Narrow Results

The need of engineered materials with high strength to weight ratio was instrumental for the development of a novel magnesium metal–metal composite with the addition of titanium (reinforcement) and aluminum (alloying element) through disintegrated melt deposition technique. The X-ray diffraction analysis and scanning electron microscopy analysis used to explore the metallurgical insights of the developed magnesium metal–metal composite. Wear tests were carried out with pin-on-disc equipment by varying the input parameters load and sliding velocity over a sliding distance of 2000m. Wear was obtained as the output from the experiments, and the same was analyzed through Pareto analysis of variance, to identify the significant parameters. Also, a fuzzy logic-based model was developed to predict the wear behavior of the metal–metal composite. The wear mechanisms involved in the dry sliding wear behavior were analyzed through worn surface analysis and wear debris analysis.

The improved mechanical properties of AA6061 make it ideal for a wide range of industries, including aerospace, nuclear, defense, and marine. The development of empirical relationships for optimizing the parameters that influence the fabrication of AA6061/B₄C_p composite is vital for using this composite in the above applications. In this study, the composites are fabricated using FSP by reinforcing B₄C particles in AA6061 plates. In order to optimize the experimental conditions, a central composite rotatable design (CCRD) matrix with four factors and five levels was used. The response surface methodology (RSM) has been used to develop empirical relationships between process parameters such as tool rotational speed, traverse feed, tool tilt angle, penetration depth, and output factors such as yield strength, ultimate tensile strength (UTS), % of elongation, microhardness, and wear rate. Microstructural characterization of AA6061/B₄C_p composites has been done in order to examine the effect of process parameters on the composite properties. The fabricated composites showed a maximum yield strength of 135MPa, a UTS of 172MPa, % elongation of 8.1, a microhardness of 179 VHN, and a minimum wear rate of 0.001185mm³/m. Upon analyzing the wear surface and wear debris of the composites, it was found that abrasion is the predominant wear mechanism. These experiments result in increased wear resistance for nuclear, defense and aerospace parts.