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Microstructure, Hardness, and Wear Behavior Investigation of the Surface

Nanocomposite Metal Matrix Reinforced by Silicon Carbide and Alumina
Nanoparticles

Article · September 2021

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 Journal of Mineral, Metal and Material Engineering, 2021, 7, 57-62 57

Microstructure, Hardness, and Wear Behavior Investigation of the

Surface Nanocomposite Metal Matrix Reinforced by Silicon Carbide
and Alumina Nanoparticles

Essam B. Moustaf 1,*, Asmaa M. Khalil2,3, Haitham M. Ahmed4, Mohammed Hefni4 and
Ahmed O. Mosleh2,3

1
Mechanical Engineering Department, Faculty of Engineering, King Abdulaziz University (KAU), P.O. Box
80204, Jeddah, Saudi Arabia
2
National University of Science and Technology “MISiS,” Leninsky Prospekt, 4, Moscow, 119049, Russian
Federation
3
Shoubra Faculty of Engineering, Benha University, Shoubra St. 108, P.O. 11629, Cairo, Egypt
4
Department of Mining Engineering, King Abdulaziz University, Jeddah, Saudi Arabia
Abstract: Aluminum alloys are widely used in applications requiring a high strength-to-weight ratio; however, their low
wear resistance constricted their applications. Improving their wear resistance is a challenge, can be resolved by
compositing aluminum alloys with nanoceramics. In the current work, and Al-Mg system alloy was reinforced with nano
silicon carbide (SiC) and nano aluminum oxide (Al2O3) by friction stir processing (FSP) to enhance their wear resistance
and hardness behavior. The microstructure, hardness, and wear behavior of the manufactured surface nanocomposite
were investigated. The results revealed that reinforcing AA5250 alloy with nanoceramics leads to more refining action on
the microstructure and increases the hardness in the stirred zone by 190% and 230% when using Al2O3 and SiC,
respectively. The wear resistance for both manufactured surface nanocomposites was significantly increased; however,
surface nanocomposite reinforced with AA5250/SiC exhibited higher wear resistance 5.7 times than AA5250/Al2O 3
surface nanocomposite.

Keywords: Nanocomposite, aluminum alloys, nanoceramics, microstructure analysis, wear resistance.

1. INTRODUCTION resistance behavior [22, 23]. AA7057/Al2O3 mechanical

and microstructure properties were enhanced
Recent years have seen an increase in demand for compared to base AA7075 alloy; furthermore, the
novel composites due to the industrial sector's growing hardness behavior was increased by 26% [24]. The
problems. Metal matrix composites are advanced FSP method employed hexagonal boron nitride (hBN)
materials that are utilized in the automotive, military, nanoparticles to strengthen Al alloys. The improved
aerospace, and marine sectors due to their superior mechanical and wear resistance was ascribed to the
mechanical characteristics, low weight, and corrosion solid lubrication mechanism; nevertheless, these
resistance. Aluminum metal matrix nanocomposite is particles had limited electrical and thermal conductivity
one of the most widely utilized materials in today's [25-27].
advanced manufacturing [1-6]. Friction stir processing
(FSP) improves surface nanocomposite materials' AA6061 alloy was reinforced with SiC and Al2O3
production and fabrication process because it is a particles using FSP. As a result, these particles were
clean, flexible, and effective method for creating observed to have an excellent dispersion in the metal
nanocomposite surfaces [7-13]. The FSP method has matrix [28-31]. It will be able to improve the composite
been used to enhance and change the surface properties by using hybrid particles as reinforcements.
characteristics of processed aluminum by utilizing Nanocomposites fabricated from hybridization of two or
reinforced particles and ceramic materials such as B4C, more reinforcements showed excellent mechanical
SiC, Al2O3, VC, CWNT, TiB2, and other reinforcement properties and significantly improved wear resistance
particles [14-21]. This method produces a composite [32-36]. An AA5083/Al2O3+SiC+B4C hybrid composite
with excellent strength, homogeneity, and grain with enhanced mechanical characteristics, hardness,
refinement. Incorporating Al/SiC+Al2O3 hybrid and wear behavior was produced utilizing a stirring cast
nanocomposites has improved the hardness and wear technique. As a result of embedding reinforcing
carbides with alumina particles into the matrix, the
authors contribute to enhancing these characteristics
*Address correspondence to this author at the Mechanical Engineering [37]. To enhance creep behavior, B4C and CNTs
Department, Faculty of Engineering, King Abdulaziz University (KAU), P.O.
Box 80204, Jeddah, Saudi Arabia; E-mail: [email protected] particles were employed to strengthen AA5083 [38].
E-ISSN: 2414-2115/21 © 2021 Scientific Array
58 Journal of Mineral, Metal and Material Engineering, 2021, Vol. 7 Moustaf et al.

The results indicated that adding 5% CNTs to AA5083 the conventional linear intercept method. The wear
reduced wear resistance, creep, and hardness, behavior of the as-received and produced surface
whereas adding B4C with CNTs increased wear nanocomposites was examined using the weight loss
resistance and creep strength. Using FSP, SiC, ZrO2, rate method, and the TNO wear (pin-on-ring) testing
and Gr particles were utilized to increase the ultimate equipment. The specimens were prepared, and the
strength of AA5083 alloy [37]. In the current work, two weight loss was determined and recorded with an
different metal matrix nanocomposites are fabricated accuracy of 10-4g using a digital balance. For ten
using the FSP process to investigate the impact of the minutes, the test conditions were 0.3 bar and 265 rpm.
reinforcement nanoparticles on the microstructure and Vickers microhardness tests were conducted using
hardness behavior. Hence Al2O3 and SiC nanoparticles ZwickRoell tester, in accordance with ASTM E-384-17
were employed to reinforce the AA5250 aluminum standards, with a shutter speed of 10 s and a weight of
alloy. 100 g.

2. MATERIALS AND METHODS 3. RESULTS AND DISCUSSIONS

As a result of its wide range of uses, commercial 3.1. Microstructure Observation

alloy 5250 rolled plates were used as the basis matrix
in this investigation. On the surface of the base alloy, Figure 2 shows the microstructure of the as-
SiC and Al2O3 nanoparticles were reinforced. The size received alloy and the manufactured surface
of the SiC and Al2O3 particles was 30±5 nm and nanocomposites. The received rolled sheet exhibits
10±5 nm, respectively. Using an automated milling elongated, non-recrystallized grains in the rolling
machine, FSP is used to manufacture aluminum metal direction (Figure 2a). The average grain size of the BM
matrix nanocomposites AMMNCs. Figure 1 illustrates is about 70±10µm, with an aspect ratio ‎ close to 4:1.
the FSP manufacturing process, including the tool Friction and severe plastic deformation during FSP
design. The reinforcement nanoparticles were injected cause the SZ to heat up, leading to a dynamically
into the cavity of the rectangular groove at the base recrystallized (DRX) microstructure; as a result, the SZ
matrix surface, which had been pre-grooved using a has more uniform equiaxed refined grains than the
standard milling machine with a dimension of 6 mm base metal. Reinforcing nanoparticles during FSP have
width and 5 mm in depth. For manufacturing MMNCs, a a significant impact on dynamic restoration phenomena
tool rotation speed of 1120 rpm, a constant tilting angle during FSP. According to particle stimulated nucleation
of 1°, and a 40 mm/min travel speed were adjusted. (PSN) and Zener-pinning processes verified by
The microstructure of the produced nanocomposites Humphreys et al. [39], the nano reinforcement particles
samples and the as-received alloy was examined using enhance the refining activity of the grains in the SZ by
an optical microscope. All samples were mechanically increasing the number of nucleation sites for new
grinded, polished with alumina paste, and etched with grains. Moreover, after DRX, nonreinforcement
Keller's etchant. The grain size was determined using particles in the SZ restrict grain development. Figure
2b,c shows that the nanoparticles are clearly

Figure 1: Typical fabrication process with schematic illustration of the FSP fabrication process.
Microstructure, Hardness, and Wear Behavior Investigation Journal of Mineral, Metal and Material Engineering, 2021, Vol. 7 59

Figure 2: The microstructure of (a) as-received AA5250 alloy, (b) surface nanocomposite reinforced with Al2O3, and (d) surface
nanocomposite reinforced with SiC.

distributed uniformly throughout the base metal matrix. 3.2. Micro-Hardness Behavior
The average grain size of the produced nanocomposite
is 4±0.8µm and 5±1.3µm when reinforcing SiC and Figure 3 shows the hardness profile of the as-
Al2O3, respectively. proceed material and the manufactured surface
nanocomposite across processed zones. The average

Figure 3: Vickers microhardness profile across samples of the as-proceed base alloy and manufactured surface
nanocomposites.
60 Journal of Mineral, Metal and Material Engineering, 2021, Vol. 7 Moustaf et al.

Figure 4: Wear rate by weight loss in mg/s of the as-proceed base alloy and manufactured surface nanocomposites.

Vickers microhardness of the as-proceed sheets is microstructure, wear, and hardness characteristics of
about 52±3 HV. It is noted that by reinforcing different the fabricated nanocomposites were significantly
nanoceramics in the stirred zone, the hardness is improved. The reinforcement particles are restricted
significantly enhanced. The refining activity of the grain development during the DRX process, which
aluminum matrix and homogeneous dispersion of hard reduces the composite grain size. The stirring zone, SZ
nanoceramics into the matrix are credited with the of the manufactured nanocomposite, was 400% finer
increased hardness. By incorporating SiC than the as-received alloy. The SiC and Al2O3
nanoparticles into the matrix, the hardness is reinforcement reduced the wear rate by 30 and 6 times
dramatically increased, reaching 160 HV. The the base alloy, respectively. The AA5250/SiC
hardness of the manufactured nanocomposite nanocomposite matrix showed a considerable increase
reinforced with Al2O3 nanoparticles was 120 HV. in wear resistance and hardness behavior due to the
excellent properties of the SiC particles. Also, the
3.3. Wear Behavior homogeneous and well-distributed reinforcing
nanoparticles in the base matrix were achieved.
Figure 4 shows the wear rate by weight loss in mg/s
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Received on 25-08-2021 Accepted on 15-09-2021 Published on 20-09-2021

DOI: https://doi.org/10.31437/2414-2115.2021.07.7

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