Production of aluminum alloy-based metal matrix composites using scrap aluminum alloy and waste materials: Influence on microstructure and mechanical properties

In the present study, aluminium metal matrix composites (AMCs) were successfully produced through stir-squeeze casting using a novel approach. The feasibility of using car scrap aluminium alloy wheels (SAAWs) as the matrix material and spent alumina catalyst (SAC) from oil refineries as reinforcemen...

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Bibliographic Details
Published in:Journal of alloys and compounds Vol. 784; pp. 1047 - 1061
Main Authors: Krishnan, Pradeep Kumar, Christy, John Victor, Arunachalam, Ramanathan, Mourad, Abdel-Hamid I., Muraliraja, Rajaraman, Al-Maharbi, Majid, Murali, Venkatraman, Chandra, Majumder Manik
Format: Journal Article
Language:English
Published: Lausanne Elsevier B.V 05.05.2019
Elsevier BV
Subjects:
Abrasive wear
Alumina
Aluminium metal matrix composites
Aluminum alloys
Aluminum base alloys
Aluminum oxide
Automotive wheels
Casting
Catalysis
Catalysts
Composite materials
Compressive strength
Energy dispersive X ray spectroscopy
Hardness
Mechanical properties
Metal scrap
Microstructure
Morphology
Porosity
Refineries
Reinforcement
Scrap aluminium alloy wheels
Silicon
Spent alumina catalyst
Squeeze casting
Ultimate tensile strength
Weight reduction
X-ray diffraction
Scrap aluminium alloy wheels
Mechanical properties
Spent alumina catalyst
Hardness
Squeeze casting
Aluminium metal matrix composites
ISSN:0925-8388, 1873-4669
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Summary:In the present study, aluminium metal matrix composites (AMCs) were successfully produced through stir-squeeze casting using a novel approach. The feasibility of using car scrap aluminium alloy wheels (SAAWs) as the matrix material and spent alumina catalyst (SAC) from oil refineries as reinforcement material was investigated. For the purpose of comparision, composites were also produced using AlSi7Mg (LM25 grade) aluminium alloy as a matrix and alumina as reinforcement particles through the stir-squeeze casting process. In total, four different combinations of composites (AlSi7Mg + alumina; scrap aluminium alloy + alumina; AlSi7Mg + spent alumina catalyst; scrap aluminium alloy + spent alumina catalyst) were produced and characterized. Microstructural investigations using an optical microscope and a scanning electron microscope (SEM) as well as energy dispersive X-ray spectroscopy (EDS) and X-ray diffraction (XRD) revealed that in all four composites the reinforcement formed a mixture in the eutectic silicon phase of the matrix alloy. The alumina particles' size and content ratio greatly influenced this mixture's formation and morphology. The composites produced using alumina exhibited smaller pore sizes and lower porosity as compared to the composites produced with a spent alumina catalyst. Superior mechanical properties were also obtained when using alumina as reinforcement, and better mechanical properties can mainly be attributed to the morphology of the reinforcement and silicon eutectic phase mixture. The scrap aluminium alloy + alumina exhibited the lowest porosity (7.3%) and abrasive wear loss (0.11 mg for the finest abrasive), highest hardness (58.5 BHN), and second highest ultimate tensile strength (UTS) (125 MPa) and ultimate compressive strength (UCS) (312 MPa) among the four composites. [Display omitted] •A novel approach used to produce metal matrix composites from waste materials.•The alumina reinforcement combines with the eutectic silicon to form a mixture.•Acicular, blunted, needle-like mixture morphology improves mechanical properties.•Enhanced ultimate tensile (125 MPa) and compressive strength (312 MPa) obtained.
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ISSN:0925-8388
1873-4669
DOI:10.1016/j.jallcom.2019.01.115