Characterization of microstructural and mechanical properties of AA6061-Al 2 O 3 in-situ aluminum matrix composites (AMCs) with addition of rare Earth (CeO 2 ) as modifier synthesized via hybrid manufacturing process

Abstract

This study systematically explores the influence of ultrasonication and varying reinforcement content on the mechanical performance of aluminum matrix composites (AMCs). The dual approach adopted in this investigation has yielded notable improvements in both ductility and strength parameters, suggesting a synergistic effect of these processing variables. Furthermore, the research delves into the evaluation of tensile strength and hardness, providing substantial evidence of ultrasonication’s role in enhancing the composite structure and resolving associated mechanical deficiencies. In general, mechanical testing of the in-situ AMCs produced via a hybrid method has revealed promising prospects for their use across various engineering disciplines. Specifically, the incorporation of 1.5 wt.% CeO₂ (cerium dioxide a rare-earth metal, CeO₂ρ∼7.215 g/cm³ and Melting point ∼2400°C), along with ultrasonication and subsequent water quenching, led to a 15% increase in stretchability relative to standard AA6061 aluminum. Hardeness was increased by 19.5% in 1% uswq AA6061-Al₂O₃ in-Situ Aluminum Matrix Composites (AMCs) and tensile strength obtained maximum in 1.5% uswq as compared to AA6061 alloy samples. These results highlight the material’s enhanced formability and mechanical adaptability, making it suitable for demanding structural and functional applications. However, generating reinforcing particles in their original location resulted in clusters, making composite material production challenging. The fractography analysis was performed using SEM and the metallography analysis was performed using microscope and XRD.