Chapter 11
Design of Copper and γ-Alumina Reinforced Recycled Aluminium
Matrix Composites through Sintering + Forging
H. M. Enginsoy, E. Bayraktar, I. Miskioglu, F. Gatamorta, and D. Katundi
Abstract The present work, reviews the toughening mechanisms and microstructural analyses of recycled aluminium matrix
composites reinforced with γ-alumina and pure recycled copper. This composite was manufactured by sintering and sinter +
forging called the combined process. Static compression, 3-point bending, impact (drop-weight) tests were conducted to
evaluate mechanical response of the composites. Additionally, wear and creep tests were carried out with a nanoindenter to
evaluate wear and time dependent behaviour of this composite. Detailed analyses of microstructure of the composites was
performed with Scanning Electron Microscopy (SEM) supported by EDS analyses. The results showed that, the composites
have homogeneous structure without porosity and very homogeneous distribution of fine γ-alumina (Al 2 O 3 ) and copper
particles. Sinter + forging process yielded a material that had higher strength, hardness and better resistance to wear. This
composite will be targeted for linkage applications where high toughness and high surface damage resistance is required.
11.1 Introduction
New family of aluminium-based composites are extensively used in the automotive and aerospace industries doped with
different metal and ceramic reinforcements to improve their mechanical and tribological properties [1–8]. A ceramic
reinforcement such as γ-alumina when added to the aluminium matrix can significantly the mechanical properties and wear
resistance of these composites. Addition of copper reinforcement together with γ-alumina can give a good combination of
high ductility and the high strength [5, 9–15].
The production process that we call combined sinter + forging used to manufacture the aluminium-based composites can
offer simplicity in processing and lower manufacturing costs as these composites are produced from recycled constituents
known as fresh scrap materials. In the frame of this present work, a new composite reinforced with γ-alumina and copper was
designed for possible use in linkage/connector parts in aeronautical applications [7, 13, 16].
The idea for composite design from fresh scrap recycled constituents can be applied very well on the industrial parts in an
economic way as low cost and efficient manufacturing. Actually, sintered forging process is a process mainly called as nearnet shape process for the manufacturing of the pieces processed from fresh scrap materials [6–11, 16–18]. Mainly, this process
H. M. Enginsoy
Supmeca-Paris, School of Mechanical and Manufacturing Engineering, Paris, France
Uşak University, School of Mechanical Engineering, Uşak, Turkey
e-mail: murat.enginsoy@usak.edu.tr
E. Bayraktar (*)
Supmeca-Paris, School of Mechanical and Manufacturing Engineering, Paris, France
University of Campinas, UNICAMP-FEM, Campinas, SP, Brazil
e-mail: bayraktar@supmeca.fr
I. Miskioglu
Michigan Technological University ME-EM Department, Houghton, MI, USA
e-mail: imiski@mtu.edu
F. Gatamorta
University of Campinas, UNICAMP-FEM, Campinas, SP, Brazil
e-mail: fabiog@fem.unicamp.br
D. Katundi
Supmeca-Paris, School of Mechanical and Manufacturing Engineering, Paris, France
e-mail: dhurata.katundi@supmeca.fr
© The Society for Experimental Mechanics, Inc. 2021
R. P. Singh, V. Chalivendra (eds.), Mechanics of Composite, Hybrid and Multifunctional Materials, Volume 6,
Conference Proceedings of the Society for Experimental Mechanics Series, https://doi.org/10.1007/978-3-030-59868-6_11
73
Design of Copper and γ-Alumina Reinforced Recycled Aluminium
Matrix Composites through Sintering + Forging
H. M. Enginsoy, E. Bayraktar, I. Miskioglu, F. Gatamorta, and D. Katundi
Abstract The present work, reviews the toughening mechanisms and microstructural analyses of recycled aluminium matrix
composites reinforced with γ-alumina and pure recycled copper. This composite was manufactured by sintering and sinter +
forging called the combined process. Static compression, 3-point bending, impact (drop-weight) tests were conducted to
evaluate mechanical response of the composites. Additionally, wear and creep tests were carried out with a nanoindenter to
evaluate wear and time dependent behaviour of this composite. Detailed analyses of microstructure of the composites was
performed with Scanning Electron Microscopy (SEM) supported by EDS analyses. The results showed that, the composites
have homogeneous structure without porosity and very homogeneous distribution of fine γ-alumina (Al 2 O 3 ) and copper
particles. Sinter + forging process yielded a material that had higher strength, hardness and better resistance to wear. This
composite will be targeted for linkage applications where high toughness and high surface damage resistance is required.
11.1 Introduction
New family of aluminium-based composites are extensively used in the automotive and aerospace industries doped with
different metal and ceramic reinforcements to improve their mechanical and tribological properties [1–8]. A ceramic
reinforcement such as γ-alumina when added to the aluminium matrix can significantly the mechanical properties and wear
resistance of these composites. Addition of copper reinforcement together with γ-alumina can give a good combination of
high ductility and the high strength [5, 9–15].
The production process that we call combined sinter + forging used to manufacture the aluminium-based composites can
offer simplicity in processing and lower manufacturing costs as these composites are produced from recycled constituents
known as fresh scrap materials. In the frame of this present work, a new composite reinforced with γ-alumina and copper was
designed for possible use in linkage/connector parts in aeronautical applications [7, 13, 16].
The idea for composite design from fresh scrap recycled constituents can be applied very well on the industrial parts in an
economic way as low cost and efficient manufacturing. Actually, sintered forging process is a process mainly called as nearnet shape process for the manufacturing of the pieces processed from fresh scrap materials [6–11, 16–18]. Mainly, this process
H. M. Enginsoy
Supmeca-Paris, School of Mechanical and Manufacturing Engineering, Paris, France
Uşak University, School of Mechanical Engineering, Uşak, Turkey
e-mail: murat.enginsoy@usak.edu.tr
E. Bayraktar (*)
Supmeca-Paris, School of Mechanical and Manufacturing Engineering, Paris, France
University of Campinas, UNICAMP-FEM, Campinas, SP, Brazil
e-mail: bayraktar@supmeca.fr
I. Miskioglu
Michigan Technological University ME-EM Department, Houghton, MI, USA
e-mail: imiski@mtu.edu
F. Gatamorta
University of Campinas, UNICAMP-FEM, Campinas, SP, Brazil
e-mail: fabiog@fem.unicamp.br
D. Katundi
Supmeca-Paris, School of Mechanical and Manufacturing Engineering, Paris, France
e-mail: dhurata.katundi@supmeca.fr
© The Society for Experimental Mechanics, Inc. 2021
R. P. Singh, V. Chalivendra (eds.), Mechanics of Composite, Hybrid and Multifunctional Materials, Volume 6,
Conference Proceedings of the Society for Experimental Mechanics Series, https://doi.org/10.1007/978-3-030-59868-6_11
73