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Journal of Polymer & Composites Original Research Special issue

Mechanical & Tribological Characterization of Al2024-Alumina-Graphite Reinforced Monolithic and Hybrid Composites

  1. M. Yashwanth Kumar Department of Mechanical Engineering, Koneru Lakshmaiah Education Foundation, Green Fields, Vaddeswaram, Guntur
  2. T. Vijayakumar Department of Mechanical Engineering, Koneru Lakshmaiah Education Foundation, Green Fields, Vaddeswaram, Guntur
  3. R. Dhanasekaran Department of Mechanical Engineering, Adhiyamaan College of Engineering, Hosur

Abstract

This work investigates the mechanical characteristics of Al2024-Al2O3-Graphite reinforced monolithic and hybrid composites fabricated by the stir casting method. Exploratory work involved the fabrication of monolithic composites with varying Al2O3 contents (5-8 wt%) and hybrid composites with the ratios of Al2O3 (2-6 wt%) and Graphite (1-3 wt%) in matrix Al2024. For improving their dispersion, preheated reinforcement particles were introduced in matrix alloy at controlled stirring rates. A homogeneous particle distribution with a clustering coefficient below 0.15 and an appropriate mean inter-particle spacing of 12.5 ± 2.3 μm was validated by quantitative microstructural analysis using image analysis software. Mechanical tests were done on the produced composites in order to analyse their mechanical and tribological characteristics. The development of graphite tribofilms during sliding wear was validated by post-wear surface characterization using SEM-EDS mapping and Raman spectroscopy. The results demonstrate that hybrid composites have enhanced mechanical and tribological properties relative to both the reference Al2024 alloy and monolithic composites. Surprisingly Hardness of hybrid composites, Sample 3 (Al2024 + 2% Al2O3+ 1% Graphite) and Sample 4 (Al2024 + 6% Al2O3 + 3% Graphite) were highly improved with samples showing 28% and 35% improvements in hardness, respectively, over the reference alloy. Besides, hybrid composite wear resistances were better than those of monolithic composites, which testified to the synergistic reinforcement effect of Al2O3 and Graphite. Comparative study with recent literature demonstrates that the current hybrid composites achieve greater performance compared to Al₂O₃-graphene (48% hardness increase vs. our 35%) and Al₂O₃-B₄C systems reported in high-impact journals. Yet, attempts at incorporating increased reinforcement levels (Al2O3 9% and Graphite 5%) failed because of agglomeration problems. The findings imply that hybrid composites provide an affordable option with improved mechanical properties and more effective alternative to monolithic composites reinforced by Al2O3 alone

Keywords

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