Investigation of Mechanical Properties of Al-B4C-Ti64-MoS2 Composite Developed Through Powder Metallurgy Technique and Optimization of Process Parameter

Abstract

The demand for lightweight materials with superior mechanical and tribological properties has been increasing in the automotive, aerospace, and marine industries. Aluminum is the most popular lightweight material, but lower strength when compared to other structural materials like titanium and steel. This thesis study focused on the fabrication of the aluminum hybrid metal matrix composite (AHMMC) reinforced with boron carbide (2, 4, 6 wt.%), titanium grade 5 (1, 3, 5 wt.%), and molybdenum disulfide (4 wt.%) using the powder metallurgy method and testing its mechanical properties. Characterization of microstructure of the sample were done using Optical Microscope (OM), Scanning Electron Microscope (SEM), and X-ray diffraction (XRD). The density and porosity of the sample were determined through Archimedes’ principle. Other properties such as hardness, compressive strength, and wear resistance were analyzed as per ASTM standard. The corrosion resistance of the sample was investigated using an electrochemical analyzer. The weight percentage of reinforcements and the process parameters of powder metallurgy were optimized using Taguchi-based grey relational analysis and genetic algorithm. From the optimally fabricated sample, significant improvement of physical, mechanical, and tribological properties was obtained. The OM and SEM results showed that the reinforcement was uniformly. distributed. The XRD test confirmed the presence of different phases in the composite. The addition of B4C, Ti64, and MoS2 reinforcements to the Al matrix has improved its physical, mechanical, and tribological properties. Hence, newly developed aluminum metal matrix composite (Al/B4C/Ti64/MoS2) was expected to be used in the automotive, aerospace, and marine industries.The Demand For Lightweight Materials With Superior Mechanical And Tribological Properties Has Been Increasing In The Automotive, Aerospace, And Marine Industries. Aluminum Is The Most Popular Lightweight Material, But Lower Strength When Compared To Other Structural Materials Like Titanium And Steel. This Thesis Study Focused On The Fabrication Of The Aluminum Hybrid Metal Matrix Composite (Ahmmc) Reinforced With Boron Carbide (2, 4, 6 Wt.%), Titanium Grade 5 (1, 3, 5 Wt.%), And Molybdenum Disulfide (4 Wt.%) Using The Powder Metallurgy Method And Testing Its Mechanical Properties. Characterization Of Microstructure Of The Sample Were Done Using Optical Microscope (Om), Scanning Electron Microscope (Sem), And X-Ray Diffraction (Xrd). The Density And Porosity Of The Sample Were Determined Through Archimedes?�? Principle. Other Properties Such As Hardness, Compressive Strength, And Wear Resistance Were Analyzed As Per Astm Standard. The Corrosion Resistance Of The Sample Was Investigated Using An Electrochemical Analyzer. The Weight Percentage Of Reinforcements And The Process Parameters Of Powder Metallurgy Were Optimized Using Taguchi-Based Grey Relational Analysis And Genetic Algorithm. From The Optimally Fabricated Sample, Significant Improvement Of Physical, Mechanical, And Tribological Properties Was Obtained. The Om And Sem Results Showed That The Reinforcement Was Uniformly. Distributed. The Xrd Test Confirmed The Presence Of Different Phases In The Composite. The Addition Of B4c, Ti64, And Mos2 Reinforcements To The Al Matrix Has Improved Its Physical, Mechanical, And Tribological Properties. Hence, Newly Developed Aluminum Metal Matrix Composite (Al/B4c/Ti64/Mos2) Was Expected To Be Used In The Automotive, Aerospace, And Marine Industries.