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<p>This study investigates the fabrication of Al–Fe/SiC/WC hybrid metal matrix composites (HMMCs) via the powder metallurgy process, highlighting the optimization of sintering temperature and reinforcement composition to enhance hardness, wear resistance, and porosity. The Al and Fe powders along with varied weight percentages of SiC and WC were blended in a ball mill. The blended mixtures were compacted into cylindrical pellets utilizing uniaxial compaction dies in a hydraulic pallet press followed by sintering. These hybrid composites underwent testing at different sintering temperatures and variable weight percentages (wt.%) of SiC and WC. The design of experiments (L9 orthogonal array) was used to set the experimentation with three levels of input factors. Response surface methodology and Desirability analysis were performed to identify the optimum set of input parameters to achieve better output. The surface hardness and wear (weight loss) have been found between 46 and 63 HRB and 0.015 to 0.028&#xa0;g respectively under different sintering temperature ranges, wt.% of SiC and WC. Moreover, minimum porosity (%) was found to be 0.0058 under a sintering temperature of 500&#xa0;°C, 1.5 wt.% of SiC and 3 wt.% of WC. Furthermore, the composite was subjected to in-depth examination of wear utilizing scanning electron microscopy corresponding to several process variables. However, diminished ranges of porosity have been evaluated at higher values of process parameters. The optimum input levels such as sintering temperature of 481.49&#xa0;°C, 1.87 wt.% of SiC, and 2.24 wt.% of WC offer the best results, achieving a minimum porosity of 0.0052%, minimum wear of 0.014&#xa0;g, and maximum hardness of 53.55 HRB at a desirability of 1.</p> Graphical abstract <p></p>

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Optimization modelling of hardness, wear, and porosity behaviour of Al–Fe/SiC/WC hybrid composite

  • 期刊论文

  • 发表日期：

    2025年5月26日

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  • Syed Abid Hasan,
  • Faisal Hasan,
  • Mohammad Umair Zaki,
  • Farhan Ahmad Shamin,
  • Abdul Faheem,
  • Farooq Ahmed,
  • S. Thirumalai Kumaran,
  • Roshan Kuruvila

摘要

This study investigates the fabrication of Al–Fe/SiC/WC hybrid metal matrix composites (HMMCs) via the powder metallurgy process, highlighting the optimization of sintering temperature and reinforcement composition to enhance hardness, wear resistance, and porosity. The Al and Fe powders along with varied weight percentages of SiC and WC were blended in a ball mill. The blended mixtures were compacted into cylindrical pellets utilizing uniaxial compaction dies in a hydraulic pallet press followed by sintering. These hybrid composites underwent testing at different sintering temperatures and variable weight percentages (wt.%) of SiC and WC. The design of experiments (L9 orthogonal array) was used to set the experimentation with three levels of input factors. Response surface methodology and Desirability analysis were performed to identify the optimum set of input parameters to achieve better output. The surface hardness and wear (weight loss) have been found between 46 and 63 HRB and 0.015 to 0.028 g respectively under different sintering temperature ranges, wt.% of SiC and WC. Moreover, minimum porosity (%) was found to be 0.0058 under a sintering temperature of 500 °C, 1.5 wt.% of SiC and 3 wt.% of WC. Furthermore, the composite was subjected to in-depth examination of wear utilizing scanning electron microscopy corresponding to several process variables. However, diminished ranges of porosity have been evaluated at higher values of process parameters. The optimum input levels such as sintering temperature of 481.49 °C, 1.87 wt.% of SiC, and 2.24 wt.% of WC offer the best results, achieving a minimum porosity of 0.0052%, minimum wear of 0.014 g, and maximum hardness of 53.55 HRB at a desirability of 1.

Graphical abstract