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<p>This work explores ultrasonic-assisted stir-cast Al-Fe-Si (AA8011) alloy-based aluminum nanocomposites (ANCs) strengthened with nano&#xa0;zirconia (nZrO<sub>2</sub>) (1-3&#xa0;wt.%), nano&#xa0;titanium carbide (nTiC) (1-3&#xa0;wt.%), and hybrid nZrO<sub>2</sub> + nTiC (1 + 1 and 1.5 + 1.5&#xa0;wt.%) to enhance physical, mechanical, and tribological performance. XRD confirmed the FCC-Al matrix with the successful incorporation of monolithic nZrO<sub>2</sub> and nTiC phases, with reinforcement peak intensity increasing with particle content. Compared with as-cast AA8011 (experimental density: 2.701&#xa0;g/cm<sup>3</sup>; porosity: 0.33%), the ANCs showed increased density and porosity (up to 1.43%), attributed to nanoparticle agglomeration and limited wettability. Mechanical attributes were enhanced markedly, ultimate tensile strength increased from 61.21&#xa0;MPa (as-cast) to 102.39&#xa0;MPa (AA8011 + 1%nZrO<sub>2</sub> + 1%nTiC), reduction in ductility was noticed from 8.62 to 2.87% due to deformation induced by reinforcements. Yield and flexural strengths elevated from 40.15&#xa0;and 72.5&#xa0;MPa to 79.06 and 132.87&#xa0;MPa (AA8011 + 1%nZrO<sub>2</sub> + 1%nTiC), indicating strong nanoparticle strengthening and hybrid effect. Hardness improved from 42.77&#xa0;HV (as-cast) to 47.26&#xa0;HV (AA8011 + 1.5%nZrO<sub>2</sub> + 1.5nTiC), whereas the impact strength ranged from 13.2 to 13.85&#xa0;J. Pin-on-disk studies demonstrated significant improvements in tribology: AA8011 + 1%nZrO<sub>2</sub> + 1%nTiC had the least wear depth (123.03&#xa0;µm) and friction coefficient (0.702). Hybrid combinations had stronger friction responses and smoother worn patterns because they formed a cohesive mechanically mixed/oxide tribolayer, which made them more resilient to wear.</p>

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Impact of Nanoceramic Inclusions on the Performance Characteristics of Al-Fe-Si Alloy Composites

  • 期刊论文

  • 发表日期：

    2026年7月7日

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  • P. Sivakumar,
  • Pon Azhagiri,
  • P. Gopal,
  • N. Senthilkumar

摘要

This work explores ultrasonic-assisted stir-cast Al-Fe-Si (AA8011) alloy-based aluminum nanocomposites (ANCs) strengthened with nano zirconia (nZrO2) (1-3 wt.%), nano titanium carbide (nTiC) (1-3 wt.%), and hybrid nZrO2 + nTiC (1 + 1 and 1.5 + 1.5 wt.%) to enhance physical, mechanical, and tribological performance. XRD confirmed the FCC-Al matrix with the successful incorporation of monolithic nZrO2 and nTiC phases, with reinforcement peak intensity increasing with particle content. Compared with as-cast AA8011 (experimental density: 2.701 g/cm3; porosity: 0.33%), the ANCs showed increased density and porosity (up to 1.43%), attributed to nanoparticle agglomeration and limited wettability. Mechanical attributes were enhanced markedly, ultimate tensile strength increased from 61.21 MPa (as-cast) to 102.39 MPa (AA8011 + 1%nZrO2 + 1%nTiC), reduction in ductility was noticed from 8.62 to 2.87% due to deformation induced by reinforcements. Yield and flexural strengths elevated from 40.15 and 72.5 MPa to 79.06 and 132.87 MPa (AA8011 + 1%nZrO2 + 1%nTiC), indicating strong nanoparticle strengthening and hybrid effect. Hardness improved from 42.77 HV (as-cast) to 47.26 HV (AA8011 + 1.5%nZrO2 + 1.5nTiC), whereas the impact strength ranged from 13.2 to 13.85 J. Pin-on-disk studies demonstrated significant improvements in tribology: AA8011 + 1%nZrO2 + 1%nTiC had the least wear depth (123.03 µm) and friction coefficient (0.702). Hybrid combinations had stronger friction responses and smoother worn patterns because they formed a cohesive mechanically mixed/oxide tribolayer, which made them more resilient to wear.