Processing and preparation of aerospace-grade aluminium hybrid metal matrix composite in a modified stir casting furnace integrated with mechanical supersonic vibration squeeze infiltration method

Composite materials are versatile, economical, and alternatives for aerospace applications due to their light in weight and high strength. The extensive range of reinforcements available and advanced material processing technique ensured special attention to composite material development's in large-scale production at low cost. In the present study, a modified bottom pouring, stir casting furnace integrated with mechanical supersonic vibration squeeze infiltration method was used to develop the aluminium alloy 7075 base cast and hybrid composite. Silicon carbide and graphite reinforcement percentages varied, and their effect on the matrix was evaluated through material characterization, mechanical testing, wear, and corrosion analysis. Distribution of reinforcement particles and their presence in the composite were examined by optical microscopy, scanning electron microscopy, energy dispersive spectroscopy with elemental mapping and X-ray diffraction.Due to high squeeze pressure, 75?80 % ultra-fine grains were present in the cast specimen. Maximum and minimum hardness values were observed in CM4 (167.98 BHN and 168.35 VHN) and CM1 (132.97 BHN and 146.1 VHN) specimens, respectively. Impact strength of developed hybrid composites (CM2, CM3, CM4) decrease with 12 % than the base cast specimen CM1.

Automated summary

Composite materials are versatile, economical, and lightweight, making them ideal alternatives for aerospace applications. A modified casting furnace integrated with mechanical supersonic vibration was used to develop an aluminum alloy base cast and hybrid composite. Various reinforcements were tested for their effects on the matrix through material characterization and mechanical testing.