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Comparison of theoretical and experimental physio-mechanical properties of coal-fly ash (CFA) reinforced iron matrix composites

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Abstract

In this work, the effect of coal-fly ash (CFA) reinforcements on the physio-mechanical properties of iron metal matrix composites (IMMCs) are predicted and compared with the experimental results. The IMMCs were synthesized by reinforcing different amounts (0, 0.15, 0.28 and 0.38 vol. %) of CFA particulates to the iron matrix through powder metallurgy technique (P/M). The iron powder/CFA mixtures were compacted at a load of 10 ton followed by sintering in inert environment at 1150 ℃ for 90 min. Structural, morphological, and elemental characterisation of iron/CFA and IMMCs were performed using X-ray diffraction (XRD), field emission scanning electron microscopy (FESEM) and Energy Dispersive X-Ray spectroscopy (EDS) respectively. Sufficient diffusion among the iron particles, uniform distribution of CFA particulates and clear interfaces between matrix and reinforcements have been observed in the FESEM micrographs. The trends of experimental results of sintered density and microhardness of the IMMCs has been found in line with the theoretical results predicted using rule of mixtures (ROM). Furthermore, the effects of increased vol.% of CFA inclusions on the elastic modulus \((E)\), yield strength \(({\sigma }_{y}\)) and ultimate tensile strength \({(\sigma }_{u})\) of the IMMCs have been conceived using Ramberg–Osgood (RO) model, under tensile loading. A significant reduction of 32% in sintered density and 42% increment in microhardness of the IMMCs have been observed. The RO model demonstrated significant enhancements of 51% in \(E\) and 42% in \({\sigma }_{y}\). On the other hand, whereas 44% reduction in ultimate tensile strength of IMMCs has been observed on increased amount of CFA (0–0.38 vol.%). The load transfer strengthening mechanism has been found dominating the Hall–Petch followed by Taylor’s strengthening mechanism. Further, the various specific properties of the IMMCs were compared with prevalent literature. The specific properties of IMMCs such as microhardness, \(E\), \({\sigma }_{y}\) and \({\sigma }_{u}\) are found comparable with the established aluminium based MMCs.

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Abbreviations

CFA:

Coal-fly ash

MMC:

Metal matrix composite

FMMC:

Ferrous metal matrix composite

NFMMC:

Non-ferrous metal matrix composite

IMMC:

Iron metal matrix composite

RSM:

Response surface methodology

P/M:

Powder metallurgy

ROM:

Rule of mixtures

RO:

Ramberg–Osgood

Wt. %:

Weight percentage

Vol. %:

Volume percentage

Hv:

Vickers’s microhardness

\(\rho_{c}\) :

Density of composite

\(\sigma\) :

Stress

E :

Young’s modulus

σ y :

Yield strength

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Authors and Affiliations

  1. Peter the Great St. Petersburg Polytechnic University, Saint Petersburg, Russia, 195251

    Saurav Dixit & Nikolai Ivonovich Vatin

  2. Division of Research & Innovation, Uttaranchal University, Uttarakhand, 248007, Dehradun, India

    Saurav Dixit

  3. Department of Material Science and Engineering, National Institute of Technology Hamirpur, Hamirpur, 177005, India

    Amarjit Singh & Ravi Kumar

  4. Department of Mechanical Engineering, KR Mangalam University Gurugram, Gurugram, 122103, India

    Jarnail Singh & Kaushal Kumar

  5. Moscow City University of Management, Moscow, Russia

    Tatyana Miroshnikova

  6. Saint-Petersburg University of Aerospace Instrumentation, Saint-Petersburg, Russia, 190000

    Kirill Epifantsev

  7. Department of Mechanical Engineering, National Institute of Technology Hamirpur, Hamirpur, 177005, India

    Manoj Kumar Sinha

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Dixit, S., Singh, A., Singh, J. et al. Comparison of theoretical and experimental physio-mechanical properties of coal-fly ash (CFA) reinforced iron matrix composites. Int J Interact Des Manuf 17, 2429–2444 (2023). https://doi.org/10.1007/s12008-022-01022-9

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