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El-Sayed Seleman MM, Ataya S, Ahmed MMZ, Hassan AMM, Latief FH, Hajlaoui K, El-Nikhaily AE, Habba MIA. The Additive Manufacturing of Aluminum Matrix Nano Al2O3 Composites Produced via Friction Stir Deposition Using Different Initial Material Conditions. MATERIALS 2022; 15:ma15082926. [PMID: 35454620 PMCID: PMC9029182 DOI: 10.3390/ma15082926] [Citation(s) in RCA: 9] [Impact Index Per Article: 4.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 03/17/2022] [Revised: 04/07/2022] [Accepted: 04/14/2022] [Indexed: 01/31/2023]
Abstract
The current work investigates the viability of utilizing a friction stir deposition (FSD) technique to fabricate continuous multilayer high-performance, metal-based nanoceramic composites. For this purpose, AA2011/nano Al2O3 composites were successfully produced using AA2011 as a matrix in two temper conditions (i.e., AA2011-T6 and AA2011-O). The deposition of matrices without nano Al2O3 addition was also friction stir deposited for comparison purposes. The deposition process parameters were an 800 rpm rod rotation speed and a 5 mm/min feed rate. Relative density and mechanical properties (i.e., hardness, compressive strength, and wear resistance) were evaluated on the base materials, deposited matrices, and produced composites. The microstructural features of the base materials and the friction stir deposited materials were investigated using an optical microscope (OM) and a scanning electron microscope (SEM) equipped with an EDS analysis system. The worn surface was also examined using SEM. The suggested technique with the applied parameters succeeded in producing defect-free deposited continuous multilayer AA2011-T6/nano Al2O3 and AA2011-O/nano Al2O3 composites, revealing well-bonded layers, grain refined microstructures, and homogeneously distributed Al2O3 particles. The deposited composites showed higher hardness, compressive strengths, and wear resistance than the deposited AA2011 matrices at the two temper conditions. Using the AA2011-T6 temper condition as a matrix, the produced composite showed the highest wear resistance among all the deposited and base materials.
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Affiliation(s)
- Mohamed M. El-Sayed Seleman
- Department of Metallurgical and Materials Engineering, Faculty of Petroleum and Mining Engineering, Suez University, Suez 43512, Egypt;
| | - Sabbah Ataya
- Department of Mechanical Engineering, College of Engineering, Imam Mohammad Ibn Saud Islamic University, Riyadh 11432, Saudi Arabia; (S.A.); (F.H.L.); (K.H.)
| | - Mohamed M. Z. Ahmed
- Mechanical Engineering Department, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Al Kharj 16273, Saudi Arabia
- Correspondence: ; Tel.: +966-115-888-273
| | - Ahmed M. M. Hassan
- Mechanical Department, Faculty of Technology and Education, Suez University, Suez 43518, Egypt; (A.M.M.H.); (A.E.E.-N.); (M.I.A.H.)
| | - Fahamsyah H. Latief
- Department of Mechanical Engineering, College of Engineering, Imam Mohammad Ibn Saud Islamic University, Riyadh 11432, Saudi Arabia; (S.A.); (F.H.L.); (K.H.)
| | - Khalil Hajlaoui
- Department of Mechanical Engineering, College of Engineering, Imam Mohammad Ibn Saud Islamic University, Riyadh 11432, Saudi Arabia; (S.A.); (F.H.L.); (K.H.)
| | - Ahmed E. El-Nikhaily
- Mechanical Department, Faculty of Technology and Education, Suez University, Suez 43518, Egypt; (A.M.M.H.); (A.E.E.-N.); (M.I.A.H.)
| | - Mohamed I. A. Habba
- Mechanical Department, Faculty of Technology and Education, Suez University, Suez 43518, Egypt; (A.M.M.H.); (A.E.E.-N.); (M.I.A.H.)
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An Approach for Material Model Identification of a Composite Coating Using Micro-Indentation and Multi-Scale Simulations. COATINGS 2022. [DOI: 10.3390/coatings12010092] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/16/2022]
Abstract
While deposited thin film coatings can help enhance surface characteristics such as hardness and friction, their effective incorporation in product design is restricted by the limited understanding of their mechanical behavior. To address this, an approach combining micro-indentation and meso/micro-scale simulations was proposed. In this approach, micro-indentation testing was conducted on both the coating and the substrate. A meso-scale uniaxial compression finite element model was developed to obtain a material model of the coating. This material model was incorporated within an axisymmetric micro-scale model of the coating to simulate the indentation. The proposed approach was applied to a Ti/SiC metal matrix nanocomposite (MMNC) coating, with a 5% weight of SiC nanoparticles deposited over a Ti-6Al-4V substrate using selective laser melting (SLM). Micro-indentation testing was conducted on both the Ti/SiC MMNC coating and the Ti-6Al-4V substrate. The results of the meso-scale finite element indicated that the MMNC coating can be represented using a bi-linear elastic-plastic material model, which was incorporated within an axisymmetric micro-scale model. Comparison of the experimental and micro-scale model results indicated that the proposed approach was effective in capturing the post-indentation behavior of the Ti/SiC MMNC coating. This methodology can also be used for studying the response of composite coatings with different percentages of reinforcements.
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