Simulation and Experimental Studies of Al Matrix Composites  Reinforced with Nano Ceria Ceramics

doi:10.21203/rs.3.rs-3086495/v1

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Simulation and Experimental Studies of Al Matrix Composites Reinforced with Nano Ceria Ceramics

https://doi.org/10.21203/rs.3.rs-3086495/v1

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Aluminum is a widely used material in the aerospace and automotive sector, and several studies have been conducted to improve the mechanical performance of aluminum during the casting process. In the present study, a novel approach is used to improve the mechanical properties of aluminum. During which the ceria ceramic was mixed with aluminum during the stir-casting process. Further, Vickers Micro Hardness Testing was used to investigate the thermo-mechanical properties of materials, such as microstructure and hardness. Additionally, the results were simulated using FEM, and significant parameters determining various thermomechanical properties of the composite were identified. The results indicate the use of ceria ceramic improves aluminum's mechanical properties.

Materials Engineering

Cerium Oxide

Expandable Pattern

Stir Casting

UTM

Hardness Testing

Thermo Mechanical properties

A composite comprises two or more components mixed via a process or chemical reaction. The chemical and physical qualities of a composite material created from multiple components may or may not be identical to the attributes of its constituent materials. Materials created through diverse engineering procedures can be divided into the following categories: Ceramic matrix composites (composite ceramic and metal matrices) and Metal Matrix composites. Another classification is based on the method of manufacturing Nanoparticles; these are called: - top-down and bottom-up approaches. The bottom-up approach is meant by synthesizing Nanoparticles through chemical reactions among the atoms [1]. At the same time, top-down involves the mechanical methods to crush/breaking of bulk into several parts to form Nanoparticles.

In today's environment, numerous reasons exist to create or develop a new material artificially for various uses. The development of various material composites is being done to get a variety of material qualities, some of which are as follows: -

1. Materials that are light in weight

2. Increased Strength.

3. Durable.

4. Biodegradable.

Composite materials being developed to meet industry demands are very challenging for researchers. Many researchers created items that can sense, act, compute, and communicate. These composite materials are often referred to as Robotic Materials. Many researchers use composite materials in numerous structures, automobiles, space industries, and aerospace industries. The most prevalent application of composite materials is in additive manufacturing methods; the composite materials are designed to be processed. Fibers or Nanoparticles (carbon Nanotubes, AL₂O₃, or SiO₂) are spread in a metallic matrix such as Aluminum, Copper, and Steel as in material sciences. The secondary phase is a ceramic substance like alumina or silicon carbide. They are categorized based on reinforcement [2]. A hybrid composite material is made up of more than two materials. Because these blended materials have a substantially higher strength-to-weight ratio, stiffness, and flexibility than standard materials, they are frequently used in various applications. MMC have low thermal and electrical conductivity [3].

Reviewed the material properties of Al-Si-SiC composites [4]. The following composite comprises Al-Si (LM-13) alloy and ten wt. % of SiC particles reinforced in cast along with T6 temperature conditions at ambient temperature. The material undergoes inverse loading with a maximum stress amplitude of up to 50,000 cycles. Due to more vital cohesive forces with the aluminum matrix, it was found that it withstood the application of cyclic stress that would have caused fatigue crack formation when scanned with an electron microscope. Studied single-phase Co/Ni substituted with Cerium Oxide Nanoparticles and conclude that the Lattice structure shrinks and strain increases due to incorporating Co/Ni substitution in Cerium Oxide [5]. Ce1-xNixO2 Nano powders made by [6] of Ce1-xNixO2 (0 x 0.1) were examined.

The imperfections created by structural alterations tend to alter P.L. emission. The increase in non-radioactive decay brought on by this unordered lattice structure lowers P.L. emissions. The different flaws were examined with the help of an X-ray absorption, UV-vis, and Raman Spectrograph. Structural, optical, and mechanical properties of the synthesized Mn-doped Cerium Dioxide were completed [7]. The substitution of the Mn results in considerable change in the lattice structure—vibrational and Optical properties of the Structures. The micro-hardness is studied, which shows the Indentation size effects with dominant plastic deformation in the composite materials. The cubic fluorite structure of cerium oxide was altered by adding oxygen and external replacements [8]. Its oxidation state greatly influences the strain deformation properties of cerium. The study of oxygen vacancy states creates defect states between the conduction and valence bands. It was shown that the strain properties rise with the substitution, but the Lattice parameter falls. The effects of oxygen vacancies and interstitials on structural phase transitions, grain development, and optical characteristics of the Ga-doped TiO² were observed by C.P. [9].

The investigation is completed by confirming that Ga doping prevents the phase transition using X-ray diffraction spectroscopy and a Raman spectrograph. [10] Investigated the evaluation of cerium oxide nanoparticles at precise awareness in maize oil methyl ester diesel combination, focusing on 10% biodiesel with diesel fuel. With the COB10, CeO2 nanoparticle concentrations range between 25, 50, and 75 PPM. The addition of CeO2 nanoparticles boosted the physicochemical properties of the gas, according to the results. The impact of pyrophosphate expansion is examined in examining the conduct of erosion of manganese-based change covering LZ91 magnesium amalgam [10]. According to the authors of a prior study, an Mn Ce-based conversion coating shields the surface of the LZ91 magnesium alloy against corrosion. However, the degradation of the acidic permanganate solution after a few days of storage substantially impacts the coating's qualities. This work solves this problem by stabilizing the acidic permanganate bath with pyrophosphate. The results show that all conversion coatings are amorphous, two-layered, and comprise a porous layer that touches the substrate. The corrosion resistance of coatings produced in a bath containing Ce ions is higher than those produced in a bath devoid of Ce ions. As-prepared Mn-Ce bath coatings are much more corrosion-resistant than coatings stored in the Mn-Ce bath for two weeks. The salt spray test results of coatings prepared using the same bath and kept for two weeks are comparable because adding pyrophosphate makes the bath more stable.

Experimental Procedures

CeO2 Ceria ceramic particles (10 wt.%) were employed to create the composites. The alloy's chemical composition was examined using an ASTM E 1751-2017. Ingots of AA6061 were melted in a crucible made of graphite using a Muffle furnace. AA6061-10 wt.% A stir-casting procedure was used to create CeO2 composites. The procedure entailed melting the AA6061 alloy at a temperature of 780–800 °C in a crucible made of graphite. The mold cavity is equipped with a K-type Thermocouple with a temperature indicator. Particles preheated at a temperature of 700°C for 120 minutes were added to the mechanically stirred melt. With a 20 mm diameter and a 200 mm height, the Al-CeO2 composite melt was poured.

Solutionization was done in a muffle furnace for 12 hours at 180 degrees. For three hours, normalizing is done at 400°C. A one-hour heat treatment at 400°C was performed. The first step in making a composite is preheating the cerium oxide. The mold used to contain the composite material is then created using mold construction. During the melting and mixing process, the CeO2 is heated and mixed to make the composite. The mold is then filled with a liquid metal to harden there. The composite is subsequently subjected to heat treatment to improve its properties further. Careful attention is paid to each step to guarantee that the final product meets the required specifications and quality standards.

Simulation Procedure

There are various processes in the simulation process for establishing the. The first stage is to create a mesh and volume meshing to represent the examined object digitally. Different material characteristics and thermo-mechanical properties are provided to do the simulation. For the simulation to produce the intended results, specific characteristics are necessary. We also need to define some limitations in addition to these properties to get results. Results are produced by meshing the model, choosing the size of the finite elements, and solving the problem. This procedure aids in precisely determining the object's heat transfer properties, providing crucial knowledge for design and engineering needs.

Simulation Constituents and Results:

Hardness testing of Samples found to be 47-51HV (including Normalizing and T6 Artificial Aging). Simulation is done on Pro Cast, and IHTC value is established. And it is found to be 30w/m2-k to 2000 w/m2-k. (other than objective). A simulation is a good tool for establishing IHTC value.

Table 1: Material Composition (Verified by Standard lab test)

S. No.	Material	Percentage (Wt. %)
1.	Al	98.12
2.	Si	0.5
3.	Mg	0.1
4.	Cu	0.16

Experimental Results

Particle Size Distribution Test

Particle size distribution tests are analytical techniques used to determine the size range and distribution of particles within a sample. These tests are commonly performed in various industries, including pharmaceuticals, cosmetics, food processing, mining, and environmental monitoring. The particle size distribution test performed for the samples indicated the presence of ceria ceramic.

Eighty-one measurement records showed that the ceria materials were well distributed inside the aluminum. The distribution range varied from 375.854 to 7.056 in the various measurement records taken.

Vickers Micro Hardness Testing

Vickers microhardness testing is used to measure the hardness of materials, particularly those with very small or thin samples. It is a widespread technique in materials science, metallurgy, and quality control.

The Vickers micro hardness testing results show an average microhardness of 51.5 HRC at a depth of 55.3 mm.

To evaluate the hardness of the samples, the researchers performed tests involving normalizing and T6 artificial aging techniques. The hardness values obtained ranged from 47 to 51HV. These values indicate the material's ability to resist indentation or deformation, providing insights into its mechanical properties.

In addition to the particle size distribution and hardness analysis, the researchers also focused on determining the heat transfer coefficient (IHTC) value. The IHTC value quantifies the heat transfer rate between a surface and a fluid or gas. This study determined the IHTC value through simulation using Pro Cast software. The calculated IHTC values ranged from 2000 W/m²-K to 5000 W/m²-K.

Determining IHTC values is crucial in various engineering applications as it enables the assessment of heat transfer efficiency and design optimization of heat exchange systems. Simulation-based approaches, such as the one employed in this study, offer a helpful tool for determining IHTC values. They provide a cost-effective and time-efficient alternative to experimental methods, allowing for rapid evaluation and comparison of different design configurations.

By combining the measured particle size distribution, hardness analysis, and IHTC determination, the researchers aimed to understand the material's physical and thermal properties comprehensively. This knowledge can be invaluable in various industries, including manufacturing, metallurgy, and heat transfer engineering, enabling better material selection, process optimization, and system design.

Overall, this paper contributes to the existing body of knowledge by providing empirical data on particle size distribution, hardness values, and IHTC determination, highlighting the significance of simulation-based tools in thermal analysis. The findings presented in this study can serve as a valuable reference for researchers, engineers, and practitioners working in related fields, facilitating further advancements in material science and heat transfer technology.

Parameter	Values
Particle Size Distribution	13.934 − 0.418 µm
Hardness	47–51 HV
IHTC Value	2000 w/m²-k

Based on the findings of this study, it has been observed that adding Ceria ceramics to AA6061 material leads to a notable alteration in its hardness when compared to AA6061 alloys alone. To establish the value of the heat transfer coefficient (IHTC), the researchers employed inverse volume techniques and simulation, which proved to be a valuable tool for analysis. However, due to the limited number of samples used in the study, further verification through more comprehensive methods is necessary to validate the results.

The production of Nano-Ceria powder involved the utilization of citric acid as the fuel in low-temperature combustion processes. At the same time, mechanical stir casting was employed to organize the powder mixtures effectively. This study examined various mechanical characteristics such as coefficient of thermal expansion (CTE), microstructure, micro hardness, ultimate tensile strength (UTS), and fatigue. The analysis of different Nano-ceria contents allowed for assessing corrosion resistance, microhardness, CTE, fatigue-fracture, and microstructure, ultimately identifying the most reliable Nano-ceria material.

To model the outcomes, Finite Element Method (FEM) was used, which proved to be an effective tool for understanding and predicting the mechanical behavior of the composite material. The hardness of the developed composite material differed significantly from that of existing aluminum composites composed of aluminum and cerium oxide. This highlights the importance of carefully selecting and modifying the component parts to achieve desired mechanical properties in composite materials.

The study's findings demonstrate the capability of simulation and testing techniques to modify the mechanical characteristics of composites. By incorporating specific components into composite materials, simulation can aid in obtaining the desired mechanical properties for various applications. This research addresses the global demand for inexpensive and lightweight materials by providing insights into the development and optimization of composite materials.

In conclusion, this study contributes valuable information on the alteration of hardness in AA6061 material through the addition of Ceria ceramics. It highlights the significance of simulation techniques and testing methods in establishing the IHTC value and optimizing the mechanical properties of composite materials. However, further validation through additional samples and comprehensive verification methods is recommended. The findings of this research have practical implications for developing lightweight materials with enhanced mechanical characteristics to meet global demands.

Competing Interests: The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.

Acknowledgments and Funding Information:

This research was supported/partially supported by TEQIP-III, RGPV, Bhopal. We thank our colleagues from [Prestige Institute of Engineering Management & Research, Indore, M.P., India] who provided insight and expertise that greatly assisted the research.

· The authors did not receive support from any organization for the submitted work.

· No funding was received to assist with the preparation of this manuscript.

· No funding was received for conducting this study.

· No funds, grants, or other support was received.

Reviewed the material properties of Al-Si-SiC composites [4]. The following composite comprises Al-Si (LM-13) alloy and ten wt. % of SiC particles reinforced in cast along with T6 temperature conditions at ambient temperature. The material undergoes inverse loading with a maximum stress amplitude of up to 50,000 cycles. Due to more vital cohesive forces with the aluminum matrix, it was found that it withstood the application of cyclic stress that would have caused fatigue crack formation when scanned with an electron microscope. Studied single-phase Co/Ni substituted with Cerium Oxide Nanoparticles and conclude that the Lattice structure shrinks and strain increases due to incorporating Co/Ni substitution in Cerium Oxide [5]. Ce1-xNixO2 Nano powders made by [6] of Ce1-xNixO2 (0 x 0.1) were examined.
The imperfections created by structural alterations tend to alter P.L. emission. The increase in non-radioactive decay brought on by this unordered lattice structure lowers P.L. emissions. The different flaws were examined with the help of an X-ray absorption, UV-vis, and Raman Spectrograph. Structural, optical, and mechanical properties of the synthesized Mn-doped Cerium Dioxide were completed [7]. The substitution of the Mn results in considerable change in the lattice structure—vibrational and Optical properties of the Structures. The micro-hardness is studied, which shows the Indentation size effects with dominant plastic deformation in the composite materials. The cubic fluorite structure of cerium oxide was altered by adding oxygen and external replacements [8]. Its oxidation state greatly influences the strain deformation properties of cerium. The study of oxygen vacancy states creates defect states between the conduction and valence bands. It was shown that the strain properties rise with the substitution, but the Lattice parameter falls. The effects of oxygen vacancies and interstitials on structural phase transitions, grain development, and optical characteristics of the Ga-doped TiO² were observed by C.P. [9].
The investigation is completed by confirming that Ga doping prevents the phase transition using X-ray diffraction spectroscopy and a Raman spectrograph. [10] Investigated the evaluation of cerium oxide nanoparticles at precise awareness in maize oil methyl ester diesel combination, focusing on 10% biodiesel with diesel fuel. With the COB10, CeO2 nanoparticle concentrations range between 25, 50, and 75 PPM. The addition of CeO2 nanoparticles boosted the physicochemical properties of the gas, according to the results. The impact of pyrophosphate expansion is examined in examining the conduct of erosion of manganese-based change covering LZ91 magnesium amalgam [10]. According to the authors of a prior study, an Mn Ce-based conversion coating shields the surface of the LZ91 magnesium alloy against corrosion. However, the degradation of the acidic permanganate solution after a few days of storage substantially impacts the coating's qualities. This work solves this problem by stabilizing the acidic permanganate bath with pyrophosphate. The results show that all conversion coatings are amorphous, two-layered, and comprise a porous layer that touches the substrate. The corrosion resistance of coatings produced in a bath containing Ce ions is higher than those produced in a bath devoid of Ce ions. As-prepared Mn-Ce bath coatings are much more corrosion-resistant than coatings stored in the Mn-Ce bath for two weeks. The salt spray test results of coatings prepared using the same bath and kept for two weeks are comparable because adding pyrophosphate makes the bath more stable.
Experimental Procedures
CeO2 Ceria ceramic particles (10 wt.%) were employed to create the composites. The alloy's chemical composition was examined using an ASTM E 1751–2017. Ingots of AA6061 were melted in a crucible made of graphite using a Muffle furnace. AA6061-10 wt.% A stir-casting procedure was used to create CeO2 composites. The procedure entailed melting the AA6061 alloy at a temperature of 780–800°C in a crucible made of graphite. The mold cavity is equipped with a K-type Thermocouple with a temperature indicator. Particles preheated at a temperature of 700°C for 120 minutes were added to the mechanically stirred melt. With a 20 mm diameter and a 200 mm height, the Al-CeO2 composite melt was poured.
Solutionization was done in a muffle furnace for 12 hours at 180 degrees. For three hours, normalizing is done at 400°C. A one-hour heat treatment at 400°C was performed. The first step in making a composite is preheating the cerium oxide. The mold used to contain the composite material is then created using mold construction. During the melting and mixing process, the CeO2 is heated and mixed to make the composite. The mold is then filled with a liquid metal to harden there. The composite is subsequently subjected to heat treatment to improve its properties further. Careful attention is paid to each step to guarantee that the final product meets the required specifications and quality standards.

Simulation and Experimental Studies of Al Matrix Composites Reinforced with Nano Ceria Ceramics

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