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Mechanical Properties of Aluminium Matrix Composite Including SiC/Al 2 O 3 by

Powder Metallurgy-A Review
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GSJ: Volume 7, Issue 3, March 2019
ISSN 2320-9186
23
Mechanical Properties of Aluminium Matrix Composite Including

SiC/Al2O3 by Powder Metallurgy-A Review
Musa Alhaji Ibrahim 1, 2, ,Yusuf Sahin 2, Auwalu Yusuf Gidado 1, M.T. Said 3
1
Department of Mechanical Engineering, Kano University of Science and Technology Wudil, Kano, Nigeria, 2 Department of Mechanical Engineer-
ing, Faculty of Engineering, Near East University, Nicosia, Cyprus, 3 Department of Mechanical Engineering, Faculty of Engineering, Bayero Uni-
versity, Kano, Nigeria.
Email: 1abbankhalil2017@gmail.com, 2yusuf.sahin@neu.edu.tr, 3auwalugidado2@gmail.com, 4smtahir.mec@buk.edu.ng
ABSTRACT
Powder metallurgy (PM) method for mass production of components plays a significant role in the fabrication of advanced ma-
terials for automobile, aerospace, defense, petroleum and chemical industries at cheaper rate. Aluminum Matrix Composites
(AMCs) including silicon carbide/Aluminum oxide (SiC/Al2O3) has received increased attention due to its excellent mechanical
properties such as hardness, strength, low density, corrosion resistance and toughness. PM gives better mechanical properties
due to good wettability between the matrix and the reinforcements, uniform microstructure with desirable phases in the compo-
site. This paper examines the effect of powder processing variables such as milling time, milling speed, compaction pressure,
sintering time and temperature on the mechanical properties of the AMC when adding to the different sizes and volumes of SiC
and Al2O3.
Keywords : Mechanical Properties; Silicon Carbide; Alumimium Oxide; Powder Metallurgy; Aluminium Matrix Composites
IJOART
1 INTRODUCTION
Composite is a multi-elements material possessing unique cal property [33], [34]. When SiC and Al2O3 are introduced
properties than the individual elements [1]. Decades ago, re- into the matrix hardness, tensile and elastic modulus are im-
search is focused upon exceptional materials like composite proved [34], [35]. Higher amount of reinforcement give better
[2]. Composite could be polymer, ceramic or metal base. Metal hardness, tensile strength and stiffness but loss of ductility
matrix composites (MMCs) are a helpful class of engineering and fracture toughness are witnessed [36]. PM processing var-
material having a light metal matrix in which hard fragments iables like sintering time, temperature, compaction load affect
are added thus possessing special importance [3], [4], [5], [6], the mechanical properties of AMCs [37]. Hence, this article
[7]. Popularly applied matrices are magnesium (Mg) [8], cop- will review mechanical properties of aluminum matrix includ-
per (Cu) [9], titanium (Ti) [10] and aluminum (Al) [11] or their ing SiC/Al2O3 produced via PM.
alloys. These matrices are better for the fabrication of MMCs.
Particulates, whiskers and fibers are utilized as reinforce-
2 PROCESSING ROUTES FOR ALUMINIUM MATRIX
ments[12]. Particulate Al2O3 and SiC MMCs are widely used
as reinforcements. AMCs including SiC/Al2O3 show better COMPOSITES (AMCS)
stiffness, hardness and tensile strength [13], [14], [15]. These The method of processing AMCs has been categorized into ex
composites have been used in automobile, aerospace, defense, situ whereby reinforcements are added into the matrix and in
chemical, structural as well as electronics industries [16], [17], situ in which there is production of hard particles by reaction
[18], [19], [20], [21], [22]. The strength of AMCs is a function of process [38], 40]. Industrially, there are solid and liquid routes
volume fraction as well as refinement of the reinforcements [41]. For liquid are squeeze casting [42], ultrasonic assisted
[23]. These particulate metal matrix composites (PMMCs) with casting and conventional stir casting [43] and solid include
better properties have given rise to a fresh breed of manipu- micro wave and conventional sintering [44], spark plasma [45]
lated engineering materials [24], [25]. Interfacial relation be- and powder metallurgy (PM) [46] to mention but a few. Selec-
tween matrix and reinforcement, dimension of ceramics, vol- tion of these depends upon optimum temperature for infiltra-
ume fraction and homogeneous dispersion of the reinforce- tion, wettability and adverse reactions at the interface [47]
ments and nature of bonding determine the structure and size, type, volume fraction of reinforcement, its distribution,
properties of these composites [26], [27], [28]. Different tech- simplicity, matrix-particle bonding, cost and control of matrix
niques are used to fabricate AMCs including SiC/Al2O3. Pow- morphology play role in the mechanical properties of the
der metallurgy (PM) is one such method used for its special AMCs [48].
attributes like lower temperature, cost effective and homoge-
neous distribution of reinforcements within matrix [29]. The 2.1 Solid State Process
mechanical properties of AMCs are a function of amount, size, 2.1.1 Powder Metallurgy
type of reinforcement and processing method used [30], [31]. Powder metallurgy (PM) involves less temperature, cost effec-
With respect to the size, nano scale yields wonderful mechani-
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tive [49], [50] and parts of complex geometry are easily fabri- While in MM there is no transfer of material the main purpose
cated by it [51] and in mass at cheaper rate [52], [53]. Funda- is to reduce the powder particles size to the barest minimum
mentally the steps in PM are mixing, compaction in a die or and increase surface area required [73]. More so, the main
mold and sintering in a furnace for consolidation [54] and sec- important factors in the process are the raw materials, mill and
ondary operation might be applied for special behavior or the process variables such as milling speed, time, ball-to-
dimensional precision [55] as indicated in Fig. 1. powder ration, process control agent and temperature [67].
Paraffin, stearic acid and methanol are utilized as process con-
trol agents acting as lubricants in order to reduce the impact of
cold welding and eventual production of large powders clus-
ters [74]. As the powders are plastically deformed, internal
structure enhancement of the powders might take place thus
yielding a nanostructured composite. Lubricants, milling time
and tools may contaminate the powders and as such the pro-
cess need to be controlled. More so, as the material is consoli-
dated, impurities may affect the microstructural evolution and
grain development thereby reducing the mechanical proper-
ties of the composite. Fig. 2 shows the representation of MA
process. Advantages and disadvantages MA as provided in
Fig. 1. Powder metallurgy process steps [56].
Table 2.
Mechanical properties are improved by PM due to thorough TABLE 2

dispersion of the reinforcing particles within the matrix [57]. MA ADVANTAGES [30], [75] AND DISADVANTAGES [75]
Correlation has been established among size, amount, type
and surface nature of reinforcement and properties of compo-
Advantages Disadvantages
IJOART
site produced by PM [58], [59], [60]. Generally, when the size
of reinforcement is scaled to nano the property will be good Parts have high strength Compaction forces involve are high
but fabrication becomes complicated [61]. The advantages and
Small sizes of powder due to re-
disadvantages of PM are given in Table 1. Homogenization is obtained
striction
TABLE 1 No need for post treatment Difficult to produce intricate shapes

PM ADVANTAGES [62] AND DISADVANTAGES [63]. Powder composition is regu-
Spontaneous burning of powder
lated
The process is mechanized Tooling and equipment expensive
Tooling and equipment are ex-
Parts have controlled porosity
pensive
Better mechanical properties are Parts have low strength and duc-
obtained tility
Parts of near net shapes are
High cost of powder materials
achieved
2.1.2 Mechanical alloying (MA) and milling (MM)

MA involves continuous cold welding, fracturing and welding
again of powder particles in a high mill [64], [65], [66]. MA is
capable of producing numerous equilibrium and non-
equilibrium alloy states beginning from ordinary or preal-
loyed powders [67]. Due to high energy given to the particles
during milling, composite fabricated from this technique is of
exceptional properties [68] such as absence of voids [69]. It
was developed by John Benjamin when he wanted to fabricate
nickel-based oxide dispersion strengthened (ODS) super al-
loys for industrial applications [70]. MA involves material
transfer in order to have a uniform material [71]. The method
begins with a small amount of powders put into an enclosure
along with the grinding medium mixed via agitation at high
speed for a fixed period. Transfer of energy takes place be-
tween the grinding media and the powders thereby reducing
size of the powders into smaller sizes media. Thereafter, the Fig. 2. Simplified block diagram of a typical mechanical alloying process
[76 ].
grinded powders are pressed, degassed and consolidated [72].
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2.1.3 Spark Plasma Sintering (SPS)

SPS also called field assisted sintering (FAST) is manufactur- TABLE 3
ing method involving direct current actuated, low voltage as ADVANTAGES [99], [98], [100], [101], [102], [103], [104] AND DIS-
well as pressure assisted sintering [77], [78], [79], [80] to fabri- ADVANTAGES [45], [105], [106], [107] OF SPS/FAST
cate dense composite with perfect grain growth/ size [81],
[82]. Joule heating provides high heating rates, allowing dense
ceramics to be obtained under uniform heating at relatively
low temperatures and in short processing times [83], [84], [85], Better mechanical properties and
It is expensive
[86], [87], [88]. Fig. 3 shows the SPS set-up. The technique can high density at same temperature
be applied to fabricate modern compounds [89]. It is the same Applied only to a simple
Energy efficient and saving
with hot pressing though there is difference in the manner of symmetrical shape
heat production and transmission to the material being sin-
tered [90]. In SPS process, the green compact (powder) placed 2.1.4 Hot isostatic pressing (HIP)
in a die is simultaneously subject to arc electric discharge pro-
Hot isostatic pressing (HIP) consolidates materials fabricated
duced by pulse electric discharge and external pressure. On
via casting and PM routes. The mechanical operation of these
the microscopic level, electric discharge process occurs thereby
materials is a function of dispersion, structure and amount of
accelerating material diffusion.The outside pressure applied is
porosity which impair the mechanical behavior such as tensile
usually 20-3000 N/M2 and heating rate of 100-10000C/minute
strength, fatigue resistance and fracture toughness [108]. It
[91]. This method regulates porosity thus gives desirable be-
comprises of application of high temperature and uniform
haviors [92]. The fastness of the method guarantees densifica-
pressure to the green compact in all direction in the presence
tion of the composite whilst eliminating coarsening which
of argon as the fluid medium [109] in built vessel [110] to con-
happens in conventional densification process [92], [93], [94],
solidate the materials [111] as shown in Fig. 4. Due to pressure
[95] thus enhancing mechanical properties [96–98]. Ad-
and temperature applied at the same time it was named ‗gas
vantages and disadvantages of SPS as provided in Table 3.
pressure bonding‘ [112]. HIP is being utilized to remove flaws
IJOART
and synthesize denser ceramics [113]. HIP improves on the
mechanical properties such as fatigue, creep, ductility and
impact resistance in addition to removal of inspection [114].
Up to now, HIP is seen as better tool of enhancing mechanical
behavior of a large number of materials [115]. Table 4 gives the
merits and demerits of HIP
Fig. 3. Schematic drawing of an SPS process [82].
SPS technique takes place under empty space or a shielded gas Fig. 4. Hot isostatic pressing (HIP) [116].
at atmospheric pressure. However the mechanism of SPS is
still unclear thus, fundamental study needs investigation.
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shaped by traditional casting method: squeeze casting, per-

TABLE 4 manent mold casting and sand casting [143], [144]. Gas en-
ADVANTAGES [117] AND DISADVANTAGES [118] OF HIP trapment, slag in the melt leading to high porosity and micro-
defect; unnecessary chemical reaction between the matrix and
the reinforcements, poor matrix-reinforcement wetting are
Advantages Disadvantages associated with the route [145], [146]. These negatively affect
High composite densification Only applied to simple part‘s shape the mechanical properties of the composite. To surmount these
Reduced temperature application Parts require secondary operation issues, process variables like melt stirring time, melt holding
temperature, temperature of the molten metal, choice of ma-
Grain growth is slowed Expensive
trix and reinforcement should adapted [147]. Fig. 5 shows the
representation of the stirring casting method. Table 6 shows
2.1.5 Microwave Sintering (MWS) the advanatges and disavantages of stir casting method.
Microwave is an integral section of electromagnetic spectrum
travelling at the speed of light having a wavelength between 1
mm to 1 m similar to 300 GHz to 300 MHz. In contrast to tradi-
tional sintering, MWS deals with conversion of electromagnet-
ic energy into thermal energy in place of heat transfer [119].
The medium of transfer of microwave energy (MWE) to the
material is molecular interaction with the electromagnetic
field. Because MWE could infiltrate material and transmit en-
ergy, heat is thus produced all over the material‘s volume
leading to volumetric heating [119], [120], [121], [122], [123],
[124]. In MWS, heat produced from the inside of the material
being sintered, is radiated outwards owing to penetrative in-
IJOART
tensity of the microwave leading to temperature differential
and differences in microstructure and behaviors. To eliminate
this, a ‗bi-directional microwave-assisted rapid sintering has
been developed [82]. This procedure ensures uniform heating
between the core and the edge of the material and shown in
figure 5 (b). MWS produces composite with fine microstruc-
ture and better mechanical properties [125], [126] due to quick
heat transfer that reduces processing time [127], [128]. MWS is
novel, promising, attractive, efficient, valuable and economical
[129], [130], [131] manufacture method. Table 5 shows the ad- Fig. 5. Fundamental stir casting process [148].
vantages and disadvantages of MWS.
TABLE 6
TABLE 5
ADVANTAGES [148], [149] AND DISADVANTAGES [151], [152] OF
ADVANTAGES [132], [133]AND DISADVANTAGES [134] OF MWS STIR CASTING METHOD
Advantages Disadvantages Advantages Disadvantages

Heating is rapid and contactless Processing time is very short It is simple, flexible, economical and Difficult to achieve homogeneity
Material heating is selective and suitable for mass production and high porosity
Tooling is expensive
equipment portable Possibility of reaction between
Good matrix-reinforcement inter-
matrix and reinforcement and poor
face and near net shapes
wetting due to high temperature
2.2 Liquid Process
2.2.1 Stir Casting
2.2.2 Spray-Up
Stir casting otherwise referred to as vortex technique is com-
monly utilized to fabricate AMCs including SiC/Al2O3 [135], Here a hand-held spray gun is employed to spray pressurized
[135], [136], [137], [138], [139], [140]. This method involves in- matrix and reinforcement in the form of chopped fibers. Usu-
troducing the reinforcements into the molten metal and then ally, the reinforcement used is roving glass that go past the
cast to the desired geometry. Prior to incorporating the rein- spray gun where it is chopped with a gun [153], [154]. Rein-
forcements, the melt should be degassed by an appropriate forcement and matrix might be sprayed at the same time in-
medium to avoid reaction with atmospheric oxygen [141]. dependent of one another. Curing is done either at high tem-
Uniform distribution of reinforcements can be realized perature or at normal temperature. After curing, mold is
through a rotor rotating inside the liquid metal creating a vor- opened and the material is ejected for additional processing.
tex and injection of a gas carrying the reinforcements into the The duration of curing depends on the kind of polymer used
liquid [142]. The well distributed slurry so fabricated can be for composite processing. The products of this technology are
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heavy, rich in resin and poor mechanical properties [154]. Fig. these variables. Disadvantages and advantages as provided in
6 shows the spray-up process. This method has many ad- Table 6. Fig. 7 indicates the squeeze casting method.
vantages and disadvantages as provided in Table 5.
IJOART
Fig. 7. Pressure applied on the melt [158].
TABLE 6
ADVANTAGES [160] AND DISADVANTAGES [159–161] OF SQUEEZE
CASTING METHOD
Fig. 6. Spray-Up method [154].

Simple and flexible Difficult to achieve homogeneity
TABLE 5
ADVANTAGES AND DISADVANTAGES OF SPRAY-UP METHOD [155] Economical for mass produc- Possibility of reaction between
tion matrix and reinforcement
Good matrix-reinforcement High porosity in composite and
It is simple and tooling is Products are heavy due to richness interface poor wetting
cheap in resin and short fibers are added
Mechanical properties are com-
Quick deposition of fiber and 2.2.4 ULTRASONIC-ASSISTED CASTING (UAC)
promised due to low viscosity of
resin
resin UAC uses wave frequency of 20 KHz to 18 KHz. When this
wave moves past a liquid, successively interchanging dilation,
2.2.3 Squeeze Casting cycles and compression are generated as shown in Fig. 8. This
wave is generated by means of mechanical vibration having a
This process integrates a forging and casting in which a mol-
frequency of 18 KHz. This produces micro bubbles that grow
ten metal solidifies under the action of pressure. The matrix in
in the liquid [162]. When they can no longer absorb the suffi-
form of molten metal is incorporated into reinforcement either
cient energy, explosion occurs (cavitation) [163]. This explo-
under pressure or without pressure [155–156]. The method
sive action of cavitation breaks agglomeration of particles and
consists preheating, pouring, application of pressure, infiltra-
distribute them uniformly within the liquid. UAC is good at
tion and withdrawal of the composite from the punch and die
disintegrating agglomeration formation which happens in
system [157]. The process can be indirect or direct. Many pro-
nanocomposites because of low wettability and high tendency
cess variables contribute to the quality of squeeze cast compo-
of cluster of nanoparticles [164], [165], [166]. At every cavita-
site including mold temperature, pressure and its duration,
tion cycle, bubbles explosively fall in less than 6-10 second
pouring temperature, time delay in pressurizing the melt, die
with the ‗hot spot‘ reaching a temperature of 5000 °C, pressure
temperature and filling velocity [158]. Adequate regulation of
of 1000 atm, and heating/cooling rates >1,010 K/S during mi-
these principal variables may remove possible defects in the
croseconds transient [167]. Table 7 gives the advantages and
cast composite. However, no standard is set on how to control
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disadvantages of the above process. investigate the impact of amount reinforcement, sintering
temperature and compaction force on composite. The finding
revealed that increasing the amount, sintering temperature as
well as pressing force enhanced the hardness and density of
the composite. The optimum hardness was achieved at 30%,
under the application of 15 ton and 500oC. [173]. Al-Raheed et
al. (1993) reinforced aluminum alloy with different percentage
of SiC [174]. Both findings revealed increase in hardness and
tensile strength with increase in reinforcement contents of SiC
as shown in figure 10. However, tensile strength decreased
above optimum value of 30-wt% SiC. Dalatkhan et al. (2012)
manufactured AMC via friction stir process by reinforcing
AA5052 of 5µm and 5nm SiC ceramics. It was observed that
with the change in rotational speed, direction between friction
stir process passes, decrease in size of SiC and increase in the
number of passes enhanced the hardness of the composite
[175]. The impact of SiC particle size in Al nanocomposite was
studied by El-Kady and Fathy (2014) fabricated via PM. It was
shown that reducing the size to nano scale greatly enhanced
the hardness (72 HV) and the compressive strength (601 MPa)
Fig. 8. Schematic of Ultrasonic-assisted casting [166]. at 10 wt.% SiC and 70 nm Fig. 9 and Fig. 10 [176]. Hossain,
Aarabi and Mohammadkhani (2015) studied the effect of
TABLE 7 amount and nano SiC on pure aluminium alloy composite
fabricated by PM and reported that there was an increase in
ADVANTAGES [167], [168] AND DISADVANTAGES [169] OF UAC
IJOART
the hardness and tensile strength with increase in the amount
and decrease in size of SiC. The best results were achieved at
Advantages Disadvantages 10% of SiC and sintering temperature of 650oC [46].
Homogeneity and better mechanical It is expensive due to tooling
properties involved
UAC can be applied in the production of High sound frequency is in-
bulk composite volved
3 MECHANICAL PROPERTIES OF AL/SIC REINFORCED

COMPOSITES
Ran, Verma and Purohit, (2012) reinforced Al with SiCp by
powder metallurgy process. The powders were mechanically
alloyed for 12 to 15 milling hours at 78 rpm. The powders un-
derwent cold isostatic pressing at 600 MPa at a rate of 3.27
KN/s in a mold and then pressed in a die using 500 KN pres-
sure. The green compact was sintered at 580°C for 1800 second
Fig.9. Impact of size and amount of SiC on hardness [176].
and 600°C 2700 seconds. The result indicated increase in hard-
ness, compressive and tensile strengths and that milled pow-
der had better properties than un-milled [170]. Donnell and
Looney (2001) introduced SiC of varying size to AA6061 via
conventional powder metallurgy. The blend was compacted in
a die at 235 ± 5 MPa at a rate of 7 MPa/s, sintered at 617 ± 20C
for 70 minutes and 614 ± 10C for 50 min. The result showed
that as the size of the SiC decreased the yield strength was
improved but its toughness or ductility decreased with in-
crease in the volume fraction of SiC and that there was ade-
quate dispersion of the reinforcement within the matrix [171].
Erdermin et al. (2015) investigated the mechanical properties
of workably graded Al2024-SiC composite and found out that
hardness increased at 30 and 40 wt. % SiC and reduced when
the amount of SiC was increased to 50 and 60%. The decrease
in hardness was attributed to high porosity [172]. Nuruzzamm
and Kamaruzzuman (2016) incorporated SiC into aluminum to Fig.10. Effect of SiC size and amount on hardness and compressive
strength [176].
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TABLE 8
Joosawat, Panomtang and Wongtimnoi (2017) introduced sili- TENSILE, COMPRESSION STRENGTH AND STIFFNESS OF AL- AL2O3
ca sand into porous aluminum via PM technique to improve AND ELEMENTAL AL RESULTS [182]
the mechanical properties of the Al. The materials were blend-
ed at 100 rev/m for 4 hours. The blended powders were com-
pacted at room temperature under 400 MPa, heated at 5500C Micro in-
Tensile Compression Young
for 5 hours. They observed that hardness, porosity and com- dentation
Material strength strength Modulus
pressive strength improved with increase in content of silica hardness
(MPa) (MPa) (GPa)
sand while density decreased. However, increasing the silica (GPa)
above 15%, hardness and compressive strength decreased Al 396 ± 4 97 ± 1 169 ± 2 74 ± 2
[177].While studying the effect of binary reinforcements of
Al–Al2O3 5% 611 ± 4 118 ± 5 170 ± 2 58 ± 1
multi-carbon nanotube and silicon carbide on mechanical and
microstructure of AMC. Wagh and Jayakumar (2016) observed Al-
743 ± 28 151 ± 3 196 ± 1 84 ± 4
increase in hardness and ultimate tensile strength as the Al2O3 10%
amount of the MCNT and SiC increased but ductility de- Al–Al2O3 15% 897 ± 43 160 ± 13 232 ± 2 100 ± 10
creased. The maximum hardness 49 BHN and UTS 246.41 MPa 1355 ± 22
were obtained at 1.5% of reinforcements. The loss in ductility Al–Al2O3 20% 96 ± 13 247 ± 2 94 ± 3
was due to increase in contents of MCNT and SiC which
raised the hardness [178]. Reddy et al. (2017) prepared Al/SiC
More so, strain decreased due to increase of the amount of
nano composite via MWS and hot extrusion. The SiC was
reinforcements with pure Al having the greatest strain and
added in volume fraction of 0, 0.3, 0.5, 1.0 and 1.5 % to the Al.
20% alumna with lowest strain. The porosity also affects the
They reported that increasing the volume fraction enhanced
mechanical properties of sintered composite as shown. Small
the compressive and tensile strength of the composite though
volume of porosity decreased ductility therefore, in usage
ductility was lost and better mechanical properties were
where high ductility is needed it is important to decrease the
shown by hot extrude composite at 1.5 % of SiC [179].
IJOART
porous level [183]. Min et al. (2005) studied the effect of sinter-
ing temperature on Al 2xxx reinforced with alumina (Al2O3)
4 MECHANICAL PROPERTIES AL/AL2O3 REINFORCED produced through powder metallurgy technique. The findings
showed that as the sintering temperature and holding time
COMPOSITES increased the densities and sinterability increased. By exten-
Nuruzzaman etal. (2016) manufactured AMC by reinforcing sion, the hardness, tensile and compressive strengths in-
aluminum with Al2O3 at various amount via conventional creased [184]. Rahimian et al. (2009) investigated the impact
powder metallurgy. The blend was pressed at 20 ton in a die, sintering temperature and volume fraction of Al2O3 on me-
sintered at two different temperatures of 550oC and 580oC. It chanical of Al. The sample was fabricated through powder
was found out that density and compressive strength of AMC metallurgy. The results revealed hardness, tensile and com-
affected by sintering temperature and the amount of Al2O3 pressive strengths increased as the sintering temperature and
[180]. Knowles et al. (2014) introduced 10 wt. % and 15 wt. % content of reinforcements increased. However, when the
SiC reinforcement particles with average size lower than 500 amount of reinforcements and sintering temperature reached
nm into Al 6061. The sample was compacted with a load of 50 optimum value, compressive and tensile strengths dropped
tons, heated to 4500C in 15 min, and held for 20 min. The re- sharply [185] as shown in Fig. 11 and Fig. 12.
sult indicated that as the amount of reinforcement, ball-milling
energy, sintering temperature and pressing pressure increased
the Young modulus, yield strength and ultimate tensile
strength also increased. This improvement in mechanical
properties was due to homogeneous distribution Al2O3 in Al
and proper bonding between the two [181].Garbiec et al.
(2015) reinforced Al with Al2O3 in 5%, 10%, 15% and 20%
through spark plasma method. The four samples were sin-
tered at 6000C at a pressure of 50 MPa. The sintering rate was
1500C per minute for 150s. Current was passed through the
samples for 125ms that lasted 5 min. The result revealed im-
provement on hardness, compression and tensile strengths as
the amount of Al2O3 increased. The maximum micro hardness
of 1355 MPa and compression strength were achieved at 20%
Al2O3 while stiffness of 100 GPa and tensile strength of 160
MPa were obtained at 15% Al2O3 [182]. Table 8 shows the me-
chanical properties results of the experimental studies of some
Fig. 11. Effect of Al2O3 particle content and sintering temperature on yield
selected MMC.
stress and hardness [185].
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Wagih (2015) studied the effect of milling time on mechanical

properties by introducing alumina into Al and Al-10wt% Mg
via mechanical alloying. The blend was milled for 20 hours at
250 rpm. The higher milling time, 20 hr led to breaking down
of both the matrix and the reinforcement into nano particles.
The finding indicated that milling time of 20 hour improved
the micro hardness of the nanocomposite due to grain refine-
ment and homogeneous distribution of the Al2O3 within the
matrix [188]. Canakci, Varol and Ertok (2012) investigated the
impact of alumina on Al produced by mechanical alloying. Al
Fig. 12. Effect of Al2O3s particle content and sintering temperature on yield and alumina of 37 μm and 13 μm were used as materials. The
stress and hardness [185]. authors discovered that the hardness value increased by in-
creasing the milling time and the amount of reinforcement.
From the figures above, it is observed that as the amount of More so, raising the content of alumina influenced both micro-
reinforcements and sintering temperature increased the yield structural and morphological properties of AMC [189]. Raju
and hardness increased to an optimum point and suddenly (2015) observed the effect of nano alumina on mechanical
decreased due to high content of alumna and increase in tem- properties of AMC produced powder and liquid metallurgy.
perature. Ghasali et al. (2017) manufactured Al-15% TiC The finding revealed that as the content of the alumina in-
through MWS, SPS and traditional sintering techniques. A creased the hardness increased similarly if the amount of alu-
temperature of 7000C for traditional sintering, 6000C for MWS mina increased the tensile strength was increased up to 1.5%
and 4000C for SPS were employed in the heating process. of Al2O3 thereafter tensile strength will decrease [190]. While
They reported that the best method was SPS having produced studying the impact of alumna on the hardness of Al-Zn-Mg-
a hardness of 253 HV and bending strength of 291 MPa [186]. Cu-Ni-Co matrix produced through PM, Naeem and Mo-
Rahimian et al. (2009) investigated the influence of size of par- hammed (2015) reported an increase in hardness of the matrix
IJOART
ticle, sintering time and temperature on mechanical properties with ageing at T6 temper and the maximum hardness was
of PM Al-Al2O3 composite and it was reported that as the size reached at retrogression and reageing of 120oC for one day
of particle was minimized, sintering time and temperature +180oC for 1800 s + 120oC for one day [191]. Liu et al. (2012)
increased hardness increased. It was concluded that the best investigated the impact of ball-milling time on CNT/Al com-
hardness (76HB) and strength (318 MPa) were achieved at 3 posite reported that as milling time increased the tensile and
µm, 600oC and 45 minutes as shown in Fig. 13 and Fig. 14 yield strengths of the composite increased reaching optimum
[187]. values at 6 hrs. This is attributed to homogeneous distribution
of the CNT in the Al. However, an increase in time above 6 hrs
reduced the mechanical properties and the elongation [192].
Dash, Murty and Aamanchi (2015) fabricated laminate nano
composite by reinforcing glass/epoxy with Al-Cu-Al2O3 parti-
cle via MA. SPS and conventional sintering sintered the green
compact. The results indicated that an increase in the amount
of Al-Cu-Al2O3 increased the hardness, yield strength and
compression of the composite, SPS composite revealed better
mechanical properties [193]. Chen et al. (2018) reinforced AA
6061 with B4C via PM. The sample having 30% B4C was ex-
truded, rolled and sintered by hot pressing. The results indi-
cated uniform dispersion of B4C within the 6061 Al and the
Fig. 13. Effect of Al2O3 size, sintering temperature and time on yield composite composed of Al2O3, B4C and Al. The yield and ul-
strength and hardness of AMC [187]. timate tensile strengths increased with increase in the defor-
mation and decrease due to breakage of sizeable B4C and
stress intensity within the site between 6061 Al and B4C [194].
Sadeghi et al. (2018) combined SPS and friction stir process to
produce a binary composite. Alumina of micro and nano size
were added to elemental Al. A load of 50 MPa and a tempera-
ture of 550oC at 5 min/oC were applied to the green compact.
The duration for heating was less than 25 minutes. They re-
ported increase in hardness as rotational speed, velocity,
pressing load and heat input increased. They concluded that
the variation in hardness was due to nano alumina particles
acting as recrystallization inducers [195].
Fig. 14. Effect of Al2O3 size, sintering temperature and time on yield
strength and hardness of AMC [187].
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5 MECHANICAL PROPERTIES OF HYBRID REINFORCED Al 100.46 72. 3 HRB

COMPOSITE Al-0.5 Al2O3 120.01 78.2 HRB
Bilal, Shaikh, and Arif (2018) fabricated the aluminum hybrid Al-1.0 Al2O3 138.01 81.5 HRB
composites by adding SiC and fly ash to Al using powder
Al-1.5 Al2O3 177.43 89.7 HRB
metallurgy method. The result showed that hardness as well
as wear resistance were increased due to increase in the Al-2.0 Al2O3 152.25 94.4 HRB PM [190]
amount fly ash and SiC [196]. Kumar et al. (2016) incorporated Al-SiC 145 51 BHN
SiC and B4C into Al metal matrix via PM route. Three various Al-0.5SiC 220 65 BHN
hybrid composite samples were studied and it was observed
Al-2.5SiC 257 72 BHN
that as the concentration of the reinforcements increased the
hardness increased and that as the amount of SiC decreased Al-4.5SiC 240 76 BHN PM [202]
the hardness decreased. The highest hardness was obtained at AA7075 574 192 HV
90%Al 3%SiC 7% B4C 32.7 HB [197]. Karabulut, Gökmen, and
AA7075-1SiC 634 198 HV
Çinic (2016) reinforced aluminum alloy 7039 with SiC, Al2O3
and B4C to look into the effect of reinforcements on the alloy. AA7075-5SiC 547 199 HV [203]
Three samples having 10% of the reinforcements were pre- A 356 128 52 BHN
pared via PM coupled with hot extrusion. The finding re- A 356-1.5 Al2O3 184 71 BHN PM [204]
vealed homogeneous distribution of the particles in the matrix
Al 95 15 BHN
and there was proper wetting between the matrix and the re-
inforcements that led to increased hardness, bending strength Al-0.5MCNTSiC 219.88 42 BHN
and elongation. They concluded that alumna gave the highest Al-1MCNTSiC 232.50 47 BHN
mechanical properties in relation to SiC and B4C [198].
Al-1.5MCNTSiC 246.41 49 BHN PM [178]
Swaminathan et al. (2016) examined the effect of compacting
load and microwave sintering on Al reinforced with SiC/ Al5058 235 55 BHN
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Al2O3/Fly ash via powder metallurgy. The samples were Al5083-1%SiC 247 60 BHN
pressed at different pressing force from 4 ton to 8 ton and sin- Al5083-2%SiC 262 68 BHN
tering was performed through conventional and microwave
Al5083-3%SiC 270 78 BHN UAC [205]
sintering 5600C for 2.5 hrs and 5600C for ½ hr. respectively.
The outcome revealed that as the compacting load and tem- Micro Composite UTS (MPa) Hardness MOM Ref.
perature increased the hardness as well as the densification A356.2 alloy 263 68 BHN
increased. Also, MWS gave better hardness and densification
A356.2/2%RHA/2%SiC 296 74 BHN
than conventional sintering [199]. Alalkawai, Azid and Alja-
wad (2019) introduced nano particles of Fe2O3 and Al2O3 into A356.2/4%RHA/4%SiC 310 83 BHN
Al of size 60 µm via PM to study mechanical and other proper- A356.2/6%RHA/6%SiC 333 96 BHN SC [206]
ties of the hybrid composite. They reported important im- A356.2/8%RHA/8%SiC 356 104 BHN
provement on the hardness and compressive strength of the
Al 6061 184 60 BHN
composite by increasing the amount of the reinforcing parti-
cles and using nano size of 30 nm and 14-20 nm of Fe2O3 and Al 6061 10% Al2O3/SiC 270 85 BHN
Al2O3 respectively. The optimum compressive strength 152 Al 6061 15% Al2O3/SiC 359 105 BHN
MPa and hardness 47 HV were achieved at 2% Al2O3 and 1.5%
Al 6061 20% Al2O3/SiC 415 122 BHN SC [207]
Fe2O3 representing 30% and 18.5% increase when compared
with strength and hardness of the elemental aluminum [200] . Al3.38%Zn 0%FA.8% 93.38 47.39 BHN
Kumar et al (2018) studied the effect of Al2O3/SiC on pure Al Al2O3
fabricated through PM. The amount of SiC was varied from 0- Al3.38%Zn 4%FA.8% 100.07 51.25 BHN
8% while that Al2O3 was kept constant at 4%. The mixed sam- Al2O3
ple was compacted in a UTM under a pressure of 300 MPa, Al3.38%Zn 8%FA.8% 113.81 58.26 BHN
sintered at fixed temperature of 400c and time 45 min for Al2O3
hardness testing while for compressive testing the applied
Al3.38%Zn 12%FA.8% 133.74 65.37 BHN SC [208]
loads were varied. The result indicated increasing the amount
Al2O3
of SiC increased the hardness and the compressive strength of
the composite. However, compression strength decreased AALM4 130.5 52.5 HV
with a decrease in compaction load [201]. AALM4 5% Al2O3/SiC 137.2 67.5 HV
AALM4 10% Al2O3/SiC 145.6 135.5 HV
TABLE 9
AALM4 12% Al2O3/SiC 161.6 157.5 HV SC [209]
MATERIAL PROPERTIES OF SELECTED COMPOSITES
Nanocomposite UTS (MPa) Hardness MOM Ref.
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ferent components in automotive, electronics, aerospace and

TABLE 10 nuclear industries [218]. The table below gives a summary of
MATERIAL PROPERTIES OF SELECTED COMPOSITES the application of various system of composites. The Fig. 15
and Fig. 16 show some parts made from AMCs.
A 7075
TABLE 11
1%Gr/2%BA 259 87.3 BHN
APPLICATION OF COMPOSITE SYSTEMS
A 7075 283.4 94.2 BHN Composite System Components Area
3%Gr/4%BA
Al/SiC/Al2O3 Piston, disc brake, fastener fan Automotive, Aerospace
A 7075 299.4 99.6 BHN SC [210] exit guide vane, rotating blade [219–220]
5%Gr/6%BA Piston, Hydraulic actuators
Al 5058 228
Al5083-3%SiC 237 AlSi7Mg2Sr0.03/SiCp Bearings, piston Automotive [221]
Al5083-5%SiC 247 Al/Gr Cutting tools, machine Automotive and manu-

facturing [222]
Al5083-8%SiC 262 78 BHN
Al/Zr /Al/SiCW Connecting rod, Sprockets Automotive [223–224]
Al5083-10%SiC 270 78 BHN UAC [205]
Cu/Gr Current Collectors Automotive [223–224]
Al 77 36 HB Al/Al2O3-CF Engine block Automotive [223– [224]
Al 5%CuTi 100 52 HB s
Al 5%CuTi 136 68 HB Al-Al2O3 Reactor core Nuclear [225]
Al 5%CuTi 170 88 HB MWS [211]
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Al-10%ZrB2 200 22 HV
Al-10%ZrB2 248 42 HV
Al- 275 54 HV
19%ZrB2/1%Co
Al- 350 63 HV MWS [212]
20%ZrB2/1%Co
Al-10 wt%B4C 240 78 HV
Al-10 wt% B4C - 270 82 HV
1wt%Co
Al-15 wt% B4C - 300 110 HV
1.5wt%Co
Al-20 wt% B4C - 330 112 HV MWS [213]
2wt%Co
Al-15 wt% B4C - 281 ± 82 ± 15 HV MWS [214] Fig. 15. AMC brake rotors [226].
1.5wt%Co 15
Al-15 wt% B4C - 438 ± 241 ± 22HV SPS [214]
1.5wt%Co 31
Nano/Micro TS Hardness MOM Ref.
Composite (MPa)
Pure B4C 24:6 ±

0:21GPa
B4C +2% C-black 34:2 ±
0:17GPa
B4C +2% CNT 34:6 ± SPS [215]
0:24GPa
6 APPLICATION FIELDS
AMC is a high performance material for industrial applica-
tions due to appreciable properties over the unreinforced Al or
its alloys [216], [217]. AMC is applied in the fabrication of dif- Fig. 16. AMC single piston sliding caliper disc brake [227].
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7. CONCLUSIONS [11] B. Venkatesh and B. Harish, ―Mechanical Property of Metal Matrix Compo-
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Mechanical Properties of Aluminium Matrix Composite Including SiC/Al 2 O 3 by

Article · March 2019

Musa Alhaji Ibrahim

CAD/CAE View project

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Mechanical Properties of Aluminium Matrix Composite Including

Mechanical properties are improved by PM due to thorough TABLE 2

TABLE 1 No need for post treatment Difficult to produce intricate shapes

2.1.2 Mechanical alloying (MA) and milling (MM)

2.1.3 Spark Plasma Sintering (SPS)

Fig. 3. Schematic drawing of an SPS process [82].

shaped by traditional casting method: squeeze casting, per-

Advantages Disadvantages Advantages Disadvantages

Fig. 6. Spray-Up method [154].

3 MECHANICAL PROPERTIES OF AL/SIC REINFORCED

Wagih (2015) studied the effect of milling time on mechanical

5 MECHANICAL PROPERTIES OF HYBRID REINFORCED Al 100.46 72. 3 HRB

Nanocomposite UTS (MPa) Hardness MOM Ref.

ferent components in automotive, electronics, aerospace and

Al5083-5%SiC 247 Al/Gr Cutting tools, machine Automotive and manu-

Pure B4C 24:6 ±

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