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<p>The high cost and suboptimal performance of conventional aluminum-based composites highlight the need for hybrid composites to enhance their mechanical and tribological properties for diverse applications. This study addresses this issue by optimizing processing parameters, including sintering temperature and compaction pressure, for fabricating aluminum alloy-based hybrid metal matrix composites via the powder metallurgy route. LM26 aluminum alloy powder was reinforced with 5wt.% aluminum nitride and 6wt.% carbonized eggshell powder to fabricate the hybrid composite. The composites were produced under varying compaction pressures (400, 450, 500, 550, and 600&#xa0;MPa) and sintering temperatures (400, 500, and 600&#xa0;°C), and their physical, mechanical, and tribological properties were comprehensively evaluated. Characterization techniques, including x-ray diffraction, energy-dispersive x-ray spectroscopy, and field emission scanning electron microscopy, were employed to examine the phase composition, elemental distribution, and microstructural characteristics of the fabricated composites. Results revealed that increasing compaction pressure improved green density, while higher sintering temperatures enhanced sintered density, which corresponds to a reduction in %porosity, as expected. Optimal parameters of 550&#xa0;MPa and 600&#xa0;°C resulted in a 37.91% increase in hardness, with maximum values at 550&#xa0;MPa across all sintering temperatures. Wear tests demonstrated significant reductions in wear loss at higher sintering temperatures, with decreases of 93.02% at 50 N and 97.69% at 30 N. However, wear loss increased with higher normal loads.</p>

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Sintering and Compaction Effect on Mechanical and Tribological Properties of LM26 Aluminum-Based Hybrid Metal Matrix Composite

  • 期刊论文

  • 发表日期：

    2025年4月29日

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  • Puneet Kumar Sonker,
  • Thingujam Jackson Singh,
  • Binayaka Nahak,
  • Sandeep Kumar Singh,
  • Ashish Srivastava

摘要

The high cost and suboptimal performance of conventional aluminum-based composites highlight the need for hybrid composites to enhance their mechanical and tribological properties for diverse applications. This study addresses this issue by optimizing processing parameters, including sintering temperature and compaction pressure, for fabricating aluminum alloy-based hybrid metal matrix composites via the powder metallurgy route. LM26 aluminum alloy powder was reinforced with 5wt.% aluminum nitride and 6wt.% carbonized eggshell powder to fabricate the hybrid composite. The composites were produced under varying compaction pressures (400, 450, 500, 550, and 600 MPa) and sintering temperatures (400, 500, and 600 °C), and their physical, mechanical, and tribological properties were comprehensively evaluated. Characterization techniques, including x-ray diffraction, energy-dispersive x-ray spectroscopy, and field emission scanning electron microscopy, were employed to examine the phase composition, elemental distribution, and microstructural characteristics of the fabricated composites. Results revealed that increasing compaction pressure improved green density, while higher sintering temperatures enhanced sintered density, which corresponds to a reduction in %porosity, as expected. Optimal parameters of 550 MPa and 600 °C resulted in a 37.91% increase in hardness, with maximum values at 550 MPa across all sintering temperatures. Wear tests demonstrated significant reductions in wear loss at higher sintering temperatures, with decreases of 93.02% at 50 N and 97.69% at 30 N. However, wear loss increased with higher normal loads.