Document Type : Original Article
Authors
1
Faculty of Engineering, Department of Mechanical Engineering, The British University in Egypt, El-Sherouk City, Cairo 11837, Egypt.
2
Faculty of Engineering, Department of Mechanical Engineering, The British University in Egypt, El-Sherouk City, Cairo 11837, Egypt., Mining, Petroleum and Metallurgical Engineering Dept., Faculty of Engineering, Cairo University, Giza,12613, Egypt.
3
Department of Mechanical Design and Production Engineering, Faculty of Engineering, Cairo University, Giza,12613, Egypt.
10.1088/1757-899X/973/1/amme.2025.449043
Abstract
A390 hyper-eutectic Al-Si alloy is fabricated as monolithic alloy and with different percentages of nano-reinforcements added to the alloy through stir casting with (1% ZrO2), (0.5% ZrO2 with 0.5% TiO2), (0.5% ZrO2 with 1.5% Al2O3), (1% ZrO2with 1% Al2O3) and (1.5% ZrO2 and 0.5% Al2O3). Mechanical and microstructural properties were investigated along with SEM and mapping images. The results shows significant refinement across all specimens of 72% in primary silicon size, 82% in dendritic arm length and 59% reduction in dendritic arm spacing. Results also shows great improvement in most specimens up to 90% in tensile strength, up to 16% hardness and around 2% enhancement in elongation. However, a great scatter in the results is present in the mechanical properties proving the challenge in the repeatability of the alloys through traditional stir casting manufacturing methods. SEM and EDX analyses confirmed non-homogeneous nanoparticle distribution in some specimens, while the presence of Al₃Zr intermetallic phases contributed to enhanced strength and reduced defects. This work provides insights into the strengthening mechanisms and fabrication challenges of hybrid nanoparticle-reinforced Al-Si alloys for various applications.
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