7.4 Conclusion
A new aluminium matrix composite was designed from fresh scrap aluminium with recycled chips of Alumix-431 (50 wt %)
and AA1050 (50 wt %) for the connection parts as a low cost and high toughness - alternative composite for aeronautical
industry. Low cost production of these composites have been successfully accomplished through the combined method of
sinter + forging.
Microstructural analysis has shown that a good chemical bonding diffusion at interface of matrix-reinforcement essentially
in the specimens manufactured with combined process sinter + forging. These composites show a tough and complete
microstructure without porosity. Wear resistance and ductility should be absolutely improved with doping process and good
powder mixture preparation conditions; ball milling in longer time is needed for helping the fine and homogeneous
distribution of the particles in the matrix.
This combined process called “Sinter + Forging” seems very confident values for future work of the production of
alternative pieces used in connection components and also for other tribological applications. Optimizations of the operational
parameters need much more experimental work to create real parts in the industrial scales.
Acknowledgements This work has been carried out on the frame of research collaboration between Supmeca/Paris-FRANCE and UNICAMPFEM/CAMPINAS-SP/BRAZIL and Michigan Technical University/Houghton-MI-USA. Authors acknowledge and appreciate so much
Dr. G. ZAMBELIS from Airbus-Helicopter-Paris/FR for supplying materials and for technical help. We acknowledge technical staff of
Supmeca/Paris, Mr. Christophe BEN BRAHIM for mechanical tests and data acquisition system analyses and installation of electronic measurement
devices.
References
1. Reddy, M.P., Manakari, V., Parande, G., Shakoor, R.A., Mohamed, A.M.A., Gupta, M.: Structural, mechanical and thermal characteristics of
Al-Cu-Li particle reinforced Al-matrix composites synthesized by microwave sintering and hot extrusion. Compos. Part B. 164, 485–492 (2019)
2. Kurşun, A., Bayraktar, E., Enginsoy, H.M.: Experimental and numerical study of alumina reinforced aluminium matrix composites: processing,
microstructural aspects and properties. Compos. Part B. 90, 302–314 (2016)
3. Mann, R.E.D., Hexemer Jr., R.L., Donaldson, I.W., Bishop, D.P.: Hot deformation of an Al–Cu–Mg powder metallurgy alloy. Mater. Sci.
Eng. A. 528, 5476–5483 (2011)
4. Ferreira, L.F.P., Bayraktar, E., Robert, M.H., Miskioglu, I.: Particles Reinforced Scrap Aluminium Based Composites by Combined Processing
Sintering + Thixoforming, pp. 145–152, chapter 17. SEM-Springer-USA (2016). ISBN 978-3-319-41766-0
5. Dashwood, R.J., Schaffer, G.B.: Powder forging of a sintered Al–3.8Cu–1Mg–0.8Si–0.1Sn alloy. Mater. Sci. Eng. A323, 206–212 (2002)
6. Li, R.T., Wang, Z.Y., Sun, W., Hu, H.L., Khor, K.A., Wang, Y., Dong, Z.L.: Microstructure and strengthening mechanisms in the Al/Al–Cu–
Cr–Fe composites consolidated using spark plasma sintering. Mater. Charact. 157, 109917 (2019)
7. Bayraktar, E., Ayari, F., Tan, M.-J., Bayraktar, A.T., Katundi, D.: Manufacturing of aluminum matrix composites reinforced with iron-oxide
nanoparticles: microstructural and mechanical properties. Metall. Mater. Trans. B. 45B(26), 352–362 (2014)
8. Tunçay, M.M., Muniz-Lerma, J.A., Bishop, D.P., Brochu, M.: Spark plasma sintering and spark plasma upsetting of an Al-Zn-Mg-Cu alloy.
Mater. Sci. Eng. A. 704, 154–163 (2017)
9. Hall, B.J., Schaffer, G.B.: Statistical experimental design of Al–Cu–Mg–Si P/M alloys. J. Light. Met. 2, 229–238 (2002)
10. Alshammari, Y., Yang, F., Bolzoni, L.: Low-cost powder metallurgy Ti-Cu alloys as a potential antibacterial material. J. Mech. Behav. Biomed.
Mater. 95, 232–239 (2019)
11. Ferreira, L.F.P., Bayraktar, E., Miskioglu, I., Katundi, D.: Design of Hybrid Composites from Scrap Aluminium Bronze Chips, pp. 131–138,
chapter 15. SEM-Springer-USA (2016). ISBN 978-3-319-41766-0
12. Fathy, A., Shaker, A., Hamid, M.A., Megahed, A.A.: The effects of nano-silica/nanoalumina on fatigue behavior of glass fiber-reinforced epoxy
composites. J. Compos. Mater. 51(12), 1667–1679 (2017)
13. Katundi, D., Ferreira, L.P., Bayraktar, E., Miskioglu, I., Robert, M.H.: Design of magnetic aluminium (A356) based composites through
combined method of sinter + forging. SEM Mech. Compos. Multi-funct Mater. 6, 89–101 (2017)
14. Need, R.F., Alexander, D.J., Field, R.D., Livescu, V., Papin, P., Swenson, C.A., Mutnick, D.B.: The effects of equal channel angular extrusion
on the mechanical and electrical properties of alumina dispersion-strengthened copper alloys. J. Mater. Sci. Eng. A. 565, 450–458 (2013)
15. Enginsoy, H.M., Gatamorta, F., Bayraktar, E., Robert, M.H., Miskioglu, I.: Numerical study of Al-Nb 2 Al composites via associated procedure
of powder metallurgy and thixoforming. Compos. Part B Eng. 162, 397–410 (2019)
52
H. M. Enginsoy et al.
A new aluminium matrix composite was designed from fresh scrap aluminium with recycled chips of Alumix-431 (50 wt %)
and AA1050 (50 wt %) for the connection parts as a low cost and high toughness - alternative composite for aeronautical
industry. Low cost production of these composites have been successfully accomplished through the combined method of
sinter + forging.
Microstructural analysis has shown that a good chemical bonding diffusion at interface of matrix-reinforcement essentially
in the specimens manufactured with combined process sinter + forging. These composites show a tough and complete
microstructure without porosity. Wear resistance and ductility should be absolutely improved with doping process and good
powder mixture preparation conditions; ball milling in longer time is needed for helping the fine and homogeneous
distribution of the particles in the matrix.
This combined process called “Sinter + Forging” seems very confident values for future work of the production of
alternative pieces used in connection components and also for other tribological applications. Optimizations of the operational
parameters need much more experimental work to create real parts in the industrial scales.
Acknowledgements This work has been carried out on the frame of research collaboration between Supmeca/Paris-FRANCE and UNICAMPFEM/CAMPINAS-SP/BRAZIL and Michigan Technical University/Houghton-MI-USA. Authors acknowledge and appreciate so much
Dr. G. ZAMBELIS from Airbus-Helicopter-Paris/FR for supplying materials and for technical help. We acknowledge technical staff of
Supmeca/Paris, Mr. Christophe BEN BRAHIM for mechanical tests and data acquisition system analyses and installation of electronic measurement
devices.
References
1. Reddy, M.P., Manakari, V., Parande, G., Shakoor, R.A., Mohamed, A.M.A., Gupta, M.: Structural, mechanical and thermal characteristics of
Al-Cu-Li particle reinforced Al-matrix composites synthesized by microwave sintering and hot extrusion. Compos. Part B. 164, 485–492 (2019)
2. Kurşun, A., Bayraktar, E., Enginsoy, H.M.: Experimental and numerical study of alumina reinforced aluminium matrix composites: processing,
microstructural aspects and properties. Compos. Part B. 90, 302–314 (2016)
3. Mann, R.E.D., Hexemer Jr., R.L., Donaldson, I.W., Bishop, D.P.: Hot deformation of an Al–Cu–Mg powder metallurgy alloy. Mater. Sci.
Eng. A. 528, 5476–5483 (2011)
4. Ferreira, L.F.P., Bayraktar, E., Robert, M.H., Miskioglu, I.: Particles Reinforced Scrap Aluminium Based Composites by Combined Processing
Sintering + Thixoforming, pp. 145–152, chapter 17. SEM-Springer-USA (2016). ISBN 978-3-319-41766-0
5. Dashwood, R.J., Schaffer, G.B.: Powder forging of a sintered Al–3.8Cu–1Mg–0.8Si–0.1Sn alloy. Mater. Sci. Eng. A323, 206–212 (2002)
6. Li, R.T., Wang, Z.Y., Sun, W., Hu, H.L., Khor, K.A., Wang, Y., Dong, Z.L.: Microstructure and strengthening mechanisms in the Al/Al–Cu–
Cr–Fe composites consolidated using spark plasma sintering. Mater. Charact. 157, 109917 (2019)
7. Bayraktar, E., Ayari, F., Tan, M.-J., Bayraktar, A.T., Katundi, D.: Manufacturing of aluminum matrix composites reinforced with iron-oxide
nanoparticles: microstructural and mechanical properties. Metall. Mater. Trans. B. 45B(26), 352–362 (2014)
8. Tunçay, M.M., Muniz-Lerma, J.A., Bishop, D.P., Brochu, M.: Spark plasma sintering and spark plasma upsetting of an Al-Zn-Mg-Cu alloy.
Mater. Sci. Eng. A. 704, 154–163 (2017)
9. Hall, B.J., Schaffer, G.B.: Statistical experimental design of Al–Cu–Mg–Si P/M alloys. J. Light. Met. 2, 229–238 (2002)
10. Alshammari, Y., Yang, F., Bolzoni, L.: Low-cost powder metallurgy Ti-Cu alloys as a potential antibacterial material. J. Mech. Behav. Biomed.
Mater. 95, 232–239 (2019)
11. Ferreira, L.F.P., Bayraktar, E., Miskioglu, I., Katundi, D.: Design of Hybrid Composites from Scrap Aluminium Bronze Chips, pp. 131–138,
chapter 15. SEM-Springer-USA (2016). ISBN 978-3-319-41766-0
12. Fathy, A., Shaker, A., Hamid, M.A., Megahed, A.A.: The effects of nano-silica/nanoalumina on fatigue behavior of glass fiber-reinforced epoxy
composites. J. Compos. Mater. 51(12), 1667–1679 (2017)
13. Katundi, D., Ferreira, L.P., Bayraktar, E., Miskioglu, I., Robert, M.H.: Design of magnetic aluminium (A356) based composites through
combined method of sinter + forging. SEM Mech. Compos. Multi-funct Mater. 6, 89–101 (2017)
14. Need, R.F., Alexander, D.J., Field, R.D., Livescu, V., Papin, P., Swenson, C.A., Mutnick, D.B.: The effects of equal channel angular extrusion
on the mechanical and electrical properties of alumina dispersion-strengthened copper alloys. J. Mater. Sci. Eng. A. 565, 450–458 (2013)
15. Enginsoy, H.M., Gatamorta, F., Bayraktar, E., Robert, M.H., Miskioglu, I.: Numerical study of Al-Nb 2 Al composites via associated procedure
of powder metallurgy and thixoforming. Compos. Part B Eng. 162, 397–410 (2019)
52
H. M. Enginsoy et al.