Energy-efficient method for developing in-situ Al-Cu metal matrix composites using microwave sintering and friction stir processing

Abstract

The problems associated with the fabrication of in situ metal matrix composites (MMC) by conventional methods can be avoided by using microwave sintering and friction stirring in combination. The current study investigates the mechanical and electrical properties of pure aluminum (Al-100 wt%) and Al-Cu MMC. The results showed that excellent ultimate tensile strength, toughness, and electrical conductivity can be acquired simultaneously. The obtained ultimate tensile strength in the case of Al-100wt% (184.5 MPa) has improved two-fold than that of a typical commercially pure aluminum AA1016 (90 MPa). Similarly, the electrical conductivity of developed pure aluminum (88.87% IACS) is 1.4 times higher compared to AA1016 alloy (62% IACS). For Al-Cu MMC the copper is added in steps of 5 wt% (5%, 10%, 15%, and 20%). The maximum ultimate tensile strength (205.2 MPa) and the electrical conductivity (71.53% IACS) obtained for Al-10wt%Cu are higher compared to the AA1016 alloy. The present investigation suggests a novel processing route and opens up new research avenues in the field of solid-state materials processing.

Keywords

• Al-Cu
• electrical conductivity
• frictions stir processing
• metal matrix composites
• microwave sintering