Investigation of the effect of manufacturing parameters on the density of AlCu-B4C composites prepared by powder metallurgy method

Öz

In this study, the effect of reinforcement ratio, compression pressure and sintering temperature on the post-sintering density of Al-10%Cu matrix composite material with B4C particle reinforcement at different ratios (0, 10 and 20% by volume) prepared by powder metallurgy method was investigated. High-purity alloy and ceramic powders were used for composite production, the obtained homogeneous mixture was compressed in a cold press and sintered in a tube furnace. The effect of the variables on the density after sintering was investigated using the Taguchi experimental design method. For this purpose, the L9 orthogonal experimental design, which is the most suitable Taguchi design for the process, was chosen and the experiments were carried out according to this matrix. According to the S/N ratio responses obtained as a result of the analyzes made with this design, it was observed that the compression pressure had the highest effect and the reinforcement ratio had a relatively low effect. As a result of the Taguchi experimental design and the regression analysis, it was concluded that the regression model was within the 95% confidence interval.

Anahtar Kelimeler

• AlCu matrix
• B4C reinforcement
• Powder metallurgy
• Taguchi experiment design
• Density after sintering

Toz metalurjisi yöntemi ile hazırlanan AlCu-B4C kompozitlerin yoğunluğuna imalat değişkenlerinin etkisinin incelenmesi

Öz

Bu çalışmada, toz metalurjisi yöntemi ile hazırlanan, farklı oranlarda (hacimce % 0, 10 ve 20) B4C parçacık takviyeli Al-%10Cu ana yapılı kompozit malzemenin sinterleme sonrası yoğunluğuna, takviye oranı, sıkıştırma basıncı ve sinterleme sıcaklığının etkisi incelenmiştir. Kompozit üretimi için yüksek saflıkta alaşım ve seramik tozları kullanılmış, elde edilen homojen karışım soğuk preste sıkıştırılmış ve tüp fırında sinterlenmiştir. Tayin edilen değişkenlerin sinterleme sonrası yoğunluğa etkisi Taguchi deney tasarımı yöntemi kullanılarak incelenmiştir. Bu amaç ile sürece en uygun Taguchi tasarımı olan, L9 ortogonal deney tasarımı seçilmiş ve deneyler bu matrise göre gerçekleştirilmiştir. Bu tasarım ile yapılan analizler sonucunda elde edilen S/N oranı yanıtlarına göre, sıkıştırma basıncının en yüksek etkiye, takviye oranının da görece düşük etkiye sahip olduğu gözlemlenmiştir. Taguchi deney tasarımı ve yapılan regresyon analizi sonucunda, oluşturulan regresyon modelinin ise %95 güven aralığın içinde olduğu sonucu elde edilmiştir.

Anahtar Kelimeler

• AlCu anayapı
• B4C takviye
• Toz metalürjisi
• Tagushi deney tasarımı
• Sinterleme sonrası yoğunluk

Kaynakça

1. Chang, Y., Yao, X., Chen, Y., Huang, L., & Zou, D. (2023). Review on ceramic-based composite phase change materials: Preparation, characterization and application. Composites Part B: Engineering, 254, 110584. https:// doi.org/10.1016/j.compositesb.2023.110584.
2. Shabani, M. O., & Mazahery, A. (2012). The GA optimization performance in the microstructure and mechanical properties of MMNCs. Transactions of the Indian Institute of Metals, 65(1), 77-83. https://doi.org/10.1007/s12666-011-0110-9.
3. Mazahery, A., & Shabani, M. O. (2012). Tribological behaviour of semisolid–semisolid compocast Al–Si matrix composites reinforced with TiB2 coated B4C particulates. Ceramics International, 38(3), 1887-1895. https://doi.org/10.1016/j.ceramint.2011.10.016.
4. Shabani, M. O., Mazahery, A., Rahimipour, M. R., & Razavi, M. (2012). FEM and ANN investigation of A356 composites reinforced with B4C particulates. Journal of King Saud University-Engineering Sciences, 24(2), 107- 113. https://doi.org/10.1016/j.jksues.2011.05.001.
5. Mazahery, A., & Shabani, M. O. (2012). Nano-sized silicon carbide reinforced commercial casting aluminum alloy matrix: Experimental and novel modeling evaluation. Powder Technology, 217, 558-565. https://doi.org/10.1016/j.powtec.2011.11.020.
6. Yang, Q. S., He, X. Q., Liu, X., Leng, F. F., & Mai, Y. W. (2012). The effective properties and local aggregation effect of CNT/SMP composites. Composites Part B: Engineering, 43(1), 33-38. https://doi.org/10.1016/j.compositesb.2011.04.027.
7. Kumar, S., & Ghosh, S. K. (2023). Comparative study of airborne particles on new developed metal matrix compositeku and commercial brake pad materials with ANN and finite element analysis. Computational Particle Mechanics, 10(2), 273-287. https://doi.org/10.1007/ s40571-022-00491-9.
8. Chatterjee, A., Sen, S., Paul, S., Roy, P., Seikh, A. H., Alnaser, I. A., … & Ghosh, M. (2023). Fabrication and characterization of SiC-reinforced aluminium matrix composite for brake pad applications. Metals, 13(3), 584. https://doi.org/10.3390/met13030584.

9. Biyik S. (2019). Investigation of the effect of different process control agents on the production of Cu25W composite powder via ball milling technique.Gümüşhane University Journal of Science and Technology, 9(2), 222- 228. https://doi.org/10.17714/gumusfenbil.426995.
10. Biyik, S., Arslan, F., & Aydin, M. (2015). Arc-erosion behavior of boric oxide-reinforced silver-based electrical contact materials produced by mechanical alloying. Journal of Electronic Materials, 44(1), 457-466. https://doi.org/10.1007/s11664-014-3399-4.
11. Guler, O., Varol, T., Alver, U., & Biyik, S. (2021). The wear and arc erosion behavior of novel copper based functionally graded electrical contact materials fabricated by hot pressing assisted electroless plating, Advanced Powder Technology, 32(8), 2873-2890. https://doi.org/10.1016/j.apt.2021.05.053.
12. Übeyli, M., Balci, E., Sarikan, B., Öztaş, M. K., Camuşcu, N., Yildirim, R. O., & Keleş, Ö. (2014). The ballistic performance of SiC-AA7075 functionally graded composite produced by powder metallurgy. Materials & Design, 56, 31-36. https://doi.org/10.1016/j.matdes.2013.10.092.
13. Ansari, A., Akbari, T., & Pishbijari, M. R. (2023). Investigation on the ballistic performance of the aluminum matrix composite armor with ceramic balls reinforcement under high velocity impact. Defence Technology, Article in press. https://doi.org/10.1016/j.dt.2023.01.015.
14. Karabulut, Ş., Karakoç, H., Bilgin, M., Canpolat, H.,Krolczyk, G. M., & Sarıkaya, M. (2023). A comparative study on mechanical and ballistic performance of functionally graded Al6061 composites reinforced with B4C, SiC, and Al2O3. Journal of Materials Research and Technology, 23, 5050-5065. https://doi.org/10.1016/j. jmrt.2023.02.116.
15. Saravanan, R., Gnanavel, C., Daniel, S. A. A., Rajesh, S., Kamatchi, T., Anbuchezhiyan, G., & Sreekanth, S. (2023). Analysis of mechanical properties enhancement on composites of AA7175 by multi walled carbon nano tube (MWCNT). Materials Today: Proceedings. Article in press. https://doi.org/10.1016/j.matpr.2023.03.788.
16. Ibrahim, T. K., Yawas, D. S., Dan-Asabe, B., & Adebisi, A. A. (2023). Taguchi optimization and modelling of stir casting process parameters on the percentage elongation of aluminium, pumice and carbonated coal composite. Scientific Reports, 13(1), 2915. https://doi.org/10.1038/s41598-023-29839-8.
17. Mazahery, A., Abdizadeh, H., & Baharvandi, H. R. (2009). Development of high-performance A356/nanoAl2O3 composites. Materials Science and Engineering: A, 518(1-2), 61-64. https://doi.org/10.1016/j.msea.2009.04.014.
18. Shabani, M. O., & Mazahery, A. (2011). Prediction of wear properties in A356 matrix composite reinforced with B4C particulates. Synthetic Metals, 161(13-14), 1226- 1231. https://doi.org/10.1016/j.synthmet.2011.04.009.
19. Abbasipour, B., Niroumand, B. & Vaghefi, S. M. (2010). Compocasting of A356-CNT composite. Transactions of Nonferrous Metals Society of China, 20(9), 1561-1566. https://doi.org/10.1016/S1003-6326(09)60339-3.
20. Pérez-Bustamante, R., Pérez-Bustamante, F., EstradaGuel, I., Licea-Jiménez, L., Miki-Yoshida, M., & Martínez-Sánchez, R. (2013). Effect of milling time and CNT concentration on hardness of CNT/Al2024 composites produced by mechanical alloying. Materials Characterization, 75, 13-19. (https://doi.org/10.1016/j.matchar.2012.09.005).
21. Uzun, A., Karakoc, H., Gökmen, U., Cinici, H., & Türker, M. (2016). Investigation of mechanical properties of tubular aluminum foams. International Journal of Materials Research, 107(11), 996-1004. https://doi. org/10.3139/146.111430.
22. Chen, H. S., Wang, W. X., Nie, H. H., Zhou, J., Li, Y. L., Liu, R. F., & Zhang, P. (2018). Microstructure evolution and mechanical properties of B4C/6061Al neutron absorber composite sheets fabricated by powder metallurgy. Journal of Alloys and Compounds, 730, 342-351. (https://doi.org/10.1016/j.jallcom.2017.09.312).
23. Gökmen, U. (2016). Fabrication and Characterization of Hot Extruded Hybrid Composites Al 2024 Matrix Reinforced With B4C/Al2O3. Journal of Polytechnic, 19(4), 445-453. https://dergipark.org.tr/en/pub/ politeknik/issue/33093/368268
24. Şimşek, İ., Şimşek, D., & Özyürek, D. (2019). The corrosion behaviours in different solutions of B4C reinforcement aluminium matrix composites. Journal of Boron, 5(1), 23-28. https://doi.org/10.30728/ boron.659969.
25. Polmear, I. J. (2006). Light alloys: From traditional alloys to nanocrystals. Elsevier. ISBN 9780750663717. [26] Zolotarevskii, V., Belov, N., Glazoff, M., & Davis, J. (2007). Casting aluminum alloys. Elsevier. ISBN 9780080550237.
26. Zolotarevskii, V., Belov, N., Glazoff, M., & Davis, J. (2007). Casting aluminum alloys. Elsevier. ISBN 9780080550237.
27. Zhou, D., Qiu, F., & Jiang, Q. (2015). The nanosized TiC particle reinforced Al-Cu matrix composite with superior tensile ductility. Materials Science and Engineering: A, 622, 189-193. https://doi.org/10.1016/j. msea.2014.11.006.
28. Zhou, D., Qiu, F., & Jiang, Q. (2014). Simultaneously increasing the strength and ductility of nano-sized TiN particle reinforced Al-Cu matrix composites. Materials Science and Engineering: A, 596, 98-102. https://doi.org/10.1016/j.msea.2013.12.049.
29. Tian, W. S., Zhao, Q. L., Zhang, Q. Q., Qiu, F., & Jiang, Q. C. (2018). Simultaneously increasing the hightemperature tensile strength and ductility of nano-sized TiCp reinforced Al-Cu matrix composites. Materials Science and Engineering: A, 717, 105-112. https://doi. org/10.1016/j.msea.2018.01.069.
30. Zhang, L. J., Qiu, F., Wang, J. G., & Jiang, Q. C. (2015). High strength and good ductility at elevated temperature of nano-SiCp/Al2014 composites fabricated by semisolid stir casting combined with hot extrusion. Materials Science and Engineering: A, 626, 338-341. https://doi.org/10.1016/j.msea.2014.12.089.
31. Özdemir, İ. (2018). Fractional factorial design and Taguchi method application on the production of composite material. (M. Sc. Thesis, Ondokuz Mayıs University) Council of Higher Education Thesis Center (Thesis Number 494867).
32. Şirvancı, M. (1997). Kalite için deney tasarımı "Taguçi yaklaşımı" [Experimental design for quality "Taguchi approach"]. Literatür. ISBN:9789757860877.
33. ASTM B962-17. (2017). Standard test methods for density of compacted or sintered powder metallurgy (PM) products using Archimedes’ principle. ASTM International.
34. Vairamuthu, J., Senthil Kumar, A., Stalin, B., & Ravichandran, M. (2020). Optimization of powder metallurgy parameters of TiC-and B4C-reinforced aluminium composites by Taguchi method. Transactions of the Canadian Society for Mechanical Engineering, 45(2), 249-261. (https://doi.org/10.1139/ tcsme-2020-0091).
35. Usca, Ü. A., Uzun, M., Kuntoğlu, M., Şap, S., Giasin, K., & Pimenov, D. Y. (2021). Tribological aspects, optimization and analysis of Cu-B-CrC composites fabricated by powder metallurgy. Materials, 14(15), 4217. https://doi.org/10.3390/ma14154217.
36. Hussain, M. Z., Khan, S., & Sarmah, P. (2020). Optimization of powder metallurgy processing parameters of Al2O3/Cu composite through Taguchi method with Grey relational analysis. Journal of King Saud University-Engineering Sciences, 32(4), 274-286. https://doi.org/10.1016/j.jksues.2019.01.003.
37. Kaya, A., Aslan, M., Yilmaz, N. F., & Kurt, H. (2020). Taguchi Analysis of Apparent Densities of Al-Mg-SiC Composites. El-Cezeri, 7(2), 773-780. (https://doi. org/10.31202/ecjse.695249).
38. Çetin, M. H. (2010). Investigation of vegetable-based cutting fluids performance in turning. (M.Sc. Thesis, Gebze Institute of Technology) Council of Higher Education Thesis Center (Thesis Number 271585).
39. Nas, E., Altan Özbek, N. (2020). Optimization of the machining parameters in turning of hardened hot work tool steel using cryogenically treated tools. Surface Review and Letters, 27(5), 1950177. https://doi. org/10.1142/S0218625X19501774