Synthesis, Characterization, And Testing Of Self-Lubricating Tetra Hybrid Reinforced Al Matrix Composites Via Powder Metallurgy Processing

Abstract

Hybrid Aluminum Matrix Composites (Hamcs) Are A New Class Of Advanced Materials That Can Be Customized And Engineered To Achieve Specific Properties For Specific Applications In Specific Environments. Hamcs Find A Wide Range Of Popularity In Transportation Sector Because Of Lower Noise And Lower Fuel Consumptions Over Another Material. This Research Aims To Synthesize, Characterize, And Test The Physicomechanical, Tribological, And Corrosion Characteristics Of Tetra Hybrid (Sic, Al2o3, Gr, And Sugar Cane Bagasse Ash (Scba)) Reinforced Hamcs Via Powder Metallurgy (Pm) Processing. In The First Section, Tetra Hybrid Reinforced Hamcs Were Synthesized Using Pure Al Matrix With Fixed Wt% Of Primary Reinforcements (5 Wt% Sic And 5 Wt% Al2o3) And Varying Wt% Of Secondary Reinforcements Such As (0.5, 2.5, 4.5, And 6.5) Wt% Gr And (0.5, 2.5, 4.5,And 6.5) Wt% Scba. This Section Focused On Phase Purity Investigation Using Xrd, Thermal Analysis Using Tga-Dta, Surface Area And Micropore Sizes Analysis Using Bet, Morphological Study Using Sem Characterizations, And Physicomechanical, Tribological, And Corrosion Tests To Explore The Materials' Behavior Of The Newly Synthesized Hamcs. The Second Section Mainly Focused On Multi-Response Optimization With An L16 Orthogonal Array Experimental DesignEmploying Taguchi-Based Grey Relational Analysis (Tgra). This Section Was Intended To Explore The Influence Of Hybrid Reinforcements Containing (5 Wt% Sic And 5 Wt% Al2o3) And The Various Wt% Of Gr And Scba On Physicomechanical Properties Of Hamcs When Milling Time, Compaction Pressure, And Sintering Temperature Were Varied. The Xrd Findings Demonstrated That All Of The Synthesized Hamcs In All Proportions Contain Main Peaks That Are Al And Hybrid Reinforcements As Miner Peaks, With No Unwanted Peaks. According To Bet And Sem Analysis, The Hamc (As4Sample) With 10 Wt% (Sic +Al2o3) And 9 Wt% (Gr +Scba) Showed Lower Micropore Size With Dense And Uniform Microstructure. The Increase In Wt% Of Secondary Reinforcements Decreases Both Density And Porosity, While Increasing Hardness And Compressive Strength Up To A Certain Level Above Which It Begins To Reverse, Because Of The Increase In Wt% Of Hard Particles Of Sic, Al2o3,And Scba. The Vickers Hardness And Compressive Strength Of The As4 Hamc Were Improved By446.40% And 209.75%, Respectively. The Wear Loss And Friction As Well As Corrosion Resistance Of The Hamcs Increases With Increasing Of Wt% Of Gr And Scba Up To Certain Limit, After Which It Begins To Decrease. The Wear Loss And Coefficient Of Friction Of The As4 Hamc Sample Were Improved By 54.89 ?�? 60.27% And 50.1 ?�? 55.1%, Respectively. The As4 Hamc Sample Also Shows99.691% Of Corrosion Inhibition Efficiency (Ie%) And Sem Results Also Confirm That The Morphology Of As4 Hamc Sample Was Not Corroded By The Nacl Solution, Which Is Due To The Uniform Distribution Of Hybrid Reinforcements With In The Al Matrix. The Confirmation Test Results Revealed That The Optimal Hamc Sample Surpasses All 16 Experimental Tests In All Physicomechanical Properties, Indicating That The Tgra Method Is A Promising Technique For Developing Hybrid Reinforced Hamcs Via Pm Processing. The Newly Synthesized Tetra Hybrid Reinforced Hamcs Showed Superior Physicomechanical, Tribological, And Corrosion Properties As Compared To Pure Al, And Single And Double Reinforced Hamcs. As A Result, The New Tetra Hybrid Reinforced Hamc Material Is Predicted To Have Potential Applications In Automotive, Aerospace, Defense, And Various Other Structural Applications.