High strength-to-weight ratio materials such as Al- and Mg-based nanocomposites have gained growing interest in engineering applications for aerospace, automotive, marine, energy, and military. This unabated demand can be met with the advent in materials science and processing technologies. The current study demonstrates a recently developed the technique that consists of the synergetic effect of contact and non-contact ultrasonication of liquid melt for dispersing nano-sized Al2O3 reinforcements in AA5083 alloy matrix. The work is primarily focused on the effects of two-step ultrasonication on wettability, dispersion of the nano-reinforcements in the AA5083 alloy matrix, and the resultant strengthening. The resultant is the AA5083–1 wt-% Al2O3 bulk nanocomposite, a high strength-to-weight ratio material. The extensive microstructure analysis comprising scanning electron microscopy (SEM), transmission electron microscopy (TEM), and energy dispersive X-ray spectroscopy (EDS) mappings reveals the uniform dispersion of nano-particles in different phases of the matrix. The electron back scattered diffraction (EBSD) studies confirm the grain refinement while the X-ray diffraction (XRD) identifies the various phases formed are determined using XRD. The achieved uniform dispersion in the nanocomposite is explicated based on the enhanced wettability due to the presence of Mg in the alloy, preheating of nano-particles, and the synergetic effect of contact and non-contact ultrasonication that avoids the formation of zones of lower cooling rates resulting in powerful micro-convection. The resultant enhancement in the mechanical properties is explained based on available strengthening mechanisms. A comprehensive discussion on process-structure-property correlation has been presented.
RohatgiPKGuptaNDaoudA. Synthesis and processing of cast metal-matrix composites and their applications. In: ASM handbook, volume 15: casting. Ohio, USA: ASM International, USA, 2008, pp.1149–1164.
2.
BeheraAPatelSPriyadarshiniM. Chapter 7. Fiber-reinforced metal matrix nanocomposites. In: HanBSharmaSNguyenTA, et al. (eds) Micro and nano technologies. Amsterdam: Elsevier, 2020, pp.147–156.
3.
BeheraAMallickP. Chapter 20. Application of nanofibers in aerospace industry. In: HanBSharmaSNguyenTA, et al. (eds) Micro and nano technologies. Amsterdam: Elsevier, 2020, pp.449–457.
4.
ChenL-YXuJ-QChoiH, et al.Processing and properties of magnesium containing a dense uniform dispersion of nanoparticles. Nature2015; 528: 539–543.
5.
LumleyRNSercombeTBSchafferGM. Surface oxide and the role of magnesium during the sintering of aluminum. Metall Mater Trans A1999; 30: 457–463.
6.
DongYShaoPGuoX, et al.Deformation characterization method of typical double-walled turbine blade structure during casting process. J Iron Steel Res Int202330: 2010–2020. DOI: 10.1007/s42243-022-00897-y.
7.
ZhangHXiaoYXuZ, et al.Effects of Ni-decorated reduced graphene oxide nanosheets on the microstructural evolution and mechanical properties of Sn–3.0Ag–0.5Cu composite solders. Intermetallics2022; 150: 107683.
8.
ZhangZZhangJXieJ, et al.Developing a Mg alloy with ultrahigh room temperature ductility via grain boundary segregation and activation of non-basal slips. Int J Plast2023; 162: 103548.
9.
ZhangCKhorshidiHNajafiE, et al.Fresh, mechanical and microstructural properties of alkali-activated composites incorporating nanomaterials: a comprehensive review. J Clean Prod2023; 384: 135390.
10.
SoniaPJainJKSaxenaKK. Influence of ultrasonic vibration assistance in manufacturing processes: a review. Mater Manuf Process2021; 36: 1451–1475.
11.
KottanaNKVishwanathaHMSenguptaS, et al.Investigation on synergetic effect of non-contact ultrasonic casting and mushy state rolling on microstructure and hardness of Al–Si–Al2O3 nanocomposites. Int J Interact Des Manuf202317: 2299–2308. DOI: 10.1007/s12008-022-00986-y.
12.
BaghelMKrishnaCM. Synthesis and characterization of MWCNTs/Al6082 nanocomposites through ultrasonic assisted stir casting technique. Part Sci Technol2022 41: 1–13.
13.
XueYZhaiWLiX, et al.Preparation and strengthening mechanisms of ultrasonic-assisted Cr3C2 particle-reinforced Al matrix composite. Coatings2022; 12: 459. DOI: 10.3390/coatings12040459.
14.
ZhouDQiuFWangH, et al.Manufacture of nano-sized particle-reinforced metal matrix composites : a review. Acta Metall Sin (English Lett)2014; 27: 798–805.
15.
MortensenALlorcaJ. Metal matrix composites. Annu Rev Mater Res2010; 40: 243–272.
16.
CasatiRVedaniM. Metal matrix composites reinforced by nano-particles—a review. Metals2014; 4: 65–83.
17.
SurappaMK. Microstructure evolution during solidification of DRMMCs (discontinuously reinforced metal matrix composites): state of art. J Mater Process Technol1997; 63: 325–333.
18.
ArunachalamRKumarPMuralirajaR. A review on the production of metal matrix composites through stir casting—furnace design, properties, challenges, and research opportunities. J Manuf Process2019; 42: 213–245.
19.
LiMGuoQChenL, et al.Microstructure and properties of graphene nanoplatelets reinforced AZ91D matrix composites prepared by electromagnetic stirring casting. J Mater Res Technol2022; 21: 4138–4150.
20.
WangLWuTWangD, et al.A novel heterogeneous multi-wire indirect arc directed energy deposition for in-situ synthesis Al–Zn–Mg–Cu alloy: process, microstructure and mechanical properties. Addit Manuf2023; 72: 103639.
21.
VenkateshVSSRaoGPPatnaikL, et al.Processing and evaluation of nano SiC reinforced aluminium composite synthesized through ultrasonically assisted stir casting process. J Mater Res Technol2023; 24: 7394–7408.
22.
DasLNayakRSaxenaKK, et al.Determination of optimum machining parameters for face milling process of Ti6A14V metal matrix composite. Materials2022; 15: 4675. DOI: 10.3390/ma15144765.
23.
JinYChenGZhangX, et al.Microstructures, mechanical properties and thixoformability of TiB2/Al composite prepared by ultrasonic-assisted squeeze casting. J Mater Eng Perform202231: 9318–9330. DOI: 10.1007/s11665-022-06887-1.
24.
AlipourMKeshavamurthyRKoppadPG, et al.Investigation of microstructure and mechanical properties of cast Al–10Zn–3.5Mg–2.5Cu nanocomposite reinforced with graphene nano sheets produced by ultrasonic assisted stir casting. Int J Met2023. 17: 935–946. DOI: 10.1007/s40962-022-00826-5.
25.
YangYLanJLiX. Study on bulk aluminum matrix nano-composite fabricated by ultrasonic dispersion of nano-sized SiC particles in molten aluminum alloy. Mater Sci Eng A2004; 380: 378–383.
EskinDGAl-helalKTzanakisI. Application of a plate sonotrode to ultrasonic degassing of aluminum melt: acoustic measurements and feasibility study. J Mater Process Tech2015; 222: 148–154.
28.
PadhiPKumarKNGhoshS, et al.Modeling and experimental validation of deagglomeration of ultrafine nanoparticles in liquid Al during noncontact ultrasonic casting of Al-Al2O3 nanocomposite. Mater Manuf Process2016; 31: 1589–1596.
29.
PadhiP. Experimental and theoretical studies on particle distribution in cast aluminium-based metal matrix composites. PhD thesis submitted to Indian Institute of Technology, Kharagpur, India, 2007.
30.
VishwanathaHMEravellyJKumarCS, et al.Microstructure and mechanical properties of aluminum–alumina bulk nanocomposite produced by a novel two-step ultrasonic casting technique. Metall Mater Trans A2016; 47: 5630–5640.
31.
VishwanathaHMEravellyJKumarCS, et al.Dispersion of ceramic nano-particles in the Al–Cu alloy matrix using two-step ultrasonic casting and resultant strengthening. Mater Sci Eng A2017; 708: 222–229.
32.
StefanescuDMJuretzkoFRDhindawBK, et al.Particle engulfment and pushing by solidifying interfaces: part II. Microgravity experiments and theoretical analysis. Metall Mater Trans A1998; 29A: 1697–1706.
33.
JuretzkoFRDhindawBKStefanescuDM, et al.Particle engulfment and pushing by solidifying interfaces: part I. Ground experiments. Metall Mater Trans A1998; 29: 1691–1696.
34.
SenSDhindawBKStefanescuDM, et al.Melt convection effects on the critical velocity of particle engulfment. J Cryst Growth1997; 173: 574–584.
35.
EskinGI. Principles of ultrasonic treatment: application for light alloys melts. Adv Perform Mater1997; 4: 223–232.
36.
IbrahimIAMohamedFALaverniaEJ. Particulate reinforced metal matrix composites—a review. J Mater Sci1991; 26: 1137–1156.
37.
IpSWKucharskiMToguriJM. Wetting behaviour of aluminium and aluminium alloys on Al2O3 and CaO. J Mater Sci Lett1993; 12: 1699–1702.
38.
RohatgiPKAsthanaRDasS. Solidification, structures, and properties of cast metal-ceramic particle composites. Int Met Rev1986; 31: 115–139.
39.
HashimJLooneyLHashmiMSJ. Metal matrix composites: production by the stir casting method. J Mater Process Technol1999; 92–93: 1–7.
40.
ScholzHGreilP. Nitridation reactions of molten Al–(Mg, Si) alloys. J Mater Sci1991; 26: 669–677.
41.
Srinivasa RaoBJayaramV. Pressureless infiltration of Al–Mg based alloys into Al2O3 preforms: mechanisms and phenomenology. Acta Mater2001; 49: 2373–2385.
42.
SangghalehAHalaliM. Effect of magnesium addition on the wetting of alumina by aluminium. Appl Surf Sci2009; 255: 8202–8206.
43.
FlanniganDJSuslickKS. Suslick DJF& KS. Plasma formation and temperature measurement during single-bubble cavitation. Nature2005; 434: 2–5.
44.
JiaSNastacL. The influence of ultrasonic stirring on the solidification microstructure and mechanical properties of A356 alloy. Chem Mater Eng2013; 1: 69–73.
45.
ASM METALS HANDBOOK VOLUME 2: properties and selection: nonferrous alloys and special-purpose materials. 10th ed. Ohio, USA: ASM International, USA, 1990.
46.
GeorgeETMackenzieDS. Handbook of aluminum. Volume 1: physical metallurgy and process. New York, USA: Macel Dekker, Inc, 2003. DOI: 10.1201/9780203912607.
47.
ZhangZChenDDL. Consideration of Orowan strengthening effect in particulate-reinforced metal matrix nanocomposites: a model for predicting their yield strength. Scr Mater2006; 54: 1321–1326.
48.
GeorgeETMackenzieDS. Handbook of aluminum. Volume 1: physical metallurgy and process. New York, USA: Macel Dekker, Inc, 2003. DOI: 10.1201/9780203912607.
49.
HuskinsELCaoBRameshKT. Strengthening mechanisms in an Al–Mg alloy. Mater Sci Eng A2010; 527: 1292–1298.
50.
MuleySVSinghSPSinhaP, et al.Microstructural evolution in ultrasonically processed in situ AZ91 matrix composites and their mechanical and wear behavior. Mater Des2014; 53: 475–481.
51.
Sanaty-ZadehA. Comparison between current models for the strength of particulate-reinforced metal matrix nanocomposites with emphasis on consideration of Hall–Petch effect. Mater Sci Eng A2012; 531: 112–118.
52.
MulaSPabiSKKochCC, et al.Workability and mechanical properties of ultrasonically cast Al–Al2O3 nanocomposites. Mater Sci Eng A2012; 558: 485–491.
53.
MulaS. Aluminium based nanocomposites developed by mechanical alloying and non-contact ultrasonic casting. PhD thesis submitted to Indian Institute of Technology, Kharagpur, India, 2009.
54.
MulaSPadhiPPanigrahiSC, et al.On structure and mechanical properties of ultrasonically cast Al–2%Al2O3 nanocomposite. Mater Res Bull2009; 44: 1154–1160.
Supplementary Material
Please find the following supplemental material available below.
For Open Access articles published under a Creative Commons License, all supplemental material carries the same license as the article it is associated with.
For non-Open Access articles published, all supplemental material carries a non-exclusive license, and permission requests for re-use of supplemental material or any part of supplemental material shall be sent directly to the copyright owner as specified in the copyright notice associated with the article.
