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Investigation on Mechanical Behavior of LM26 Aluminum Alloy—ZrB2 and Copper-Coated Short Steel Fiber-Reinforced Composites Using Stir Casting Process

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Abstract

Currently there is a growing interest in investigating aluminum alloy-based hybrid composites due to their growing importance in the automotive and aerospace sectors. To enhance the value of this field, an attempt was made to synthesize zirconium diboride (ZrB2) and copper-coated short steel fiber-reinforced LM26 aluminum alloy hybrid composites using stir casting with varying weight percentages of ZrB2 (2.5, 5, and 10wt%) and copper-coated short steel fiber (5wt% kept constant) for applications requiring a lightweight and high strength, particularly for high-temperature applications. Matrix, fiber-reinforced composite (FRC), and hybrid composite specimens were synthesized using stir casting technique with the process parameters of 750°C for pouring temperature, 10 minutes for stirring time, 650 rpm for stirring speed, and 400°C for preheating temperature of reinforcements. With the use of a wire-cut electrical discharge machine, the specimens were prepared for various tests in accordance with ASTM standards. A complete microstructural (optical microscope and scanning electron microscope) investigation and mechanical property (hardness, tensile properties, and impact strength) evaluation were carried out according to the ASTM standard to comprehend the influence of the reinforcements, and the findings were presented. The optical microscopic images clearly showed that the ZrB2 and copper-coated short steel fiber reinforcements were uniformly distributed throughout the matrix (LM26 aluminum alloy). The Brinell hardness values increased as the reinforcements were added, reaching a maximum hardness of 152 BHN for the hybrid composite with 15wt% cumulative reinforcement, which is 35.71% higher than the matrix. Compared to matrix alloy, the composite with 15% cumulative reinforcement exhibited a maximum 38.41% improvement in ultimate tensile strength. As further reinforcement is added after 10wt%, yield strength declines to 6.36%, and for the composite with 15wt% of reinforcement, elongation gradually drops to 33.7% as compared to the matrix. The energy absorption of reinforced composites with 5wt% and 15wt% shows a similar percentage decrease of 42.86%, when compared to the matrix. However, a notable decline in ductility was identified for the composites because of the addition of strong reinforcements, while the LM26 alloy retained its ductility. Further, hybrid composites showed poor resistance to impact load due to the incorporation of hybrid reinforcements, and respective fractography showed brittle fracture. The results make it quite evident that the hybrid composites of copper-coated short steel fiber and ZrB2-reinforced LM26 aluminum alloy have outstanding mechanical properties, making them a good choice for use in the automobile industry as a newer material.

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  1. Department of Mechanical Engineering, Karpagam Institute of Technology, Coimbatore, Tamil Nadu, 641 105, India

    S. N. Vijayan & A. Saiyathibrahim

  2. Department of Mechanical Engineering, Sri Krishna College of Engineering and Technology, Coimbatore, Tamil Nadu, 641 008, India

    Samson Jerold Samuel Chelladurai

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Vijayan, S.N., Chelladurai, S.J.S. & Saiyathibrahim, A. Investigation on Mechanical Behavior of LM26 Aluminum Alloy—ZrB2 and Copper-Coated Short Steel Fiber-Reinforced Composites Using Stir Casting Process. Inter Metalcast (2024). https://doi.org/10.1007/s40962-024-01303-x

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