Effect of Chromium Addition on ZA40 Alloy Fabricated by Powder Metallurgy Method

Year 2025, Volume: 11 Issue: 2, 233 - 242, 31.08.2025

Kemal Aydın

Abstract

The aim of this study is to develop and investigate the properties of chromium powder-reinforced metal-metal composites using powder metallurgy methods with a ZA40 alloy matrix. To analyze the effect of varying chromium particle amounts on ZA40-Cr composites, samples with chromium weight percentages of 5%, 10%, and 15% were produced. To ensure uniform distribution of chromium particles, the matrix and composite powders were mixed in ball mills for five hours. These powders were then hot-pressed under an argon gas atmosphere at 500°C and 500 MPa pressure for two hours to form the samples. The samples were evaluated by determining the microstructure, hardness, density, and tensile properties of the ZA40-Cr metal-metal composites with varying chromium content. Porosity and relative density results revealed that increasing Cr content increased porosity while reducing relative density. Hardness measurements showed that the sample with 10% Cr addition exhibited the highest hardness value (182 Brinell). However, increased porosity in the 15% Cr sample caused a decline in hardness. Tensile strength tests indicated that the sample with 10% Cr addition achieved the highest strength (240 MPa). The results demonstrated that the reinforcement of the ZA40 matrix with Cr particles at specific ratios enhanced the mechanical performance, but that excessive Cr content adversely affected the properties due to increased porosity. The optimum Cr content was determined to be 10%, providing the best mechanical properties. This study highlights the potential of ZA40-Cr composites as cost-effective and high-performance materials for engineering applications.

Keywords

ZA40 , composite , powder metallurgy , tensile.

References

• [1] S. S. Owoeye, D. O. Folorunso, B. Oji, and S. G. Borisade, “Zinc-aluminum (ZA-27)-based metal matrix composites: a review article of synthesis, reinforcement, microstructural, mechanical, and corrosion characteristics,” The International Journal of Advanced Manufacturing Technology, vol. 100, no. 1–4, pp. 373–380, Jan. 2019. doi: 10.1007/s00170-018-2760-9
• [2] M. Babic, S. Mitrovic, and B. Jeremic, “The influence of heat treatment on the sliding wear behavior of a ZA-27 alloy,” Tribol Int, vol. 43, no. 1–2, pp. 16–21, Jan. 2010. doi: 10.1016/j.triboint.2009.04.016
• [3] C. Testani and F. Ferraro, “Development of a Low-Cost Process for Manufacturing of Ti-Metal Matrix Composite by Roll-Diffusion Bonding,” J Mater Eng Perform, vol. 19, no. 4, pp. 521–526, Jun. 2010. doi: 10.1007/s11665-010-9620-6
• [4] G. M. Reddy, K. S. Prasad, K. S. Rao, and T. Mohandas, “Friction surfacing of titanium alloy with aluminium metal matrix composite,” Surface Engineering, vol. 27, no. 2, pp. 92–98, Mar. 2011. doi: 10.1179/174329409X451128
• [5] J. Hashim, “The Production of Cast Metal Matrix Composite by a Modified Stir Casting Method,” J Teknol, vol. 35, no. A, pp. 9-20, Jan. 2012. doi: 10.11113/jt.v35.588
• [6] P. Choudhury, S. Das, and B. K. Datta, “Effect of Ni on the wear behavior of a zinc-aluminum alloy,” J Mater Sci, vol. 37, no. 10, pp. 2103–2107, 2002. doi: 10.1023/A:1015297904125
• [7] S. C. Sharma, B. M. Girish, R. Kamath, and B. M. Satish, “Graphite particles reinforced ZA-27 alloy composite materials for journal bearing applications,” Wear, vol. 219, no. 2, pp. 162–168, Sep. 1998. doi: 10.1016/S0043-1648(98)00188-4
• [8] M. T. Abou El-khair, A. Daoud, and A. Ismail, “Effect of different Al contents on the microstructure, tensile and wear properties of Zn-based alloy,” Mater Lett, vol. 58, no. 11, pp. 1754–1760, Apr. 2004. doi: 10.1016/j.matlet.2003.10.058
• [9] E. Gervais, R. J. Barnhurst, and C. A. Loong, “An Analysis of Selected Properties of ZA Alloys,” JOM, vol. 37, no. 11, pp. 43–47, Nov. 1985. doi: 10.1007/BF03258743
• [10] M. T. Abou El-khair, A. Daoud, and A. Ismail, “Effect of different Al contents on the microstructure, tensile and wear properties of Zn-based alloy,” Mater Lett, vol. 58, no. 11, pp. 1754–1760, Apr. 2004. doi: 10.1016/j.matlet.2003.10.058
• [11] W. Zhang, X. Ma, and D. Ding, “Aging behavior and tensile response of a SiCw reinforced eutectoid zinc-aluminium-copper alloy matrix composite,” J Alloys Compd, vol. 727, pp. 375–381, Dec. 2017. doi: 10.1016/j.jallcom.2017.08.130
• [12] R. Michalik, A. Iwaniak, and J. Wieczorek, “Influence of heat treatment on the wear resistance of the ZnAl40Cu1.5Ti1.5 alloy,” Archives of Metallurgy and Materials, vol. 62, no. 1, pp. 129–136, Mar. 2017. doi: 10.1515/amm-2017-0017
• [13] P. P. Ritapure, R. G. Yadav, V. T. Rasal, A. V. Damale, and Y. R. Kharde, “Comparative review and experimental validation of Tribological and Mechanical Properties of Zinc Aluminium Alloy (ZA27) and Aluminium Zinc Alloy (Al-25Zn),” Journal of Alloys and Metallurgical Systems, vol. 7, p. 100099, Sep. 2024. doi: 10.1016/j.jalmes.2024.100099
• [14] B. K. Prasad, “Dry sliding wear response of zinc-based alloy over a range of test speeds and loads: a comparative study with cast iron,” Tribol Lett, vol. 25, no. 2, pp. 103–115, Jan. 2007. doi: 10.1007/s11249-006-9054-3
• [15] S. Özkaya, “Microstructural, Mechanical, and Tribological Characteristics of ZA40 Alloy Reinforced with AlCrCuFeNi High Entropy Alloy: An Experimental Study,” JOM , vol. 77, no. 7, pp. 5510–5525, 2025. doi: 10.1007/s11837-025-07401-3
• [16] T Varol, O Güler, S. B. Akçay, H. Çolak, “The evolution of microstructure and properties of Cu-Cr alloys synthesized via flake powder metallurgy assisted by mechanical alloying and hot pressing,” Mater Today Commun, vol. 33, p. 104452, 2022. doi: 10.1016/j.mtcomm.2022.104452
• [17] M. Çelebi, A. Çanakçi, O. Güler, B. Akgül, and A. H. Karabacak, “Study on Effect of Milling Time on the Mechanical and Wear Properties of the ZA40-B4C-Graphene Hybrid Nanocomposites Fabricated by Vacuum Hot-Pressing,” JOM, vol. 75, no. 9, pp. 3935–3950, Sep. 2023. doi: 10.1007/s11837-023-06007-x
• [18] A. Çanakçı and E. Deniz Yalçın, “Investigation of Tribological Applications and Mechanical Properties of Zinc-Aluminium (ZA40)/Multi-Wall Carbon Nanotube (MWCNT) Composite Alloys,” Tehnički glasnik, vol. 17, no. 4, pp. 620–627, Oct. 2023. doi: 10.31803/tg-20220831200112
• [19] A. Çanakçı and M. Çelebi̇, “Determination of nano-graphene content for improved mechanical and tribological performance of Zn-based alloy matrix hybrid nanocomposites,” J Alloys Compd, vol. 1001, p. 175152, Oct. 2024. doi: 10.1016/j.jallcom.2024.175152
• [20] M. Çelebi, A. Çanakçı, O. Güler, H. Karabacak, B. Akgül, and S. Özkaya, “A study on the improvement of wear and corrosion properties of ZA40/Graphene/B4C hybrid nanocomposites,” J Alloys Compd, vol. 966, p. 171628, Dec. 2023. doi: 10.1016/j.jallcom.2023.171628
• [21] T. Yu, G. Geng, P. Xue, and L. Zhang, “The Research of Reinforced Cu-SiCp/ZA40 and Cu-SiCp/AZ91D Metal Matrix Composites’ Mechanisms,” IOP Conf Ser Mater Sci Eng, vol. 381, p. 012173, Aug. 2018. doi: 10.1088/1757-899X/381/1/012173
• [22] M. Li, S. Lu, F. Long, M. Sheng, H. Geng, and W. Liu, “Effect of Y Addition on the Mechanical Properties and Microstructure of Zn-Al Alloys,” JOM, vol. 67, no. 5, pp. 922–928, May 2015. doi: 10.1007/s11837-014-1269-4