Characterization of Al–Al 2 O 3 composite prepared using reinforced fused deposition pattern in investment casting

Abstract

The commercially available techniques for developing aluminium matrix composite can be broadly classified into two categories namely liquid-state and solid-state processing. In the category of liquid-state processing, modified investment casting process has ability to produce complex and near net shape geometries of aluminium matrix composite for various industrial applications. In the present research work, an effort has been made to characterize the Al–Al₂O₃ based composites prepared with modified investment casting process. Initially, two reinforced fused deposition modeling filaments consisting of 60% nylon 6 + 30% Al + 10% Al₂O₃ (by percentage weight) and 60% nylon 6 + 28% Al + 12% Al₂O₃ (by percentage weight) proportions were prepared in wire form on single screw extruder of L/D 20. After this, reinforced patterns fabricated on existing fused deposition modeling system (using newly prepared filaments) were used as master pattern in modified investment casting process. Finally prepared castings were characterized by scanning electron microscope, EDS, X-ray diffraction analysis, and optical microscopy. Tribological analysis has been made on the finally prepared castings to investigate the affect of filament proportion and fused deposition modeling system density on their wear resistance. The result of study suggests that wear resistance of the finally prepared castings was increased with increase in percentage weight of Al₂O₃ particle in filament and density of fused deposition modeling pattern.