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The Effect of Electroless Ni–P-Coated Al2O3 on Mechanical and Tribological Properties of Scrap Al Alloy MMCs

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Abstract

In this research work, fabrication of Al alloy metal matrix composites (MMCs) reinforced with electroless Ni-P-coated Al2O3 is carried out using the stir-squeeze casting method. Scrap Al alloy wheels as matrix materials and Al2O3 particles as reinforcements are used to develop the MMCs. The Ni-P coating on Al2O3 particles is carried out using an electroless process to improve mechanical and tribological properties by increasing the bonding strength between the ceramic particles and the matrix material. A pre-treatment process on Al2O3 particles is done before the electroless Ni-P coating. To analyse the properties, the composites are fabricated in three different variations, i.e. as-cast scrap Al alloy, scrap Al alloy with uncoated Al2O3 (5 wt%), and scrap Al alloy with coated Al2O3 (5 wt%). Metallurgical properties are analysed using an optical microscope (OM), scanning electron microscope (SEM), energy-dispersive X-ray analysis (EDAX), and X-ray diffraction (XRD). The test results show that the porosity is reduced by 15.45% in a composite reinforced with coated Al2O3 compared to the as-cast scrap Al alloy. Also, the mechanical properties such as hardness, tensile strength, and impact strength are improved significantly by 15.2, 23, and 31.25%, respectively. Reduction of 31.47% in specific wear rate and 7.34% in coefficient of friction are achieved in the composite reinforced with coated Al2O3 particles compared to the as-cast scrap Al alloy. The compressive strength is decreased significantly with the addition of uncoated Al2O3 particles. After the addition of coated Al2O3, the compressive strength of the composite is increased compared with the uncoated Al2O3-reinforced composite.

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The corresponding author [Dega Nagaraju] can provide the data and materials that support the findings of this study.

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  1. School of Mechanical Engineering (SMEC), Vellore Institute of Technology (VIT), Vellore, Tamil Nadu, 632014, India

    P. Chandrasekar & Dega Nagaraju

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[P. Chandrasekar] carried out experiments on material characterization. [Dr. Dega Nagaraju] was in charge of the results analysis, which included SEM, EDAX, and XRD. [Dr. Dega Nagaraju] and [P. Chandrasekar] worked for the plotting of all of the graphs in the paper. [Dr. Dega Nagaraju] and [P. Chandrasekar] worked together for the samples preparation for experiments as well as manuscript preparation.

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Chandrasekar, P., Nagaraju, D. The Effect of Electroless Ni–P-Coated Al2O3 on Mechanical and Tribological Properties of Scrap Al Alloy MMCs. Inter Metalcast 17, 356–372 (2023). https://doi.org/10.1007/s40962-022-00779-9

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