Investigation of Al/Mg composite behaviour by the adaptation of SiC and Al 2 O 3 nanoparticle via electromagnetic stir cast route

Abstract

Developing hybrid composite material has demonstrated various benefits, and conventional stir-cast composites have been found to exhibit microporosity and uneven particle distribution, leading to variations in mechanical behaviour. This study aims to synthesize, examine, and assess the mechanical and turning machining characteristics of Al/Mg alloy and its hybrid composite integrated with 5 weight percentages (wt%) of alumina (Al₂O₃) and varying wt% of silicon carbide nanoparticles (SiC) using the electromagnetic stir cast process, which overcomes the challenges associated with traditional casting processes. Actions of Al₂O₃ and SiC and the processing on the structural and mechanical behaviour of Al/Mg composites are evaluated. Structural analysis indicates that the nanoparticles are uniformly dispersed, and X-ray analysis confirms the formation of a better crystalline structure. The composite HC3 (Al/Mg/5wt% Al₂O₃/6wt% SiC) exhibits superior tensile strength (234.2 MPa), reduced impact strength (7.19 J/mm²), and improved microhardness (145.2 HV) value. The turning process involves the use of a titanium carbonitride (TiCN) tool insert at different speeds (N), feed (f), and depth of cut (DOC). Influences of turning operation parameters on tool wear (TW), surface roughness (Ra), and temperature (T) of Al/Mg alloy nanocomposite were measured. By leveraging the ANOVA Taguchi L16 design, the optimal turning operation parameter combination was determined to achieve the lowest TW and Ra, represented by the L11 and L12 configurations in the array.