Journal of Composites Science

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13 pages, 6067 KiB

Open AccessArticle

Stress Analysis of Tibial Bone Using Three Different Materials for Bone Fixation Plates

by Mario Ceddia, Giuseppe Solarino, Maria Tucci, Luciano Lamberti and Bartolomeo Trentadue

J. Compos. Sci. 2024, 8(9), 334; https://doi.org/10.3390/jcs8090334 - 23 Aug 2024

Cited by 2 | Viewed by 1011

Abstract

Stress shielding is a problem for traditional metal bone fixation plates made of magnesium and titanium alloys. This problem can be solved by using composite materials with a low elastic modulus. This study analyzed the effect of carbon fiber reinforced PEEK (CFRP) composites [...] Read more.

Stress shielding is a problem for traditional metal bone fixation plates made of magnesium and titanium alloys. This problem can be solved by using composite materials with a low elastic modulus. This study analyzed the effect of carbon fiber reinforced PEEK (CFRP) composites on stress shielding under static loading using finite element simulations. Callus formation times relative to the healing period were gradually imposed according to the elapsed time, considering 1% and 75% as healing stages. The Inventor© 3D CAD 2024 software was used for modeling, and the ANSYS© FEA R2023 software was used for analysis. The results showed that metal fixation plates made of titanium and magnesium alloys transferred less stress to the bone than the CFRP fixation plate. In particular, the use of the CFRP fixation plate resulted in a higher peak stress and a more uniform stress field in the bone, especially in the bone-plate contact area, where the risk of stress shielding is higher in the 1% and 75% healing phases. Full article

(This article belongs to the Special Issue Metal Composites, Volume II)

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12 pages, 3548 KiB

Open AccessArticle

Co-Deposition of Bimetallic Au-Pt with L-Cysteine on Electrodes and Removal of Copper by Iron Powder for Trace Aqueous Arsenic Detection

by Wei-Zhi Zhang, Kan Wang, Ning Bao and Shou-Nian Ding

J. Compos. Sci. 2024, 8(8), 327; https://doi.org/10.3390/jcs8080327 - 18 Aug 2024

Viewed by 988

Abstract

Much progress has been made in the determination of As (III), while numerous electrochemical sensors based on metal nanomaterials with significant sensitivity and precision have been developed. However, further research is still required to achieve rapid detection and avoid interference from other metal [...] Read more.

Much progress has been made in the determination of As (III), while numerous electrochemical sensors based on metal nanomaterials with significant sensitivity and precision have been developed. However, further research is still required to achieve rapid detection and avoid interference from other metal ions (especially copper ions). In this study, bimetallic AuPt nanoparticles are electrochemically modified with screen printing electrodes. What’s more, L-cysteine also self-assembles with AuNPs through Au-S bond to enhance the electrochemical performance. To overcome the interference of Cu (II) in the sensing process, the reduced iron powder was chosen to remove Cu (II) and other oxidizing organics in aqueous solutions. The lowest detectable amount is 0.139 ppb, a linear range of 1~50 ppb with superlative stability by differential pulse anodic stripping voltammetry. Fortunately, the reduced iron powder could eliminate the Cu (II) with no effect on the As (III) signal. Full article

(This article belongs to the Special Issue Metal Composites, Volume II)

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19 pages, 4165 KiB

Open AccessArticle

Modifying the Characteristics of the Electrical Arc Generated during Hot Switching by Reinforcing Silver and Copper Matrices with Carbon Nanotubes

by Bruno Alderete, Christian Schäfer, U. Pranav Nayak, Frank Mücklich and Sebastian Suarez

J. Compos. Sci. 2024, 8(7), 285; https://doi.org/10.3390/jcs8070285 - 22 Jul 2024

Viewed by 763

Abstract

Switching elements are crucial components in electrical and electronic systems that undergo severe degradation due to the electrical arc that is generated during breaking. Understanding the behavior of the electrical arc and modifying its characteristics via proper electrode design can significantly improve durability [...] Read more.

Switching elements are crucial components in electrical and electronic systems that undergo severe degradation due to the electrical arc that is generated during breaking. Understanding the behavior of the electrical arc and modifying its characteristics via proper electrode design can significantly improve durability while also promoting optimal performance, reliability, and safety in circuit breakers. This work evaluates the feasibility of carbon nanotube (CNT)-reinforced silver and copper metal matrix composites (MMCs) as switching electrodes and the influence of CNT concentration on the characteristics of the arcs generated. Accordingly, three different concentrations per MMC were manufactured via powder metallurgy. The MMCs and reference materials were subjected to a single break operation and the electrical arcs generated using 100 W and 200 W resistive loads were analyzed. The proposed MMCs displayed promising results for application in low-voltage switches. The addition of CNTs improved performance by maintaining the arc’s energy in the silver MMCs and reducing the arc’s energy in the copper MMCs. Moreover, a CNT concentration of at least 2 wt.% is required to prevent unstable arcs in both metallic matrices. Increased CNT content further promotes the splitting of the electrical arc due to a more complex phase distribution, thereby reducing the arc’s spatial energy density. Full article

(This article belongs to the Special Issue Metal Composites, Volume II)

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13 pages, 4535 KiB

Open AccessArticle

Minimizing Porosity in 17-4 PH Stainless Steel Compacts in a Modified Powder Metallurgical Process

by Tamás Mikó, Dionysios Markatos, Tamás I. Török, Gábor Szabó and Zoltán Gácsi

J. Compos. Sci. 2024, 8(7), 277; https://doi.org/10.3390/jcs8070277 - 16 Jul 2024

Viewed by 737

Abstract

Nowadays, powder-based manufacturing processes are recognized as cost-efficient methods frequently employed for producing parts with intricate shapes and tight tolerances in large quantities. However, like any manufacturing method, powder-based technologies also have several disadvantages. One of the most significant issues lies in the [...] Read more.

Nowadays, powder-based manufacturing processes are recognized as cost-efficient methods frequently employed for producing parts with intricate shapes and tight tolerances in large quantities. However, like any manufacturing method, powder-based technologies also have several disadvantages. One of the most significant issues lies in the degree of porosity. By modifying the morphology of the gas-atomized spherical 17-4PH stainless steel powder via prior ball milling and then raising both the pressure of cold compaction (1.6 GPa) and sintering temperature (1275 °C), the porosity could be reduced considerably. In our novel powder metallurgical (PM) experimental process, an exceptionally high green density of 92% could be reached by employing die wall lubrication instead of internal lubrication and utilizing induction heating for rapid sintering. After sintering (at temperatures of 1200, 1250, and 1275 °C), the samples aged in the H900 condition were then mechanically tested (Charpy impact, HV hardness, and tensile tests) as a function of porosity. Sintering at 1275 °C for one hour enabled porosity reduction to below 4%, resulting in 1200 MPa yield strength and 1350 MPa ultimate tensile strength with significant (16%) fracture strain. These values are comparable to those of the same alloy products fabricated via ingot metallurgy (IM) or additive manufacturing (AM). Full article

(This article belongs to the Special Issue Metal Composites, Volume II)

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12 pages, 3104 KiB

Open AccessArticle

Hydrolyzed Forms of Cellulose and Its Metal Composites for Hydrogen Generation: An Experimental and Theoretical Investigation

by Omar Faye, Inimfon A. Udoetok, Jerzy A. Szpunar and Lee D. Wilson

J. Compos. Sci. 2024, 8(7), 262; https://doi.org/10.3390/jcs8070262 - 6 Jul 2024

Cited by 1 | Viewed by 875

Abstract

The quest for a smooth transition from fossil fuels to clean and sustainable energy has warranted studies on alternative energy materials. Herein, we report on an experimental and theoretical study focused on hydrogen generation through the hydrolysis of microcrystalline cellulose (MCC) treated in [...] Read more.

The quest for a smooth transition from fossil fuels to clean and sustainable energy has warranted studies on alternative energy materials. Herein, we report on an experimental and theoretical study focused on hydrogen generation through the hydrolysis of microcrystalline cellulose (MCC) treated in different media (deionized water, sodium hydroxide) and MCC functionalized with magnesium (MCC-Mg), titanium (MCC-Ti), and niobium (MCC-Nb). The XRD results reveal the decreased crystallinity of MCC due to ball milling along with the formation of metal oxide composites between MCC and various metals (magnesium, titanium, and niobium). Theoretical studies using NVT molecular dynamic simulations with the NH chain thermostat implemented in the Dmol3 provides further support to the experimental results reported herein. The results from the experimental and theoretical studies revealed that ball milling and composite formation with metal species enhanced the kinetics of the hydrolysis of MCC and, consequently, hydrogen generation, while the addition of NaOH and urea inhibited the hydrogen yield. Full article

(This article belongs to the Special Issue Metal Composites, Volume II)

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22 pages, 5538 KiB

Open AccessArticle

Dynamic FEA Analysis of the Super Lightweight External Cryogenic Fuel Tank (SLWT) Made of Aluminium Alloy 2195–Graphene Nano Composite for Launch Vehicle Aerospace Application

by Ashwath Pazhani, Syed Saad Salman, M. Venkatraman, Alicia Patel, M. Anthony Xavior, Andre Batako, Jeyapandiarajan Paulsamy and Joel Jayaseelan

J. Compos. Sci. 2024, 8(7), 260; https://doi.org/10.3390/jcs8070260 - 4 Jul 2024

Viewed by 1667

Abstract

This research presents a comprehensive dynamic finite element analysis (FEA) of a cryogenic fuel tank made from an innovative aluminium/lithium–graphene nano-composite material, assessing its suitability for aerospace launch vehicles carrying cryogenic hydrogen and oxygen. The study focuses on the effects of lightweighting, utilizing [...] Read more.

This research presents a comprehensive dynamic finite element analysis (FEA) of a cryogenic fuel tank made from an innovative aluminium/lithium–graphene nano-composite material, assessing its suitability for aerospace launch vehicles carrying cryogenic hydrogen and oxygen. The study focuses on the effects of lightweighting, utilizing 0.5 wt.% reinforced graphene in the Al 2195 matrix, a material poised to revolutionize the aerospace industry. Objectives include developing a digital twin of the fuel tank, CAD modeling to aerospace standards, and conducting ANSYS simulations under launch conditions to evaluate stress, strain, and deformation. Numerical results reveal a significant weight reduction of approximately 19,420 kg and a notable maximum stress reduction of 1.3% compared to traditional Al 2195 alloy tanks. The novelty of this research lies in its pioneering analysis of aluminium/lithium–graphene composites for lightweighting in cryogenic fuel tanks under space launch conditions. Conclusions affirm the composite’s viability, advocating for the development of lighter yet robust aerospace structures and fostering innovation in spacecraft design and materials science. Full article

(This article belongs to the Special Issue Metal Composites, Volume II)

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21 pages, 5671 KiB

Open AccessArticle

Competitive Adsorption of Aqueous Cd(II) and Pb(II) Solutions onto Silicas Synthesized with Saponin as Template Agent

by Claudia-Maria Simonescu, Florina Dumitru, Bianca Zărnescu, Daniela Cristina Culiţă, Anca Răzvan, Ovidiu Oprea, Roxana Truşcă and Eugeniu Vasile

J. Compos. Sci. 2024, 8(6), 227; https://doi.org/10.3390/jcs8060227 - 16 Jun 2024

Viewed by 932

Abstract

The aim of the research was to prepare silica adsorbents using an environmentally friendly pathway, a template synthesis with saponin biosurfactant as a structure-directing agent. The adsorbents prepared in this way exhibit improved adsorption properties while maintaining environmental innocuousness. For the preparation of [...] Read more.

The aim of the research was to prepare silica adsorbents using an environmentally friendly pathway, a template synthesis with saponin biosurfactant as a structure-directing agent. The adsorbents prepared in this way exhibit improved adsorption properties while maintaining environmental innocuousness. For the preparation of porous silica, the biosurfactant template sol–gel method was used with tetraethoxysilane as a silica precursor. The silica adsorbents were analyzed by FTIR spectroscopy, nitrogen adsorption–desorption and SEM/EDX microscopy, TEM/HRTEM microscopy, and thermogravimetric analyses. Batch tests were carried out to remediate Pb(II)/Cd(II) ions in single/binary aqueous solutions, and the effect of the surfactant on the adsorption properties was assessed. The optimal adsorption parameters (pH, contact time, initial concentration of metal ions) have been determined. The adsorption was fitted using Langmuir and Freundlich adsorption isotherms and kinetic models. Mathematical modeling of the retention process of Pb(II) and Cd(II) ions from binary solutions indicated a competitive effect of each of the two adsorbed metal ions. The experimental results demonstrated that saponin has the effect of modifying the silica structure through the formation of pores, which are involved in the retention of metal ions from aqueous solutions and wastewater. Full article

(This article belongs to the Special Issue Metal Composites, Volume II)

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18 pages, 18979 KiB

Open AccessArticle

Friction Stir Processed AA5754-Al₂O₃ Nanocomposite: A Study on Tribological Characteristics

by M. Nafea M. Rohim, Mahmoud E. Abdullah, Moustafa M. Mohammed, Andrzej Kubit and Hamed Aghajani Derazkola

J. Compos. Sci. 2024, 8(6), 216; https://doi.org/10.3390/jcs8060216 - 7 Jun 2024

Viewed by 984

Abstract

This study investigates the tribological properties of an AA 5754 aluminum alloy composite reinforced with the nanopowder of Al₂O₃, fabricated using the friction stir processing (FSP) technique with blind holes. The aim is to analyze the effects of varying [...] Read more.

This study investigates the tribological properties of an AA 5754 aluminum alloy composite reinforced with the nanopowder of Al₂O₃, fabricated using the friction stir processing (FSP) technique with blind holes. The aim is to analyze the effects of varying the tool rotational speed (rpm) and blind hole diameter on the wear and friction behavior of the produced composite. A pin-on disk test is conducted under dry conditions and room temperature to assess the tribological properties against steel. Scanning electron microscopy (SEM) coupled with energy dispersive X-ray spectroscopy (EDS) is employed to examine the worn and wear surfaces of the produced composites post test. The results indicate that increasing the applied load results in a decrease in the coefficient of friction (COF), with values ranging from 0.775 to 0.852 for 10 N and 0.607 to 0.652 for 20 N. Moreover, the wear rate diminishes with higher Al₂O₃ content and optimal FSP tool rotation (1280 rpm). Hardness analysis reveals variations between 33–42 HV and 35–39 HV, influenced by nanoparticle distribution. The composite demonstrates superior wear resistance compared to raw AA5754 aluminum due to its reinforced nature. However, high FSP tool rotation rates lead to abrasive wear and surface cracks. These findings offer insights into optimizing FSP parameters to enhance the tribological performance of nano-reinforced aluminum alloys. Full article

(This article belongs to the Special Issue Metal Composites, Volume II)

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24 pages, 4145 KiB

Open AccessArticle

Thermal Emissivity and Heat Capacity of Composite Metal Foam

by Nigel Amoafo-Yeboah and Afsaneh Rabiei

J. Compos. Sci. 2024, 8(6), 202; https://doi.org/10.3390/jcs8060202 - 27 May 2024

Cited by 1 | Viewed by 1032

Abstract

Composite metal foam (CMF) is a new class of material based on a mixture of metal matrix composites and metal foams. While the mechanical properties of CMF are well studied, its thermal properties, particularly at extreme temperatures, are yet to be evaluated and [...] Read more.

Composite metal foam (CMF) is a new class of material based on a mixture of metal matrix composites and metal foams. While the mechanical properties of CMF are well studied, its thermal properties, particularly at extreme temperatures, are yet to be evaluated and established. This study investigates the specific heat capacity of stainless-steel composite metal foam at temperatures up to 1200 °C while comparing data obtained using the laser flash method and a differential scanning calorimetry method (DSC). Moreover, it outlines a detailed procedure for investigating the surface emissivity of composite metal foam (CMF) as a function of the emissivity of separate components (spheres and matrix). It uses experimental and analytical procedures to show how emissivity is directly affected by surface roughness, temperature, sphere curvature and viewing angles. The CMF used in this study consists of 316L stainless steel matrix and stainless-steel hollow spheres with varying sphere sizes. Full article

(This article belongs to the Special Issue Metal Composites, Volume II)

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17 pages, 3673 KiB

Open AccessArticle

Technological Analysis of the Production of Nickel-Containing Composite Materials

by Bauyrzhan Kelamanov, Dauren Yessengaliyev, Otegen Sariev, Askhat Akuov, Yerulan Samuratov, Talgat Zhuniskaliyev, Yerbol Kuatbay, Yerbol Mukhambetgaliyev, Olga Kolesnikova, Assel Zhumatova, Zukhra Karaidarova and Assylbek Abdirashit

J. Compos. Sci. 2024, 8(5), 179; https://doi.org/10.3390/jcs8050179 - 12 May 2024

Cited by 1 | Viewed by 1324

Abstract

The article presents the results of obtaining a composite material by sintering nickel-containing raw materials mixed with carbon-containing materials, namely using coke and semi-coke. The sintering process was performed at a charge layer height of 240 mm and the temperature of the lower [...] Read more.

The article presents the results of obtaining a composite material by sintering nickel-containing raw materials mixed with carbon-containing materials, namely using coke and semi-coke. The sintering process was performed at a charge layer height of 240 mm and the temperature of the lower layer was T = 1200 °C. The results of the sieve analysis showed (a fraction of 10 mm) that the yield of a suitable composite material using coke was 68.3% and with semi-coke 67.0%. The average nickel and chromium content in the composite materials was 1.42% and 3.07%, accordingly. As a result of determining the strength characteristics of the obtained composite materials with various reducing agents by dropping from a height of 2 m onto a steel pallet, it was found that the obtained composite materials have high mechanical properties in terms of strength of 81% and 89.2%. The results of the elemental composition at the studied points and the thermal analysis of the studied composite material are presented. The mineralogical composition of the composite material is presented in the form of serpentine and nontronite, and the empty rock is made of quartz and talc. The activation energy of thermal analysis by the method of non-isothermal kinetics were calculated. The results of experiments on the production of composite materials from nickel-containing raw materials will be recommended for obtaining the optimal composition of composite materials at the stage of pilot tests and industrial development of the developed technology for processing nickel ores of the Republic of Kazakhstan. For the processing of nickel-poor nickel ores, it is of great importance to obtain optimal technological and technical and economic indicators that ensure low cost of nickel in the resulting product. Full article

(This article belongs to the Special Issue Metal Composites, Volume II)

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12 pages, 21074 KiB

Open AccessArticle

Radiation-Induced Defect Formation Kinetics in Inconel–Cu Multimetallic Layered Composites

by Rajesh Ramesh and Kasra Momeni

J. Compos. Sci. 2024, 8(4), 139; https://doi.org/10.3390/jcs8040139 - 10 Apr 2024

Viewed by 1193

Abstract

This study investigates the stability of Inconel–Cu Multimetallic Layered Composites (MMLCs) in nuclear reactor applications using Molecular Dynamics simulations. The focus is on understanding the underlying mechanisms governing the properties of MMLCs for advanced nuclear reactors, specifically, the mechanochemistry of the interface between [...] Read more.

This study investigates the stability of Inconel–Cu Multimetallic Layered Composites (MMLCs) in nuclear reactor applications using Molecular Dynamics simulations. The focus is on understanding the underlying mechanisms governing the properties of MMLCs for advanced nuclear reactors, specifically, the mechanochemistry of the interface between Inconel and copper alloys. The selection of Inconel–Cu MMLCs is primarily due to copper’s superior thermal conductivity, enhancing heat management within reactors by preventing hotspots and ensuring uniform temperature distribution. This research examines Incoloy 800H and two Inconel variants (718 and 625), assessing their stability at 1000 K after exposure to 10 keV collision cascades up to 0.12 dpa. Notable findings include defect clustering on the {1 2 0} family of planes of Inconel and Cu, with Stacking Faults and Lomer–Cottrell locks on the Inconel side. Full article

(This article belongs to the Special Issue Metal Composites, Volume II)

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24 pages, 12006 KiB

Open AccessArticle

A Comparative Study between a Thermal Spray CoCrFeMnNi_0.8V/WC-Co High Entropy Alloy Composite Coating and Plain CoCrFeMnNi_0.8V and WC-Co Thermal Spray Coatings

by Stavros Kiape, Maria Glava, Emmanuel Georgatis, Spyros Kamnis, Theodore E. Matikas and Alexandros E. Karantzalis

J. Compos. Sci. 2024, 8(4), 120; https://doi.org/10.3390/jcs8040120 - 24 Mar 2024

Cited by 2 | Viewed by 2037

Abstract

High entropy alloys (HEAs) have emerged as a frontier in surface engineering, challenging the status quo of traditional alloy systems with their exceptional mechanical properties and corrosion resistance. This study investigates the CoCrFeMnNi_0.8V HEA, both as a standalone alloy and in [...] Read more.

High entropy alloys (HEAs) have emerged as a frontier in surface engineering, challenging the status quo of traditional alloy systems with their exceptional mechanical properties and corrosion resistance. This study investigates the CoCrFeMnNi_0.8V HEA, both as a standalone alloy and in a composite with WC-Co, to evaluate their potential as innovative surface coatings. The CoCrFeMnNi_0.8V alloy, enriched with vanadium, demonstrates a unique microstructure with enhanced hardness and wear resistance, while the addition of WC-Co particles contributes to improved toughness and durability. By employing High Velocity Oxy-Fuel (HVOF) thermal spray techniques, coatings are deposited onto steel substrates and subjected to rigorous microstructural characterization, wear, and corrosion resistance testing. The results reveal that the CoCrFeMnNi_0.8V coating exhibits impressive corrosion resistance in chloride-rich environments. The composite coating leverages the synergy between the HEA’s inherent corrosion resistance and WC-Co’s wear resistance, striking a balance that suits demanding applications. With optimized processing conditions, the composite WC-Co-reinforced high entropy alloy coating could offer a significant advancement in protective coatings technology, especially for maritime and other corrosive settings. This work not only underscores the versatility of HEAs in surface engineering applications but also opens avenues for the development of new material mixtures. Full article

(This article belongs to the Special Issue Metal Composites, Volume II)

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16 pages, 7064 KiB

Open AccessArticle

Evaluation of Joint Strength for CFRPs and Aluminum Alloys by Friction Stir Spot Welding Using Multi-Stage Heating

by Kazuto Tanaka and Yusuke Aiba

J. Compos. Sci. 2024, 8(3), 110; https://doi.org/10.3390/jcs8030110 - 20 Mar 2024

Cited by 1 | Viewed by 1340

Abstract

To reduce car body weight, multi-material structures with lightweight materials such as carbon-fiber-reinforced plastics (CFRPs) and aluminum alloys (Als) are used to replace parts of steel components, and joining technologies for such dissimilar materials are essential. Friction stir spot welding (FSSW) is one [...] Read more.

To reduce car body weight, multi-material structures with lightweight materials such as carbon-fiber-reinforced plastics (CFRPs) and aluminum alloys (Als) are used to replace parts of steel components, and joining technologies for such dissimilar materials are essential. Friction stir spot welding (FSSW) is one of the technologies used to rapidly and strongly join dissimilar materials. FSSW for carbon-fiber-reinforced thermosetting resin (CFRTS) and Als has been developed using composite laminates with integrally molded thermoplastic resin in the outermost layer. To suppress excessive heating under the tool, this study investigated whether multi-stage heating with a non-heating time during joining affects the heat distribution and strength properties of the joint. Due to heat diffusion in Al during the non-heating time, multi-stage heating can suppress excessive heating under the tool compared to continuous heating, resulting in up to 27% larger welded area, up to 37% smaller decomposed area, and up to 6% lower maximum temperature. The use of multi-stage heating results in up to 5% higher tensile shear strength and 210% longer fatigue life by reducing the thermal decomposition of CFRP matrix resin and PA12 resin. Full article

(This article belongs to the Special Issue Metal Composites, Volume II)

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25 pages, 20956 KiB

Open AccessArticle

Studies on the Mechanical, Strengthening Mechanisms and Tribological Characteristics of AA7150-Al₂O₃ Nano-Metal Matrix Composites

by K. Chinna Maddaiah, G. B. Veeresh Kumar and R. Pramod

J. Compos. Sci. 2024, 8(3), 97; https://doi.org/10.3390/jcs8030097 - 7 Mar 2024

Cited by 6 | Viewed by 1848

Abstract

Stir-casting with ultrasonic cavitation produced nano-Al₂O₃-filled AA7150 matrix composites in this study. The SEM microstructure study shows that all composites include nano-Al₂O₃ particles with consistent particle sizes and homogenous distribution. EDS and XRD showed no secondary [...] Read more.

Stir-casting with ultrasonic cavitation produced nano-Al₂O₃-filled AA7150 matrix composites in this study. The SEM microstructure study shows that all composites include nano-Al₂O₃ particles with consistent particle sizes and homogenous distribution. EDS and XRD showed no secondary phases or impurities in the composite. Optical microscopy showed intense ultrasonic cavitation effects, and nano-Al₂O₃ particles caused grain refinement in the AA7150 matrix. The composite’s mechanical characteristics improved when the Al₂O₃ nanoparticle weight percentage (wt.%) increased. With only 2.0 wt.% nano-Al₂O₃ particles, the composites yielded 232 MPa, 97.52% higher than the sonicated AA7150 matrix alloy. Multiple models were used to characterize the strength of the AA7150 nano-Al₂O₃ composite. The findings showed that thermal incongruity, Orowan strengthening, the Hall–Petch mechanism, and load transfer effects contributed the most towards the increased strength of the composite. Increasing the nano-Al₂O₃ wt.% in the AA7150 matrix improved hardness by 95.08%, yield strength by 90.34%, and sliding wear resistance by 46.52%. This enhancement may be attributed to the combined effects of better grain refinement, enhanced dispersion with dislocation strengthening, and better load transfer between the matrix and reinforcement, which are assisted by the inclusion of reinforcements. This result was confirmed by optical studies. Full article

(This article belongs to the Special Issue Metal Composites, Volume II)

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15 pages, 4233 KiB

Open AccessArticle

An Investigation of the Thermal Properties of LM13- Quartz- Fly-Ash Hybrid Composites

by B. R. N. Murthy, Amar Murthy Ambekar and Anupama Hiremath

J. Compos. Sci. 2024, 8(3), 90; https://doi.org/10.3390/jcs8030090 - 1 Mar 2024

Cited by 3 | Viewed by 1510

Abstract

In the present work, a metal–matrix composite was casted using the LM13 aluminum alloy, which is most widely used for casting automotive components. Such applications require materials to withstand high operating temperatures and perform reliably without compromising their properties. In this regard, particulate-reinforced [...] Read more.

In the present work, a metal–matrix composite was casted using the LM13 aluminum alloy, which is most widely used for casting automotive components. Such applications require materials to withstand high operating temperatures and perform reliably without compromising their properties. In this regard, particulate-reinforced composites have gained widespread adaptability. The particulate reinforcements used comprise of one of the widely available industrial by-products. which is fly ash, along with the abundantly available quartz. Hybrid composites are fabricated through the economical liquid route that is widely used in mass production. Though there are numerous published research articles investigating the mechanical properties of metal–matrix composites, very few investigated the thermal properties of the composites. In the present work, thermal properties such as thermal conductivity and thermal diffusivity of cast hybrid composites were evaluated. The particulate reinforcements were added in varied weight percentages to the molten LM13 alloy and were dispersed uniformly using a power-driven stirrer. The melt with the dispersed particulate reinforcements was then poured into a thoroughly dried sand mold, and the melt was allowed to solidify. The quality of the castings was ascertained through density evaluation followed by a microstructural examination. It was found that the composites with only the fly ash particles as a reinforcement were less dense in comparison to the composites cast with the quartz particulate reinforcement. However, the hybrid composite, with both particulate reinforcements were dense. The microstructure revealed a refined grain structure. The thermal diffusivity and thermal conductivity values were lower for the composites cast with only the fly ash reinforcement. On the other hand, the composites cast with only quartz as the particulate reinforcement exhibited higher thermal diffusivity and thermal conductivity. The specific heat capacity was found to be lower for the fly ash-reinforced composites and higher for the quartz-reinforced composites in comparison to the LM13 base matrix alloy. However, the highest value of thermal diffusivity and thermal conductivity were reported for the hybrid composites with a 10 wt.% inclusion of both fly ash and quartz particulate reinforcements. Full article

(This article belongs to the Special Issue Metal Composites, Volume II)

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18 pages, 5974 KiB

Open AccessArticle

Hybrid Treatment and Natural Aging Behavior of Peak-Aged Eutectoid Steel Powder-Reinforced Al 7075 Matrix Composites

by Ananda Hegde, Karthik Birur Manjunathaiah, Sathyashankara Sharma, Gowrishankar Mandya Chennegowda, Gajanan Anne and Ramakrishna Vikas Sadanand

J. Compos. Sci. 2024, 8(3), 89; https://doi.org/10.3390/jcs8030089 - 29 Feb 2024

Viewed by 1395

Abstract

The current work focuses on the natural aging phenomenon of a eutectoid steel powder-(0.8 wt.%) reinforced Al-Zn-Mg (Al 7075) alloy, which was subjected to a hybrid heat treatment. The hybrid treatment comprises the aging treatment of a matrix and the conventional treatment of [...] Read more.

The current work focuses on the natural aging phenomenon of a eutectoid steel powder-(0.8 wt.%) reinforced Al-Zn-Mg (Al 7075) alloy, which was subjected to a hybrid heat treatment. The hybrid treatment comprises the aging treatment of a matrix and the conventional treatment of a steel reinforcement in a single stretch on the stir cast composite. This material finds uses in space and transportation applications. The hybrid treatment consists of a conventional heat treatment cycle to obtain pearlite, bainite, and martensite phases in steel powder, followed by an age-hardening treatment for the Al 7075 matrix. This hybrid heat treatment resulted in improvements in the hardness and strength over the conventional aging treatment. The peak-aged hybrid specimens were subjected to natural aging in an open atmosphere for a continuous duration of 25 weeks to study the stability of the properties after peak aging. Tests of the mechanical properties such as the hardness and tensile strength along with microstructure analysis were carried out. During natural aging, the hardness of composites decreases irrespective of the quantity of the reinforcement in the composites and the type of reinforcement phase alteration during hybrid heat treatment. Also, the composites subjected to hybrid heat treatment show better resistance to natural aging compared to the conventionally aged samples. Within the group, the hybrid-treated martensite formed into a composite with 6 wt.% reinforcement showed only a 4% reduction in hardness during natural aging, which is an indication of a decent level of resistance to natural aging. Full article

(This article belongs to the Special Issue Metal Composites, Volume II)

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13 pages, 4628 KiB

Open AccessArticle

Influence of Cu Addition on the Wear Behavior of a Eutectic Al–12.6Si Alloy Developed by the Spray Forming Method

by Dayanand M. Goudar, Julfikar Haider, K. Raju, Rajashekar V. Kurahatti and Deesy G. Pinto

J. Compos. Sci. 2024, 8(3), 88; https://doi.org/10.3390/jcs8030088 - 27 Feb 2024

Cited by 2 | Viewed by 1466

Abstract

In the present study, the influence of the addition of copper (Cu) on the wear behavior of a Al-12.6Si eutectic alloy developed using the spray forming (SF) method was discussed, and the results were compared with those of as-cast (AC) alloys. The microstructural [...] Read more.

In the present study, the influence of the addition of copper (Cu) on the wear behavior of a Al-12.6Si eutectic alloy developed using the spray forming (SF) method was discussed, and the results were compared with those of as-cast (AC) alloys. The microstructural features of the alloys were examined using both optical and the scanning electron microscopy, and the chemical composition and phase identification were achieved by X-ray diffraction (XRD) analysis. The results revealed that the microstructure of binary the SF alloy consisted of fine primary and eutectic Si phases, evenly distributed in the equiaxed α-Al matrix, whereas the Cu-based SF ternary alloy consisted of uniformly distributed fine eutectic Si particulates and spherical-shaped θ-Al₂Cu precipitates, uniformly distributed in α-Al matrix. In contrast, the AC ternary (Al-12.6Si-2Cu) alloy consisted of unevenly dispersed eutectic Si needles and the coarse intermetallic compound θ-Al₂Cu in the α-Al matrix. The addition of Cu enhanced the micro hardness of the SF ternary alloy by 8, 34, and 41% compared to that of the SF binary, AC ternary, and binary alloys, respectively. The wear test was conducted using a pin-on-disc wear testing machine at different loads (10–40 N) and sliding velocities (1–3 ms⁻¹). The wear tests revealed that SF alloys exhibited an improved wear behavior in the entire applied load and sliding velocity range in comparison to that of the AC alloys. At a load of 40 N and a sliding velocity of 1 ms⁻¹, the wear rate of the SF2 alloy is 62, 47, and 23% lower than that of the AC1, AC2, and SF1 alloys, respectively. Similarly, at a sliding velocity of 3 ms⁻¹, the wear rate of the SF2 alloy is 52%, 42%, and 21% lower than that of the AC1, AC2, and SF1 alloys, respectively. The low wear rate in the SF2 alloy was due to the microstructural modification during spray forming, the precipitation of fine Al₂Cu intermetallic compounds, and increased solid solubility. The SF alloys show an increased transition from oxidative to abrasive wear, while the AC alloys demonstrate wear mechanisms that change from oxidative to abrasive, including delamination, with an increase in sliding velocity and load. Full article

(This article belongs to the Special Issue Metal Composites, Volume II)

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10 pages, 6230 KiB

Open AccessArticle

CoCuMgAl-Mixed-Oxide-Based Catalysts with Fine-Tunable Composition for the Hydrogenation of Furan Compounds

by Liudmila N. Stepanova, Roman M. Mironenko, Mikhail V. Trenikhin, Aleksandra N. Serkova, Aleksei N. Salanov and Aleksandr V. Lavrenov

J. Compos. Sci. 2024, 8(2), 57; https://doi.org/10.3390/jcs8020057 - 2 Feb 2024

Cited by 1 | Viewed by 1558

Abstract

Catalysts based on CoCuMgAl mixed oxides were synthesized and studied in the hydrogenations of furfural and 5-hydroxymethylfurfural under different conditions. The changes in the structural properties of the catalysts at different stages of their preparation were studied using a set of physical methods [...] Read more.

Catalysts based on CoCuMgAl mixed oxides were synthesized and studied in the hydrogenations of furfural and 5-hydroxymethylfurfural under different conditions. The changes in the structural properties of the catalysts at different stages of their preparation were studied using a set of physical methods (XRD, SEM, and TEM). It was shown that the fine regulation of the chemical compositions of the mixed oxides (i.e., changes in the Co/Cu ratio) made it possible to vary the structure, morphology, and catalytic properties of the samples. The phase composition of catalysts with Co/Cu = 1 did not change during the catalytic reaction, although the initial catalysts had a less-homogeneous morphology. 5-hydroxymethylfurfural conversion was higher for the samples with Co/Cu = 1. Furfural conversion increased when raising the Co/Cu ratio. The selectivity toward furfuryl alcohol for the catalyst with Co/Cu = 2 under mild conditions of furfural hydrogenation was more than 99%. The results obtained are important for the development of the scientific foundations of the preparation of hydrogenation catalysts with a fine-tunable composition in order to obtain the desired hydrogenation products. Full article

(This article belongs to the Special Issue Metal Composites, Volume II)

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17 pages, 4298 KiB

Open AccessArticle

Synthesis of Silver Nanoparticles Using Green Reducing Agent: Ceylon Olive (Elaeocarpus serratus): Characterization and Investigating Their Antimicrobial Properties

by Kumudu M. Fernando, Chamila A. Gunathilake, Chandi Yalegama, Upeka K. Samarakoon, Chacrawarthige A. N. Fernando, Gangani Weerasinghe, Geethi K. Pamunuwa, Ibrahim Soliman, Nomi Ghulamullah, Suranga M. Rajapaksha and Omar Fatani

J. Compos. Sci. 2024, 8(2), 43; https://doi.org/10.3390/jcs8020043 - 24 Jan 2024

Cited by 6 | Viewed by 2541

Abstract

Silver nanoparticles (AgNPs) are widely recognized as a prominent antimicrobial agent and have found applications in the field of medicine. This study focuses on the synthesis of AgNPs utilizing the natural reducing agent of Ceylon olive (Elaeocarpus serratus), presenting an economically [...] Read more.

Silver nanoparticles (AgNPs) are widely recognized as a prominent antimicrobial agent and have found applications in the field of medicine. This study focuses on the synthesis of AgNPs utilizing the natural reducing agent of Ceylon olive (Elaeocarpus serratus), presenting an economically viable and ecologically friendly approach. For the first time, this research demonstrated the synthesis of AgNPs using phytochemicals extracted from Ceylon olive, serving as both natural reducing and stabilizing agents. The synthesized AgNPs were characterized with UV–visible spectroscopy, a particle size analyzer (PSA), X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FTIR), and scanning electron microscopy (SEM) coupled with an energy dispersive X-ray spectrometer (EDX). The UV–visible spectra primarily indicated the formation of the AgNPs by the surface plasmon resonance band around 434 nm. SEM analysis confirmed the presence of silver nanoparticles within a size range of 50–110 nm, with an average size of approximately 70 nm. FTIR determined that proteins, phenols, and flavonoids may have acted as reducing and capping agents. Experimental parameters were optimized to improve the yield and size of the AgNPs and eventually evaluate their antibacterial properties. The well diffusion method exhibits a significantly larger zone of inhibition for Gram-negative bacterial strains (18.4 ± 0.55 mm for Pseudomonas aeruginosa and 14.4 ± 0.55 mm for Escherichia coli) compared to Gram-positive bacterial strains (11.6 ± 0.55 mm for Staphylococcus aureus and 10.4 ± 0.55 mm for Staphylococcus epidermidis) for 50 µg/mL AgNPs. These findings demonstrate that AgNPs synthesized with Ceylon olive have the potential to develop into novel materials for bacterial-mediated diseases. Full article

(This article belongs to the Special Issue Metal Composites, Volume II)

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38 pages, 2644 KiB

Open AccessReview

Conventional Machining of Metal Matrix Composites towards Sustainable Manufacturing—Present Scenario and Future Prospects

by Endalkachew Mosisa Gutema and Hirpa G. Lemu

J. Compos. Sci. 2024, 8(9), 356; https://doi.org/10.3390/jcs8090356 - 12 Sep 2024

Viewed by 1055

Abstract

Metal matrix composites (MMCs) epitomize a promising class of resources in modern manufacturing, offering an enhanced strength-to-weight ratio and high-temperature performance which make them ideal for applications demanding over conventional metals. However, their machining presents significant challenges due to their inherent material properties. [...] Read more.

Metal matrix composites (MMCs) epitomize a promising class of resources in modern manufacturing, offering an enhanced strength-to-weight ratio and high-temperature performance which make them ideal for applications demanding over conventional metals. However, their machining presents significant challenges due to their inherent material properties. The conventional machining methods including turning, milling, drilling, shaping, and the grinding of MMCs pose several challenges, facing limitations in terms of sustainability and efficiency. This paper explores the current perspective and prospects of the conventional machining techniques applied to MMCs, emphasizing sustainable manufacturing practices. Key aspects include the challenges posed by MMCs’ inherent heterogeneity, the MMC materials used, the MMC manufacturing process, the cutting constraints employed, tool wear, surface unevenness, surface integrity, and high energy consumption throughout machining. The study also explores promising advancements in tooling materials, cutting parameters’ optimization, innovative machining techniques aimed at minimizing the environmental impact and maximizing material utilization, and the strategies developed to overcome these challenges. The paper concludes by highlighting optimizing tools, and processes, and adopting emerging optimization techniques and opportunities for further research aimed at the industry, allowing it to move towards more efficient, eco-friendly production methods. Full article

(This article belongs to the Special Issue Metal Composites, Volume II)

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23 pages, 4295 KiB

Open AccessReview

Hot-Dip Galvanizing Process and the Influence of Metallic Elements on Composite Coatings

by Qi Liu, Yuqing Cao, Shuai Chen, Xinye Xu, Mutian Yao, Jie Fang, Kuan Lei and Guiqun Liu

J. Compos. Sci. 2024, 8(5), 160; https://doi.org/10.3390/jcs8050160 - 25 Apr 2024

Cited by 1 | Viewed by 3721

Abstract

The corrosion of steel materials has become a global issue, causing significant socio-economic losses and safety concerns. Hot-dip galvanizing is currently one of the most widely used steel anti-corrosion processes. With the rapid advancement of science and technology and emerging industries, the performance [...] Read more.

The corrosion of steel materials has become a global issue, causing significant socio-economic losses and safety concerns. Hot-dip galvanizing is currently one of the most widely used steel anti-corrosion processes. With the rapid advancement of science and technology and emerging industries, the performance of pure galvanized products struggles to meet the demands of practical applications in various environments. Consequently, researchers have begun introducing various metals into the zinc solution to form high-performance alloy coatings. This article primarily explains the process flow of hot-dip galvanizing and the impact of metal elements such as Al, Mg, Sn, and Bi on the coating, as well as outlining the major issues currently faced by the hot-dip galvanizing process. The objective is to offer a more comprehensive introduction to those new to the field of hot-dip galvanizing and to provide theoretical insights for addressing production issues. Full article

(This article belongs to the Special Issue Metal Composites, Volume II)

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30 pages, 8160 KiB

Open AccessReview

A Review on the Recent Trends in Forming Composite Joints Using Spot Welding Variants

by Aravinthan Arumugam and Alokesh Pramanik

J. Compos. Sci. 2024, 8(4), 155; https://doi.org/10.3390/jcs8040155 - 19 Apr 2024

Cited by 5 | Viewed by 1701

Abstract

Traditional resistance spot welding (RSW) has been unsuccessful in forming quality composite joints between steel– or aluminum–polymer-based composites. This has led to the development of spot welding variants such as friction stir spot welding (FFSW), ultrasonic spot welding (USW), and laser spot welding [...] Read more.

Traditional resistance spot welding (RSW) has been unsuccessful in forming quality composite joints between steel– or aluminum–polymer-based composites. This has led to the development of spot welding variants such as friction stir spot welding (FFSW), ultrasonic spot welding (USW), and laser spot welding (LSW). The paper reviewed the differences in the bonding mechanisms, spot weld characteristics, and challenges involved in using these spot welding variants. Variants of RSW use series electrode arrangement, co-axial electrodes, metallic inserts, interlayers, or external energy to produce composite joints. FFSW and USW use nanoparticles, interlayers, or energy directors to create composite spot welds. Mechanical interlocking is the common composite joint mechanism for all variants. Each spot welding variant has different sets of weld parameters and distinct spot weld morphologies. FFSW is the most expensive variant but is commonly used for composite spot weld joints. USW has a shorter welding cycle compared to RSW and FFSW but can only be used for small components. LSW is faster than the other variants, but limited work was found on its use in composite spot weld joining. The use of interlayers in FFSW and USW to form composite joints is a potential research area recommended in this review. Full article

(This article belongs to the Special Issue Metal Composites, Volume II)

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