Effect of particle size and weight fraction of SiC on the mechanical, tribological, morphological, and structural properties of Al-5.6Zn-2.2Mg-1.3Cu composites using RSM: fabrication, characterization, and modelling.

Stir-casting was employed to create Al-5.6Zn-2.2Mg-1.3Cu composites with particle sizes ranging from 30 to 90 µm and a weight fraction of 5-15 SiC articles. The mechanical and wear properties of the material have been assessed. The wear-behaviour of Al-5.6Zn-2.2Mg-1.3Cu composites was investigated using dry pin-on-disc wear testing. Various loads (20 N-60 N), speeds (2 m/s-6 m/s), and sliding-distances were used in the sliding wear experiments (2000 m-4000 m). In the experimental process, XRD, SEM, and EDX were used to characterize the microstructures and materials of diverse composites. Uniform dispersion of the SiC particles is clearly observed in the SEM image. The micro hardness of SiC particles increases by 13% when the weight percent of SiC particles is increased from 5% to 15%. SiC particles outperform tiny SiC particles in terms of wear-resistance. With increasing load, the particular wear-rate showed an increasing trend (20-60 N). The wear-rate of the composite lowers as the weight percentage reinforcement increases (wt. 5% to wt. 15%), and the wear-rate of the composite increases when the particle-size (30 µm-90 µm) increases. The results demonstrated that composites supplemented with coarse SiC particles outperform tiny SiC particles in terms of wear resistance.

In Situ Micro-Observation of Surface Roughness and Fracture Mechanism in Metal Microforming of Thin Copper Sheets with Newly Developed Compact Testing Apparatus.

A better understanding of material deformation behaviours with changes in size is crucial to the design and operation of metal microforming processes. In order to facilitate the investigation of size effects, material deformation behaviours needed to be determined directly from material characterizations. This study was aimed at the design and manufacture of a compact universal testing machine (UTM) compatible with a 3D laser-confocal microscope to observe the deformation behaviour of materials in real-time. In this study, uniaxial micro tensile testing was conducted on three different thin (0.05 mm, 0.1 mm, and 0.3 mm) copper specimens with characteristic dimensions at micro scales. Micro tensile experimental runs were carried out on copper specimens with varying grain sizes on the newly developed apparatus under a 3D laser-confocal microscope. Microscale experiments under 3D laser-confocal microscope provided not only a method to observe the microstructure of materials, but also a novel way to observe the early stages of fracture mechanisms. From real-time examination using the newly developed compact testing apparatus, we discovered that fracture behaviour was mostly brought about by the concave surface formed by free surface roughening. Findings with high stability were discovered while moving with the sample grasped along the drive screw in the graphical plot of a crosshead's displacement against time. Our results also showed very low mechanical noise (detected during the displacement of the crosshead), which indicated that there were no additional effects on the machine, such as vibrations or shifts in speed that could influence performance. The engineering stress-strain plots of the pure copper-tests with various thicknesses or samples depicted a level of stress necessary to initiate plastic flowing inside the material. From these results, we observed that strength and ductility declined with decreasing thickness. The influence of thickness on fracture-strain, observed during tensile testing, made it clear that the elongation-at-break of the pure-copper foils intensely decreased with decreases in thickness. The relative average surface-roughness Ra was evaluated, which showed us that the surface-roughness escalated with the increasing trend of plasticity deformation (plastic strain) ε. For better understanding of the effects of plastic strain on surface roughness prior to material fractures, micro tensile tests were performed on the newly developed machine under a 3D laser-confocal-microscope. We observed that homogeneous surface roughness was caused by plastic strain, which further formed the concave surface that led to the fracture points. Finally, we concluded that surface roughness was one of the crucial factors influencing the fracture behaviour of metallic sheet-strips in metal microforming. We found that this type of testing apparatus could be designed and manufactured within a manageable budget.

Assessment of Dimensional Stability, Biodegradability, and Fracture Energy of Bio-Composites Reinforced with Novel Pine Cone.

In this investigation, biodegradable composites were fabricated with polycaprolactone (PCL) matrix reinforced with pine cone powder (15%, 30%, and 45% by weight) and compatibilized with graphite powder (0%, 5%, 10%, and 15% by weight) in polycaprolactone matrix by compression molding technique. The samples were prepared as per ASTM standard and tested for dimensional stability, biodegradability, and fracture energy with scanning electron micrographs. Water-absorption and thickness-swelling were performed to examine the dimensional stability and tests were performed at 23 °C and 50% humidity. Results revealed that the composites with 15 wt % of pine cone powder (PCP) have shown higher dimensional stability as compared to other composites. Bio-composites containing 15-45 wt % of PCP with low graphite content have shown higher disintegration rate than neat PCL. Fracture energy for crack initiation in bio-composites was increased by 68% with 30% PCP. Scanning electron microscopy (SEM) of the composites have shown evenly-distributed PCP particles throughout PCL-matrix at significantly high-degrees or quantities of reinforcing.