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<p>Aluminum composites reinforced with kaolin clay and ZrO<sub>2</sub> exhibit inherent mechanical properties, rendering as selective applications in aerospace and structural applications. This research illustrates the fabrication, microstructural and mechanical characterization of the Al-6&#xa0;wt.% Kaolin-6&#xa0;wt.% ZrO<sub>2</sub> composite via stir casting, conventional powder metallurgy (CPM) and microwave-assisted sintering (MAS). Using ball milling, a uniform distribution of reinforcements in the aluminum matrix was achieved. Microstructural analysis, porosity and mechanical testing were performed to study the effect of fabrication method on the synthesized composite. The MAS Al-6% Kaolin-6% ZrO<sub>2</sub> composite reveals the optimized compression strength, tensile strength, hardness and impact energy of 372&#xa0;MPa, 290&#xa0;MPa, 201 Hv and 12.3&#xa0;J, respectively. The composite fabricated through the stir casting method resulted in higher porosity, clustered reinforcements, and inferior mechanical properties. Overall, the MAS Al-6&#xa0;wt.% Kaolin-6&#xa0;wt.% ZrO<sub>2</sub> composite shows a notable improvement in properties compared to the stir casting and CPM methods.</p>

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Effect of Processing Methods on the Mechanical Behavior and Microstructural Characteristics of Al/Kaolin/ZrO2 Hybrid Composite

  • 期刊论文

  • 发表日期：

    2026年4月22日

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  • V. S. S. Venkatesh,
  • B. Surekha,
  • Pandu Ranga Vundavilli

摘要

Aluminum composites reinforced with kaolin clay and ZrO2 exhibit inherent mechanical properties, rendering as selective applications in aerospace and structural applications. This research illustrates the fabrication, microstructural and mechanical characterization of the Al-6 wt.% Kaolin-6 wt.% ZrO2 composite via stir casting, conventional powder metallurgy (CPM) and microwave-assisted sintering (MAS). Using ball milling, a uniform distribution of reinforcements in the aluminum matrix was achieved. Microstructural analysis, porosity and mechanical testing were performed to study the effect of fabrication method on the synthesized composite. The MAS Al-6% Kaolin-6% ZrO2 composite reveals the optimized compression strength, tensile strength, hardness and impact energy of 372 MPa, 290 MPa, 201 Hv and 12.3 J, respectively. The composite fabricated through the stir casting method resulted in higher porosity, clustered reinforcements, and inferior mechanical properties. Overall, the MAS Al-6 wt.% Kaolin-6 wt.% ZrO2 composite shows a notable improvement in properties compared to the stir casting and CPM methods.