Skip to main content
SpringerLink
Log in

Evaluation of Fracture Mechanisms in Al-Si Metal Matrix Nanocomposites Produced by Three Methods of Gravity Sand Casting, Squeeze Casting and Compo Casting in Semi-Solid State

  • Original Paper
  • Published:
Silicon Aims and scope Submit manuscript

Abstract

Magnetic stirring is considered to be the most useful stirring method in semi-solid casting processes which doesn’t have the restrictions of the mechanical stirring. In this research, fracture mechanisms of aluminum-Al2O3 nanocomposites produced by three methods of gravity sand casting, squeeze casting and compo casting in semi-solid state using electromagnetic stirring were studied and discussed. For this purpose, microstructure and fracture surfaces obtained from broken tensile test samples were analyzed using optical and scanning electron microscopies. On the fracture surfaces of all the samples, dimples were observed, which are the sign of ductile fracture. It was revealed that the dimples on the samples produced by the compo casting method are smaller, more spherical and uniformly distributed in the metal matrix in comparison with the ones from sand and squeeze casting. It also investigated that on the fracture surfaces of compo casting samples less cleavage planes, dendritic fracture and particles agglomeration were observed in comparison with the ones from the sand and squeeze casting processes.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Mazahery A, Shabani MO (2014) Experimental investigation on the aging response, hardness and total impact energy absorption of Sr-modified heat-treatable cast automotive aluminum alloys. Trans Indian Inst Metals 67(5):753–759

    CAS  Google Scholar 

  2. Shabani M, Alizadeh M, Mazahery A (2011) Modelling of mechanical properties of cast A356 alloy. Fatigue Fract Eng Mater Struct 34(12):1035–1040

    CAS  Google Scholar 

  3. Rahimipour M et al (2014) The enhancement of wear properties of compo-cast A356 composites reinforced with Al 2 O 3 nano particulates. Tribol Ind 36(2)

  4. Dezecot S et al (2017) 3D characterization and modeling of low cycle fatigue damage mechanisms at high temperature in a cast aluminum alloy. Acta Mater 123:24–34

    CAS  Google Scholar 

  5. Bahmani A et al (2013) A mathematical model for prediction of microporosity in aluminum alloy A356. Int J Adv Manuf Technol:1–9

  6. Mazahery A et al (2012) Hardness and tensile strength study on Al356–B4C composites. Mater Sci Technol 28(5):634–638

    CAS  Google Scholar 

  7. Shabani M et al (2012) Silicon morphology modelling during solidification process of A356 Al alloy. Int J Cast Metal Res 25(1):53–58

    CAS  Google Scholar 

  8. Baghani A et al (2015) Application of computational fluid dynamics to study the effects of Sprue Base geometry on the surface and internal turbulence in gravity casting. Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications 229(2):106–116

  9. Kheirabi A et al (2015) Understanding the occurrence of the surface turbulence in a nonpressurized bottom gating system: Numerical simulation of the melt flow pattern. Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications 1464420715621930

  10. Zhao ZY et al (2016) Effects of Activation Treatment on Interfacial Bonding in A356-10 wt% B4C Composite Sheets Prepared by Rheo-Rolling. In Proceedings of the 5th International Conference on Electrical Engineering and Automatic Control. Springer

  11. Mazahery A, Alizadeh M, Shabani M (2012) Wear of Al–Si alloys matrix reinforced with sol–gel coated particles. Mater Technol 27(2):180–185

    CAS  Google Scholar 

  12. Shabani M et al (2012) The most accurate ANN learning algorithm for FEM prediction of mechanical performance of alloy A356. Kov Mater 50:25–31

    Google Scholar 

  13. Baghani A et al (2013) Numerical investigation of the effect of sprue base design on the flow pattern of aluminum gravity casting. In Defect and Diffusion Forum. Trans Tech Publications

  14. Kumar SM, Pramod R, Govindaraju H (2017) Evaluation of mechanical and wear properties of aluminium AA430 reinforced with SiC and Mgo. Mater Today-Proc 4(2):509–518

  15. Shabani MO, Mazahery A (2014) Automotive copper and magnesium containing cast aluminium alloys: report on the correlation between yttrium modified microstructure and mechanical properties. Russ J Non-Ferr Metals 55(5):436–442

  16. Tofigh AA et al (2013) Optimized processing power and trainability of neural network in numerical modeling of Al matrix nano composites. J Manuf Process 15(4):518–523

    Google Scholar 

  17. Ramnath BV et al (2014) Evaluation of mechanical properties of aluminium alloy–alumina–boron carbide metal matrix composites. Mater Des 58:332–338

    Google Scholar 

  18. Efzan E et al (2016) Fabrication method of aluminum matrix composite (AMCs): a review. In Key engineering materials. Trans Tech Publ

  19. Shabani MO, Heydari F (2018) Influence of solutionising temperature and time on spherodisation of the silicon particles of AMNCs. Int J Mater Prod Technol 57(4):336–349

    Google Scholar 

  20. Mazahery A, Shabani MO (2012) The enhancement of wear properties of squeeze-cast A356 composites reinforced with B4C particulates. Int J Mater Res 103(7):847–852

    CAS  Google Scholar 

  21. Sree Manu KM et al (2016) Liquid metal infiltration processing of metallic composites: a critical review. Metall Mater Trans B 47(5):2799–2819

    CAS  Google Scholar 

  22. Mazahery A, Shabani MO (2013) Application of the extrusion to increase the binding between the ceramic particles and the metal matrix: enhancement of mechanical and tribological properties. J Mater Sci Technol 29(5):423–428

    CAS  Google Scholar 

  23. Mazahery A, Shabani MO (2013) Existence of good bonding between coated B4C reinforcement and al matrix via semisolid techniques: enhancement of wear resistance and mechanical properties. Tribol Trans 56(3):342–348

    CAS  Google Scholar 

  24. Shabani MO, Mazahery A (2013) Good bonding between coated B4C particles and aluminum matrix fabricated by semisolid techniques. Russian Journal of Non-Ferrous Metals 54(2):154–160

    Google Scholar 

  25. Katz-Demyanetz A et al (2017) Manufacturing of Aluminum Metal Matrix Cast Composites with Carbon Based Additives for Thermal Management Applications. In Materials Science Forum. Trans Tech Publ

  26. Mazahery A, Shabani MO (2014) Extruded AA6061 alloy matrix composites: the performance of multi-strategies to extend the searching area of the optimization algorithm. J Compos Mater 48(16):1927–1937

    Google Scholar 

  27. Shabani MO et al (2016) Superior tribological properties of particulate aluminum matrix Nano composites. Prot Metals Phys Chem Surf 52(2):244–248

    CAS  Google Scholar 

  28. Kumar UKAV (2017) Method of stir casting of aluminum metal matrix composites: a review. Mater Today-Proc 4(2):1140–1146

  29. Mazahery A, Shabani M (2012) Mechanical properties of A356 matrix composites reinforced with nano-SiC particles. Strength Mater 44(6):686–692

    CAS  Google Scholar 

  30. Shabani MO, Mazahery A (2013) Optimization of Al matrix reinforced with B4C particles. JOM 65(2):272–277

    CAS  Google Scholar 

  31. Shamsipour M et al (2016) Optimization of the EMS process parameters in compocasting of high-wear-resistant Al-nano-TiC composites. Appl Phys A 122(4):1–14

    CAS  Google Scholar 

  32. Ficici F, Koksal S (2016) Microstructural characterization and wear properties of in situ AlB2–reinforced Al–4Cu metal matrix composite. J Compos Mater 50(12):1685–1696

    CAS  Google Scholar 

  33. Mazahery A, Shabani MO (2014) The effect of primary and secondary processing on the abrasive wear properties of compocast aluminum 6061 alloy matrix composites. Prot Metals Phys Chem Surf 50(6):817–824

    CAS  Google Scholar 

  34. Shabani MO, Heydari F (2019) The enhancement of wear properties of compo-cast A356 composites reinforced with SiC nano particulates. Prot Metals Phys Chem Surf 55(4):748–752

    CAS  Google Scholar 

  35. Chen Q et al (2016) Microstructure evolution of SiC p/ZM6 (Mg–Nd–Zn) magnesium matrix composite in the semi-solid state. J Alloys Compd 656:67–76

    CAS  Google Scholar 

  36. Shabani MO, Mazahery A (2013) Computational modeling of cast aluminum 2024 alloy matrix composites: adapting the classical algorithms for optimal results in finding multiple optima. Powder Technol 249:77–81

    CAS  Google Scholar 

  37. Wang K et al (2016) A novel method to achieve grain refinement in aluminum. Metall Mater Trans A 47(10):4788–4794

    CAS  Google Scholar 

  38. Shabani MO et al (2016) Wear wear properties of rheo-squeeze cast aluminum matrix reinforced with nano particulates. Prot Metals Phys Chem Surf 52(3):486–491

    CAS  Google Scholar 

  39. Murthy N et al (2016) Preparation of SiC based Aluminium metal matrix nano composites by high intensity ultrasonic cavitation process and evaluation of mechanical and tribological properties. In IOP Conference Series: Materials Science and Engineering. IOP Publishing

  40. Mazahery A, Shabani MO (2015) The performance of pressure assisted casting process to improve the mechanical properties of Al-Si-Mg alloys matrix reinforced with coated B4C particles. Int J Adv Manuf Technol 76(1–4):263–270

    Google Scholar 

  41. Shabani MO, Mazahery A (2013) Suppression of segregation, settling and agglomeration in mechanically processed composites fabricated by a semisolid agitation processes. Trans Indian Inst Metals 66(1):65–70

    CAS  Google Scholar 

  42. Jayashree P et al (2013) Review on effect of silicon carbide (SiC) on stir cast aluminium metal matrix composites. Int J Curr Eng Technol 3(3):1061–1071

    Google Scholar 

  43. Shabani MO et al (2018) Performance of ANFIS coupled with PSO in manufacturing superior wear resistant aluminum matrix nano composites. Trans Indian Inst Metals 71(9):2095–2103

    CAS  Google Scholar 

  44. Jiang L et al (2016) Toughening of aluminum matrix nanocomposites via spatial arrays of boron carbide spherical nanoparticles. Acta Mater 103:128–140

    CAS  Google Scholar 

  45. Tofigh AA, Shabani MO (2013) Efficient optimum solution for high strength Al alloys matrix composites. Ceram Int 39(7):7483–7490

    CAS  Google Scholar 

  46. Rahimipour MR et al (2014) Strategic developments to improve the optimization performance with efficient optimum solution and produce high wear resistance aluminum–copper alloy matrix composites. Neural Comput & Applic 24(7–8):1531–1538

    Google Scholar 

  47. Mazahery A, Shabani M (2012) Sol–gel coated B4C particles reinforced 2024 Al matrix composites. Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications 226(2):159–169

    CAS  Google Scholar 

  48. Shamsipour M et al (2017) Squeeze casting of electromagnetically stirred aluminum matrix nanocomposites in semi-solid condition using hybrid algorithm optimized parameters. Kovove Mater 55(1):33–43

  49. Mazahery A, Shabani MO (2013) Elaboration of an operative and efficacious optimization route to ameliorate the mechanical and tribological properties of implants. Powder Technol 249:530–535

    CAS  Google Scholar 

  50. Srivastava MC, Lohne O (2016) Effects of heat treatment on the microstructure and mechanical properties of ductile AlSi9MgMn die castings. Int J Met 10(4):556–565

    CAS  Google Scholar 

  51. Mazahery A et al (2013) Concurrent fitness evaluations in searching for the optimal process conditions of Al matrix nanocomposites by linearly decreasing weight. J Compos Mater 47(14):1765–1772

    CAS  Google Scholar 

  52. Kumar SD et al (2017) Erosion response of Thixoformed A356-5TiB2 in situ composite using Taguchi's experimental design. Tribol Trans 60(1):39–46

    CAS  Google Scholar 

  53. Shabani MO, Heydari F, Khorram A (2018) The effect of electromagnetic stirrer on the size and morphology of intermetallic particles in Al-Si metal matrix composite. Silicon:1–8

  54. Mazahery A, Shabani MO, Elrefaei A (2014) Searching for the superior solution to the population-based optimization problem: processing of the wear resistant commercial AA6061 AMCs. Int J Damage Mech 23(7):899–916

    Google Scholar 

  55. Yang X et al (2016) High shear dispersion technology prior to twin roll casting for high performance magnesium/SiC p metal matrix composite strip fabrication. Compos A: Appl Sci Manuf 90:349–358

    CAS  Google Scholar 

  56. Mazahery A, Shabani MO (2013) Development of the principle of simulated natural evolution in searching for a more superior solution: proper selection of processing parameters in AMCs. Powder Technol 245:146–155

    CAS  Google Scholar 

  57. Kim H, Babu J, Kang C (2014) Hot extrusion of A356 aluminum metal matrix composite with carbon nanotube/Al2O3 hybrid reinforcement. Metall Mater Trans A 45(5):2636–2645

    CAS  Google Scholar 

  58. Tofigh AA et al (2015) Application of the combined neuro-computing, fuzzy logic and swarm intelligence for optimization of compocast nanocomposites. J Compos Mater 49(13):1653–1663

    CAS  Google Scholar 

  59. Shabani MO et al (2015) Refined microstructure of compo cast nanocomposites: the performance of combined neuro-computing, fuzzy logic and particle swarm techniques. Neural Comput & Applic 26(4):899–909

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Materials and Energy Research Center (MERC), Tehran, Iran

    Mohsen Ostad Shabani

  2. Amirkabir University of Technology, Tehran, Iran

    Mohsen Ostad Shabani

  3. Department of mechanical engineering, University of Iowa, Iowa City, IA, USA

    Amir Baghani

  4. K.N.Toosi University of Technology, Tehran, Iran

    Ali Khorram

  5. Iran University of Industries and Mines (IUIM), Tehran, Iran

    Fatemeh Heydari

Authors
  1. Mohsen Ostad Shabani
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Amir Baghani
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Ali Khorram
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Fatemeh Heydari
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Mohsen Ostad Shabani.

Additional information

Publisher’s Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Shabani, M.O., Baghani, A., Khorram, A. et al. Evaluation of Fracture Mechanisms in Al-Si Metal Matrix Nanocomposites Produced by Three Methods of Gravity Sand Casting, Squeeze Casting and Compo Casting in Semi-Solid State. Silicon 12, 2977–2987 (2020). https://doi.org/10.1007/s12633-020-00390-9

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12633-020-00390-9

Keywords

Search

Navigation