and related engineering applications [35]. Aluminium composite provided higher wear resistance than those of the base alloys in all tribo-conditions. Composites exhibited improved wear resistance and seizure pressure as compared to the alloy under both dry and lubricated sliding wear. Das et al., (2004) prepared LM13–10 wt.-% SiC composite using stircasting technique[36]. At higher angle of impingement, the possibility of fracturing of the reinforcement is more and results in enhancing the rate of wear. These composites have been proved useful in making marine and mineral processing machinery components experiencing erosion-corrosion wear in practice. Also these Al-SiC composite are useful in making automobile components like brake drums and cylinder blocks and engineering components like refrax apex insert for D-15 hydro cyclones. Maleque et al.,(2012) fabricated new natural fiber reinforced aluminium composite for automotive brake pad application using powder metallurgy technique. Coconut fiber of 5% and 10% reinforced with aluminium composite revealed better physical and mechanical properties compared to other formulations[37]. 10% content of coconut fiber exhibited higher strength to withstand the load application and higher ability to hold the compressive force. Manoj et al., (2009) Al–SiC composites prepared using liquid metallurgy route with varied SiC 5%, 10%, 20% and 25% wt.-% [38]. For a given load, the cumulative wear volumes of composites and pure aluminium pins increased linearly with sliding distance under dry sliding. As normal load increased, the wear rate linearly increased. These composites have been used in making marine and mineral processing machinery components which experiences erosion-corrosion wear in practice. Coefficient of friction is less for composites than that of observed in pure aluminium. 5. Conclusions The paper presents the review on various combination of reinforcements used in the synthesis of AMCs and its effects on the mechanical properties. As the stiffness and strength of a material rises, the dimensions and accordingly the mass of the material required for a certain load bearing application is reduced. This leads to numerous benefits in the field of aircraft and automobiles such as increase in payload and improvement of the fuel efficiency. However, it has also been observed that at higher CNT, loading properties tend to degrade. This is due to the inability of most of the process to homogeneously distribute CNTs or to obtain dense components at high CNT content. To address the issues, furthermore research needs to be conducted on influence of synthesis process upon the mechanical properties to optimize the process and to determine the optimum machining parameters.
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References [1] Sumio. Iijima, Nature, 354 (1991) 56–58. [2] S. R. Bakshi, D. Lahiri, and A. Agarwal, Int. Mater. Rev., 55 (2010)41–64. [3] N. Silvestre, Int.J. Compos. Mater., 3 (2013) 28–44,. [4] T. Laha, A. Agarwal, T. McKechnie and S. Seal, J. Nanosci. Nanotech., 7 (2007) 1–10. [5] R. Casati and M. Vedani, Metals, 4(2014) 65–83. [6] A.K. Srivastava, C. L. Xu, B. Q. Wei, R. Kishore & K. N. Sood, Indi. Jour. of Engg. & Mate. Scie., 15 (2008) 247-255. [7] X. H. Chen, J. C. Peng, X. Q. Li, F. M. Deng, J. X. Wang and W. Z. Li: J. Mater. Sci. Lett., 20 (2001) 2057–2060. [8] X. Chen, G. Zhang, C. Chen, L. Zhou, S. Li and X. Li: Adv. Eng. Mater., 5 (2003) 514–518. [9] W. X. Chen, J. P. Tu, L. Y. Wang, H. Y. Gan, Z. D. Xu and X. B.Zhang: Carbon, 41 (2003) 215–222. [10]K. T. Kim, S. I. Cha and S. H. Hong: Mater. Sci. Eng.A, A449–A451 (2007) 46–50. [11] S. R. Dong, J. P. Tu and X. B. Zhang: Mater. Sci. Eng. A, A313 (2001) 83–87. [12]X. H. Chen, W. H. Li, C. S. Chen, L. S. Xu, Z. Yang and J. Hu: Trans. Nonfer. Met. Soc., 15 (2005) 314–318. [13]J. P. Tu,Y. Z. Yang, L. Y. Wang, X. C. Ma and X. B. Zhang: Tribol. Lett. 10(2001) 225–228. [14]S.M. Zhou, X.B. Zhang, Z.P. Ding, C.Y. Min, G.L. Xu and W.M Zhu: Composites A, 38A (2007) 301–306. [15]C. F. Deng, D. Z. Wang, X. X. Zhang and A. B. Li: Mater. Sci. Eng. A, 444 (2007) 138–145. [16]T. Kuzumaki, K. Miyazawa, H. Ichinose and K. Ito: J. Mater. Res., 13 (1998) 2445–2449. [17]W. Salas, N. G. Alba-Baena and L. E. Murr: Met. Mater. Trans. A, 38A (2007) 2928–2935. [18]K. Morsi and A. Esawi: J. Mater. Sci., 42 (2007) 4954–4959. [19]A. Esawi and K. Morsi: Composites A,38A (2007) 646–650. [20]L. X. Pang, K. N. Sun, S. Ren, C. Sun and J. Q. Bi: J. Compos. Mater., 41 (2007) 2025–2057. [21]G. Majkic and Y. C. Chen: Proc. 47th AiAA Conf., Newport,Rhode Island, (2006–2007) 1–5. [22]T. Laha and A. Agarwal: Mater. Sci. Eng. A, A480 (2008) 323–332. [23]S. R. Bakshi, V. Singh, S. Seal and A. Agarwal: Surf. Coat. Technol., 203 (2009) 1544–1554. [24]T. Noguchi, A. Magario, S. Fukazawa, S. Shimizu, J. BeppuandM. Seki: Mater. Trans., 45 (2004) 602–604. [25]Meenakshi Sundaram. U and Mahamani. A (2015). Dr. BrahimAttaf (Ed.), ISBN 978-0-9889190-1-3, WAP-AMSA, Available from: http://www.academicpub.org/amsa/ [26]R.George,K.T.Kashyap,R.Rahul,S.Yamdagni,Sriptamaterialia 53(2005) 1159-1163. [27]S. R. Bakshi, V. Singh, S. Seal and A. Agarwal: Surf. Coat. Technol., 203 (2009) 1544–1554. [28]W. Salas, N. G. Alba-Baena and L. E. Murr: Met. Mater. Trans. A,38A (2007) 2928–2935. [29]M. A. L. Reis, S. Simões, J. Del Nero, F. Viana, M. F. Vieira ECCM15 - 15th European conference on composite materials, Venice, Italy, (June 2012) 24-28 . [30]K. V. Gangadharan, K. S. Umashankara, Ravisha, V. Desaia,Jordan J. Mech. Ind. Eng., 5 (2011) (ISSN 1995-6665). [31]T.S. Mahesh Babu, M.S.AldrinSugin and N. Muthukrishnan, Procedia Engineering, 38 (2012) 2617-2624. [32]Rajaneesh N. Marigoudara and Kanakuppi,Sadashivappa, International Journal of Applied Science and Eng., 11, 3(2013) 317-330. [33]K.Krishnamurthy and J.Venkatesh IJSRP, 3(April 2013) 4. [34]S.Senthilraja, R.Chinnadurai and J.Satheeshkumar, International Journal of Innovations in Engineering and Technology (ijiet), 5 (2015) 2. [35]O.P. Modi, B.K. Prasad, R. Dasgupta, A.K. Jha and D.P. Mondal, Journal of Materials and Technology, 15(1999) 933-938. [36]S. Das, Trans. Indian Inst. Met. 57, 4 (August 2004) 325-334. [37]M.A. Maleque, A. Atiqah, R.J. Talib and H. Zahurin, International Journal of Mechanical and Materials Engineering (IJMME), 7 (2012) 166170. [38]ManojSingla, Lakhvir Singh, Vikas Chawla, Scientific research, 8 (2009) 10.
ScienceDirect Materials Today: Proceedings 5 (2018) 22576–22580
www.materialstoday.com/proceedings
ICASE_2017
Effect of Fabrication Methods on Mechanical Properties and Machining Parameters of Aluminium Matrix Composites-A Review. J.P. Savina, B.V. Raghavendra* Department of Mechanical Engineering, JSS Academy of Technical Education, Bangalore-560060, India
Abstract
Aluminium matrix composites (AMCs) are potential material for numerous applications due to their excellent mechanical and physical properties. The stiffness, specific strength, wear, creep and fatigue properties can be enhanced by the addition of the reinforcements in to metallic matrix compared to the conventional engineering materials. Improvement in strength and stiffness has been observed in most metal systems and lowering of the coefficient of friction and the wear rates have been observed by addition of CNTs in Ni, Cu and Al based composites. This paper presents the overview of the effect of addition on various reinforcements in Aluminium highlighting their merits and demerits. Effect of different reinforcement on AMCs on the machining parameters and mechanical properties like tensile strength, strain, hardness, wear and fatigue is discussed in this paper. Major issues like agglomerating phenomenon, fiber-matrix bonding and the problems related to distribution of particles are also discussed in detail. Major applications of different AMCs are also highlighted in this review. © 2018 Elsevier Ltd. All rights reserved. Selection and/or Peer-review under responsibility ofInternational Conference on Advances in Science & Engineering ICASE - 2017. Keywords:Aluminium Matrix Composites; carbon nanotube; Processing Techniques; Machining Parameters.
* Corresponding author. Tel.:+91-848-177-6070; Fax: 0-802-861-2706 E-mail address :[email protected] 2214-7853© 2018 Elsevier Ltd. All rights reserved. Selection and/or Peer-review under responsibility ofInternational Conference on Advances in Science & Engineering ICASE - 2017.
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1. Introduction Review summarizes the research work carried out in the field of metal matrix composites (MMCs) of aluminium with carbon nanotube (CNT) and other materials. Since 1970, Carbon Nano Tube(CNT) reinforced MMC’s have been largely used in a wide array of applications such as aircraft brakes, space structures, military and commercial planes, lithium batteries, sporting goods and structural reinforcement in construction. Research in the field of carbon was revolutionized by the discovery of carbon nanotubes (CNTs) by Ijjima in 1991[1]. Carbon nanotubes have a Young’s modulus of 1TPa, making those ideal reinforcements for composite materials. It is important to understand the relevant strengthening mechanisms involved in CNT/Al composites, in order to produce optimized composites. Three major mechanisms are analysed along with experimental procedure for making CNT/Al composites. The results have shown that mechanical properties of the CNT/Al composite, including Young’s modulus, have shown improvement. The lack of metals and alloys in giving both stiffness and strength to a structure has led to the evolution of metal matrix composites. Among various MMCs, Aluminium has grabbed noteworthy attention due to its good mechanical properties, corrosion resistance, high thermal conductivity, low density and higher strength. Metal matrix composites reinforced with nanoparticles and nanotubes are increasing attention in areas such as aerospace, alternative transport, renewable energy, architectural structure and electronics in order to make lighter and stronger structures [2–5]. The carbon nanotubes having excellent chemical stability due to their seamless cylindrical graphite structure are an exceptional candidate for the reinforcement in aluminum matrix[6]. The Aluminium MMCs have gained the attention for its application in various fields. Aluminium metal matrix composites (AMMC's) with high specific stiffness and high strength could be used in longterm application in which saving weight is an important feature, such applications include aircrafts, high speed machinery, high-speed rotating shafts, and automotive engine and brake parts. 2. Processing Techniques and Effect on Mechanical Properties Wear properties are more critical for coatings and hence most of the wear studies are on Ni-CNT composite coatings formed by electro-deposition techniques [7,8].There are few studies on Cu-CNT and Al-CNT composites [9-14]. All of these studies have reported a decrease in the coefficient of friction (COF) and increase in the wear resistance with addition of CNTs to the metal matrix. The decrease in the COF has been attributed to the lubricating nature of the MWCNTs caused by the easy sliding of their walls, which are attached by weak Van-der Waals forces. The improved resistance to wear is attributed to role of CNTs as spacer’s preventing the rough surfaces of the matrix from contact with the wear pin. Deng et al., (2007) have prepared Al-CNT (1 and 2 wt.-%) composites, through different methods such as hot pressed compacts and hot extrusion (733 K, extrusion ratio of 25:1) of cold isostatic pressing [15]. High temperature processes result in Al4C3 formation at CNT/matrix interface. Al-1 wt.-%CNT composites exposed bridging and pullout in the fracture surface while Al-2 wt.-%CNT displayed interface de-bonding and agglomeration and had relative density of 99%. Kuzumaki et al., (1998) examined 100% increase in the tensile strength for the first time with the addition of 10 vol.-% CNT by the powder metallurgyroute accompanied by SPS60 and/or hot deformation [16]. He reported increased tensile strength about 129% with the addition of 5 vol.-% CNT addition. Salas et al., (2007) have reported deterioration in hardness in a shock-wave-consolidated Al5 vol.-%CNT composite. Agglomeration of CNTs in the matrix and weak interface bonding led to deterioration in the properties [17]. Morsi and Esawiet al. (2007) disperse CNTs in Al matrix by using ball milling technique. Good dispersion is achieved by Milling for up to 48 hrs of CNTs but due to cold welding lead to formation of large spheres (0.1 mm) [18,19]. L. X. Pang et al., (2007) prepared Fe3Al-CNT composites by hot-pressingwhich had revealed enhanced mechanical properties (bend strength, compressive strength and hardness) owing to uniform dispersion of CNTs [20]. The improvement in the mechanical properties was ascribed to inhibition of grain growth caused by interlocking nanotubes. Majkic et al., (2007) prepared Al-CNT composite using Spark Plasma Sintering(SPS) followed by hot extrusion of powders synthesized by a nanoscale dispersion method [21]. This method enhanced the mechanical strength by 129% by adding of 5 vol.-%CNT due to good alignment and distribution of CNTs in the
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matrix.T. Laha et al., (2008) used plasma spray processing to fabricate Al-CNT composite, elastic modulus increased by 40% and addition of CNT revealed the drastic increase in elastic recovery of the composite [22]. Bakshi et al.,(2009) produced Al-CNT composite by cold spraying method has been revealed to performheterogeneously with respect to mechanical properties and no quantification on improvement of the strength has been provided as a result of CNT addition [23]. Noguchi et al.,(2004) have reported a 350% increase in the compressive yield strength with 1/6 vol.-% CNT addition, which, is due to a very homogeneous distribution of CNTs obtained by the Nano-scale dispersion method. They also have achieved 333% increase in hardness and 184% increase in tensile strength with 6%, 5 vol.% CNT additions. Hence, it is clear that homogeneous distribution of CNTs and strong bonding with the matrix are the main means to control the mechanical properties of the MM-CNT composites[24].Meenakshi Sundaram et al.,(2015) carried out experiment for A356-CNT composites fabricated by a special reinforcement technique and compo casting route. Using Vickers scale found that hardness of the samples is increased significantly with the addition of CNTs[25]. Both coefficient of friction and wear rate were increased with addition of MWCNT reinforcements with the rise of normal load, sliding speed and vice versa but decreases by increasing the reinforcement ratio. Jinzhi Liao et al., (2005) have examined, (0.5wt.-%) CNTs reinforced aluminum matrix composites prepared by powder metallurgy technique (PBA)[26]. The experimental result explored the high tensile strength and hardness of composites with less amount of CNTs. Comparing with the pure matrix the small addition of CNTs effectively enhanced the mechanical properties. The study showed good dispersion effects with PBA and high energy ball milling technique. Bakshi et al., (2009)reported spray drying route to prepare homogeneously dispersed CNT in bulk Al-CNT nanocomposite cylinders with thickness of 5 mm[27].The fabricated nanocomposite constituted a matrix comprising CNT rich clusters and uniform dispersion of CNTs. The CNTs were distributed uniformly within the splats and pull out phenomena was noticed with a degree of alignment that could leads in strengthening. Salas et al., (2007) discovered shock wave consolidation of alternate layers of Al powder with 2 and 5 wt.-% CNT [28]. The trail resulted unsuccessful in terms of uniform distribution of CNTs in the matrix due to agglomeration of CNT’s at grain boundaries and triple points of the matrix. He noticed that the rise in the content of CNT resulted in more agglomeration. This agglomeration had direct adverse effect on the mechanical properties of the composite material. Though this fabrication method is more ease to process. Reis et al.,(2012) synthesized CNTs successfully by DC arc discharge process under argon/acetone atmosphere, in the form of CNT-Al agglomerates with other forms of carbon[29]. Conventional powder metallurgy route was used to prepare Aluminum matrix composites reinforced by these CNT-Al agglomerates. The strengthening effect of the CNT-Al agglomerates on the Aluminum matrix increased from 0 to 1.0 wt.-% in CNT-Al agglomerates concentration, hardness raised by 40% in spite of its poor dispersion. 3. Effect on Machining Parameters. Gangadharan et al.,(2011) adopted a relatively new tool to examine nonlinear and chaotic systems called Recurrence Quantification Analysis (RQA) and Recurrence Plots (RP)[30]. Powder metallurgy route was used to develop CNT reinforced Al/Al-Si composites, Al and Al-Si alloys (LM6 and LM25) to study the machining characteristics of cast and powder metallurgy. RQA technique was mainly used to examine, acquire and sense the cutting force signals. The deterministic nature of the cutting force signal for the fabricated materials was found by RQA tool. The results found were maximum for reinforced 0.5% CNTs of Al/Al-Si composites. Mahesh et al.,(2012) conducted turning experiments on machining of Al-SiC-B4C composite prepared by stir casting method[31]. Surface roughness was measured to determine the effect of machining parameters like feed rate, depth of cut and cutting speed. The optimal cutting conditions were found to be depth of cut as 0.5 mm, cutting speed as 90 m/mm and feed rate 0.1 mm/rev. The results were confirmed by ANOVA and the percentage of contribution of machining parameters was obtained. It was confirmed that the depth of cut had less impact on surface roughness. Rajaneesh et al., (2013) studied the effect of machining zinc-aluminium alloy reinforced with silicon carbide particles with Wire Electric Discharge Machining Process(WEDM)[32]. Electrical discharge machining process compare to conventional machining prevents the tool damage and generates complicated contours with superior
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finish. Material Removal Rate (MRR) was reduced as the pulse on time and applied current was increased. With increase in reinforcement percentage, surface roughness increased and material removal rate decreased. Krishnamurthy et al., (2013) used a melt stirring squeeze casting route to fabricate TiB2/Al-6063 MMCs with 40μm in mean size[33]. The machining parameters for turning operations of 5 wt.-% and 10 wt.-% were examined using Taguchi method. For higher MRR of TiB2/Al-6063 MMCs, the optimal conditions of machining parameters with depth of cut as 0.75 mm, cutting speed as 113.07 m/min and feed rate 0.15 mm/min. For lower surface finish of TiB2/Al-6063 MMCs, the optimal conditions of machining parameters with depth of cut as 0.25 mm, cutting speed as 113.07 m/min and feed rate 0.05 mm/min. The less surface roughness value was obtained for K20 compared to K10 type carbide tool. Senthilraja et al., (2015) developed empirical mathematical model about the machining parameters to reduce the surface roughness in drilling of LM25/Sic/B4C -MMC composites by employing the feedback surface methodology (RSM)[34]. The Drilling parameters are cutting speed, Depth of cut, feed rate and environmental conditions. Using empirical relation cutting condition, surface roughness in machining was evaluated. 4. Applications of Aluminium Matrix Composites Modi et al.,(1999) prepared aluminum alloy composite was by stir casting technique. The mechanical, tribological and electrochemical properties of composite makes it a potential material for automobile and related engineering applications [35]. Aluminium composite provided higher wear resistance than those of the base alloys in all tribo-conditions. Composites exhibited improved wear resistance and seizure pressure as compared to the alloy under both dry and lubricated sliding wear. Das et al., (2004) prepared LM13–10 wt.-% SiC composite using stircasting technique[36]. At higher angle of impingement, the possibility of fracturing of the reinforcement is more and results in enhancing the rate of wear. These composites have been proved useful in making marine and mineral processing machinery components experiencing erosion-corrosion wear in practice. Also these Al-SiC composite are useful in making automobile components like brake drums and cylinder blocks and engineering components like refrax apex insert for D-15 hydro cyclones. Maleque et al.,(2012) fabricated new natural fiber reinforced aluminium composite for automotive brake pad application using powder metallurgy technique. Coconut fiber of 5% and 10% reinforced with aluminium composite revealed better physical and mechanical properties compared to other formulations[37]. 10% content of coconut fiber exhibited higher strength to withstand the load application and higher ability to hold the compressive force. Manoj et al., (2009) Al–SiC composites prepared using liquid metallurgy route with varied SiC 5%, 10%, 20% and 25% wt.-% [38]. For a given load, the cumulative wear volumes of composites and pure aluminium pins increased linearly with sliding distance under dry sliding. As normal load increased, the wear rate linearly increased. These composites have been used in making marine and mineral processing machinery components which experiences erosion-corrosion wear in practice. Coefficient of friction is less for composites than that of observed in pure aluminium. 5. Conclusions The paper presents the review on various combination of reinforcements used in the synthesis of AMCs and its effects on the mechanical properties. As the stiffness and strength of a material rises, the dimensions and accordingly the mass of the material required for a certain load bearing application is reduced. This leads to numerous benefits in the field of aircraft and automobiles such as increase in payload and improvement of the fuel efficiency. However, it has also been observed that at higher CNT, loading properties tend to degrade. This is due to the inability of most of the process to homogeneously distribute CNTs or to obtain dense components at high CNT content. To address the issues, furthermore research needs to be conducted on influence of synthesis process upon the mechanical properties to optimize the process and to determine the optimum machining parameters.
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