Development and Characterization of Fe-NiTi-Cr Reinforced Metal Matrix Composites Made by Powder Metallurgy

Abstract

In the modern developed world, new materials are being discovered at a rapid rate. The main issues with employing iron are its short lifespan, low strength-to-weight ratio, poor corrosion resistance, and increased density. The goal of this thesis study was to create high-hardness, and corrosion-resistant Fe- metal matrix composite materials for use in industrial and automotive applications. The composite was created using powder metallurgy with additions of different weight percentages of base metal iron (81 wt%), Nitinol (5, 7.5, 10) wt%, Chromium (10, 7.5, 5) wt%, and 4 wt% MoS2 smart reinforcing particulates at the same milling time (2 hours), compaction pressure (60 MPa), and sintering temperature (1100°C). After proper fabrication of samples, phases analyzed by XRD, distribution and microstructure morphology by (OM, SEM), the physio mechanical properties (density, porosity, Vickers hardness and compression), and corrosion behavior sintered samples were characterized, and analyzed. The XRD results showed that the (Fe-Cr) and (Fe-Ni) (kamacite) phases were exhibited and due to small reinforcing particle addition, the smaller peaks not identified. From OM micrographs the grain distribution was analyzed and SEM showed particles distributed finely in base matrix. (Fe-5%NiTi-10%Cr 4%MoS2) shows minimum pores (4.37%), high relative densities (95.6%), uniform microstructure, higher Vickers hardness (465HV) with 86% improvement, compressive strength (636MPa), with (76%) corrosion protection efficiency with minimum corrosion rate was investigated. Increment of both reinforcement (NiTi and Cr) up to 10 wt.% shows there were an improvement in all sectors, yet the mechanical characteristics and corrosion behavior of iron metal matrix composites are significantly improved by the addition of chromium. The addition of promising particles increases the manufactured Iron Metal Matrix Composite (IMMC) hardness and corrosion resistance compared to base metal pure iron. The new reinforced IMMC material is thus expected to have potential uses in the automobile industry, as well as a variety of other structural applications.In The Modern Developed World, New Materials Are Being Discovered At A Rapid Rate. The Main Issues With Employing Iron Are Its Short Lifespan, Low Strength-To-Weight Ratio, Poor Corrosion Resistance, And Increased Density. The Goal Of This Thesis Study Was To Create High-Hardness, And Corrosion-Resistant Fe- Metal Matrix Composite Materials For Use In Industrial And Automotive Applications. The Composite Was Created Using Powder Metallurgy With Additions Of Different Weight Percentages Of Base Metal Iron (81 Wt%), Nitinol (5, 7.5, 10) Wt%, Chromium (10, 7.5, 5) Wt%, And 4 Wt% Mos2 Smart Reinforcing Particulates At The Same Milling Time (2 Hours), Compaction Pressure (60 Mpa), And Sintering Temperature (1100??C). After Proper Fabrication Of Samples, Phases Analyzed By Xrd, Distribution And Microstructure Morphology By (Om, Sem), The Physio Mechanical Properties (Density, Porosity, Vickers Hardness And Compression), And Corrosion Behavior Sintered Samples Were Characterized, And Analyzed. The Xrd Results Showed That The (Fe-Cr) And (Fe-Ni) (Kamacite) Phases Were Exhibited And Due To Small Reinforcing Particle Addition, The Smaller Peaks Not Identified. From Om Micrographs The Grain Distribution Was Analyzed And Sem Showed Particles Distributed Finely In Base Matrix. (Fe-5%Niti-10%Cr 4%Mos2) Shows Minimum Pores (4.37%), High Relative Densities (95.6%), Uniform Microstructure, Higher Vickers Hardness (465hv) With 86% Improvement, Compressive Strength (636mpa), With (76%) Corrosion Protection Efficiency With Minimum Corrosion Rate Was Investigated. Increment Of Both Reinforcement (Niti And Cr) Up To 10 Wt.% Shows There Were An Improvement In All Sectors, Yet The Mechanical Characteristics And Corrosion Behavior Of Iron Metal Matrix Composites Are Significantly Improved By The Addition Of Chromium. The Addition Of Promising Particles Increases The Manufactured Iron Metal Matrix Composite (Immc)Hardness And Corrosion Resistance Compared To Base Metal Pure Iron. The New Reinforced Immc Material Is Thus Expected To Have Potential Uses In The Automobile Industry, As Well As A Variety Of Other Structural Applications.