Nanoparticle-reinforced Aluminium Matrix Hybrid Composites: Processing and Characterization
J. Environ. Nanotechnol., Volume 15, No 1 (March 2026) pp. 1-10
Abstract
In the pursuit of high-performance materials for demanding applications, the development of hybrid composites has emerged as a breakthrough solution. In the present work, A356 matrix hybrid nanocomposites reinforced with boron carbide (B4C) (1, 2, 3, 4, and 5 wt.%) and zirconium dioxide (ZrO2) (1 wt.% constant) were produced by the two-step stir casting technique assisted by ultrasonic vibrations. Microstructure, mechanical characteristics, and tribological behaviour of A356–B4C–ZrO₂ hybrid composites were investigated. The impact of T6 heat treatment on the mechanical characteristics of the prepared composites was also examined. The microhardness, yield strength, and ultimate tensile strength of the hybrid composites showed improvements of 35%, 66%, and 60%, respectively, compared to the A356 matrix. The fracture morphology of the hybrid nanocomposites was analyzed using scanning electron microscopy. The even dispersion of nanoparticles achieved through mechanical stirring and ultrasonic vibration assistance, along with microstructural changes such as precipitation hardening and spheroidization of silicon particles due to thermal treatment, significantly lowered the wear rate and friction coefficient.
Full Text
Reference
Akbar, H. I., Surojo, E., Ariawan, D., Putra, G. A. and Wibowo, R. T., Effect of reinforcement material on properties of manufactured aluminum matrix composite using stir casting route, Procedia Struct. Integr., 27(2019), 62–68(2020).
https://doi.org/10.1016/j.prostr.2020.07.009
Alam, M. T., Ansari, A. H., Arif, S. and Alam, M. N., Mechanical properties and morphology of aluminium metal matrix nanocomposites-stir cast products, Adv. Mater. Process Technol., 3(4), 600–615(2017).
https://doi.org/10.1080/2374068X.2017.1350543
Awate, P. P. and Barve, S. B., Microstructural observation and mechanical properties behavior of Al2O3/Al6061 nanocomposite fabricated by stir casting process, Eng. Res. Exp., 4(1), 015023(2022a).
https://doi.org/10.1088/2631-8695/ac54ed
Awate, P. P. and Barve, S. B., Enhanced microstructure and mechanical properties of Al6061 alloy via graphene nanoplates reinforcement fabricated by stir casting, Funct. Compos. Struct., 4(1), 015005(2022b).
https://doi.org/10.1088/2631-6331/ac586d
Azadi, M., Rezanezhad, S., Zolfaghari, M. and Azadi, M., Investigation of tribological and compressive behaviors of Al/SiO2 nanocomposites after T6 heat treatment, Sadhana - Acad. Proc. Eng. Sci., 45(1), 28(2020).
https://doi.org/10.1007/s12046-019-1257-z
Balamurugan, K., Shanmugam, V., Palani, G., Sundarakannan, R., Sathish, T., Linul, E., Khan, S. A. and Asif, M., Effect of TiC/RHA on solid particle erosion of Al6061 hybrid composites fabricated through a 2-step ultrasonic-assisted stir casting process, J. Mater. Res. Technol., 25, 4888–4900(2023a).
https://doi.org/10.1016/j.jmrt.2023.06.225
Bhoi, N. K., Singh, H. and Pratap, S., Developments in the aluminum metal matrix composites reinforced by micro/nano particles – A review, J Compos Mater, 54(6), 813–833(2020).
https://doi.org/10.1177/0021998319865307
Boppana, S. B., Dayanand, S., Anil Kumar, M. R., Kumar, V. and Aravinda, T., Synthesis and characterization of nano graphene and ZrO2 reinforced Al 6061 metal matrix composites, J. Mater. Res. Technol., 9(4), 7354–7362(2020).
https://doi.org/10.1016/j.jmrt.2020.05.013
Borisade, S. G., Owoeye, S. S., Akindutire, S. and Epstein, H., Effects of alumina-rich waste (valoxy) as an alternative sustainable material to alumina on the morphology, mechanical and wear behavior of Al-6063 alloy by stir casting, J. Alloys Metall. Syst., 3(, 100021(2023).
https://doi.org/10.1016/j.jalmes.2023.100021
Çanakçı, A., Karabacak, A. H., Çelebi, M., Özkaya, S. and Arpacı, K. A., A Study on the Optimization of Nano-B4C Content for the Best Wear and Corrosion Properties of the Al-Based Hybrid Nanocomposites,. Arab. J. Sci. Eng., 49(11), 14625-14641(2024).
https://doi.org/10.1007/s13369-024-08736-w
Casati, R. and Vedani, M., Metal matrix composites reinforced by Nano-Particles—A review, Metals, 4(1), 65–83(2014).
https://doi.org/10.3390/met4010065
Chak, V., Chattopadhyay, H. and Dora, T. L., A review on fabrication methods, reinforcements and mechanical properties of aluminum matrix composites, J. Manuf. Process, 56, 1059–1074(2020).
https://doi.org/10.1016/j.jmapro.2020.05.042
Chandel, R., Sharma, N. and Bansal, S. A., A review on recent developments of aluminum-based hybrid composites for automotive applications, Emergent Mater., 4(5), 1243–1257(2021).
https://doi.org/10.1007/s42247-021-00186-6
Chandla, N. K., Yashpal., Kant, S., Goud, M. M. and Jawalkar, C. S., Experimental analysis and mechanical characterization of Al 6061/alumina/bagasse ash hybrid reinforced metal matrix composite using vacuum-assisted stir casting method, J. Compos. Mater., 54(27), 4283–4297(2020).
https://doi.org/10.1177/0021998320929417
Chandrashekar, J. R., Chandrashekar, R.,Haseebuddin, M. R. and Savitha, Y. L., Effect of Heat Treatment (T6) on Mechanical Behaviour of Double Sized B4C Ceramic Particle Reinforced A356 Composite, J. Inst. Eng. India. Ser. D. (2024).
https://doi.org/10.1007/s40033-024-00825-2
Fadavi, B. A., Tahamtan, S., Jiang, Z. Y., Wei, D., Yazdani, S., Azari Khosroshahi, R.,Taherzadeh, M. R., Xu, J., Zhang, X. and Gong, D., Enhanced tensile properties of aluminium matrix composites reinforced with graphene encapsulated SiC nanoparticles, Compos. Part Appl. Sci. Manuf., 68, 155–163(2015).
https://doi.org/10.1016/j.compositesa.2014.10.010
Fanani, E. W. A., Surojo, E., Prabowo, A. R. and Akbar, H. I., Recent progress in hybrid aluminum composite: Manufacturing and application, Metals, 11(12), 1919(2021).
https://doi.org/10.3390/met11121919
Fayomi, J., Popoola, A. P. I., Popoola, O. M.,Oladijo, O. P. and Fayomi, O. S. I., Understanding the microstructural evolution, mechanical properties, and tribological behavior of AA8011-reinforced nano-Si3N4 for automobile application, Int. J. Adv. Manuf. Technol., 111(1–2), 53–62(2020).
https://doi.org/10.1007/s00170-020-06054-7
Geng, R., Qiu, F. and Jiang, Q. C., Reinforcement in Al Matrix Composites: A Review of Strengthening Behavior of Nano-Sized Particles, Adv. Eng. Mater., 20(9), 1–13(2018).
https://doi.org/10.1002/adem.201701089
Kammer, C., Aluminum and aluminum alloys, Springer Handb, 157–193(2018).
https://doi.org/10.1007/978-3-319-69743-7_6
Khalili, V., Heidarzadeh, A., Moslemi, S. and Fathyunes, L., Production of Al6061 matrix composites with ZrO2 ceramic reinforcement using a low-cost stir casting technique: Microstructure, mechanical properties, and electrochemical behavior, J. Mater. Res. Technol., 9(6), 15072–15086(2020).
https://doi.org/10.1016/j.jmrt.2020.10.095
Kumar, M. S., Vasumathi, M., Begum, S. R.,Luminita, S. M., Vlase, S. and Pruncu, C. I., Influence of B4C and industrial waste fly ash reinforcement particles on the micro structural characteristics and mechanical behavior of aluminium (Al–Mg–Si-T6) hybrid metal matrix composite, J. Mater. Res. Technol., 15, 1201–1216(2021).
https://doi.org/10.1016/j.jmrt.2021.08.149
Kumar, P. and Kumar, B., Effect of T6 Heat Treatment on Mechanical and Tribological Properties of Fabricated AA7075/ZrB2/Fly Ash Hybrid Aluminum Metal Matrix Composite by Ultrasonic-Assisted Stir Casting Enroute, Int. J. Met., 18(3), 2396–2414(2024).
https://doi.org/10.1007/s40962-023-01177-5
Kumar, S., Dixit, G. and Dixit, S., Investigating microstructural and mechanical behavior of stir-squeeze cast TiO2–SiC/Al6082 bimodal hybrid composites, J. Mater. Res. Technol., 26, 150–163(2023).
https://doi.org/10.1016/j.jmrt.2023.07.186
Manda, C. S., Babu, B. S. and Ramaniah, N., Effect of Heat Treatment on Mechanical properties of Aluminium metal matrix composite (AA6061/MoS2), Adv. Mater. Process Technol., 8(sup1), 205–222(2022).
https://doi.org/10.1080/2374068X.2020.1860593
Moona, G., Walia, R. S., Rastogi, V. and Sharma, R., Aluminium metal matrix composites: A retrospective investigation, Indian J. Pure Appl. Phys., 56(2), 164–175(2018).
Oyewo, A. T., Oluwole, O. O., Ajide, O. O.,Omoniyi, T. E. and Hussain, M., A summary of current advancements in hybrid composites based on aluminium matrix in aerospace applications, Hybrid Adv., 5, 100117(2024).
https://doi.org/10.1016/j.hybadv.2023.100117
Pandiyarajan, R., Maran, P., Marimuthu, S. and Prabakaran, M. P., Investigation on mechanical properties of ZrO2, C and AA6061 metal matrix composites, Adv. Mater. Process Technol., 8(sup1), 178–186(2022).
https://doi.org/10.1080/2374068X.2020.1810946
Pingale, A. D., Belgamwar, S. U. and Rathore, J. S., A novel approach for facile synthesis of Cu-Ni/GNPs composites with excellent mechanical and tribological properties, Mater. Sci. Eng. B, 260, 114643(2020).
https://doi.org/10.1016/j.mseb.2020.114643
Ravindra., Rajesh, M., Dilip, K. K., Sailender, M., Pathalinga, P. G., Nagaraj, N. and Janaki Ramulu, P., Effect of Boron Carbide Particles Addition on the Mechanical and Wear Behavior of Aluminium Alloy Composites, Adv. Mater. Sci. Eng., 2023(2023).
https://doi.org/10.1155/2023/2386558
Sahu, M. K. and Sahu, R. K., Experimental Investigation, Modeling, and Optimization of Wear Parameters of B4C and Fly-Ash Reinforced Aluminum Hybrid Composite, Front. Phys., 8, 1–14(2020).
https://doi.org/10.3389/fphy.2020.00219
Sambathkumar, M., Gukendran, R., Mohanraj, T., Karupannasamy, D. K., Natarajan, N. and Christopher, D. S., A Systematic Review on the Mechanical, Tribological, and Corrosion Properties of Al 7075 Metal Matrix Composites Fabricated through Stir Casting Process, Adv. Mater. Sci. Eng., 2023, 1-17(2023).
https://doi.org/10.1155/2023/5442809
Sharma, S., Nanda, T. and Pandey, O. P., Investigation of T4 and T6 heat treatment on the wear properties of sillimanite reinforced LM30 aluminium alloy composites, Wear, 426–427, 27–36(2019a).
https://doi.org/10.1016/j.wear.2018.12.065
Shinde, S. S. and Barve, S. B., Synthesis of A356 Matrix Hybrid Nanocomposites : Microstructural, Mech. Tribological Character., 78, 230(2025).
https://doi.org/10.1007/s12666-025-03697-6
Singh, N., Belokar, R. M. and Walia, R. S., A Critical Review on Advanced Reinforcements and Base Materials on Hybrid Metal Matrix Composites, Silicon, 14(2), 335–358(2022).
https://doi.org/10.1007/s12633-020-00853-z
Tabandeh, K. M., Omrani, E., Menezes, P. L. and Rohatgi, P. K., Tribological performance of self-lubricating aluminum matrix nanocomposites: Role of graphene nanoplatelets, Eng. Sci. Technol. Int. J., 19(1), 463–469(2016).
