A REVIEW ON CNT REINFORCED AL7075 ALUMINIUM ALLOY NANOCOMPOSITES by IRJET Journal

A REVIEW ON CNT REINFORCED AL7075 ALUMINIUM ALLOY NANOCOMPOSITES

Mr. Vijay Chavan1, Dr. Pankaj P. Awate2

1 PG Student- Department of Mechanical Engineering, P. V. P. I. T. Budhgaon, Maharashtra, India.

2Head of Department- Department of Mechanical Engineering, P. V. P. I. T Budhgaon, Maharashtra, India.

Abstract

Aluminium alloy 7075 (Al7075) is widely used in aerospace, automotive, and structural applications due to its excellent strength-to-weightratioandgoodfatigueresistance.However,limitationssuchaspoorwearresistance,thermalinstability, andreducedfatigueperformanceatelevatedtemperaturesrestrictitsbroaderapplicability.Toovercomethesedrawbacks, carbonnanotube(CNT)reinforcementhasemergedasa promisingapproach.CNTspossessoutstandingtensile strength, lowdensity,andhighthermal andelectrical conductivity,makingthemsuitable for enhancingaluminiummatrices.CNTreinforced Al7075 nanocomposites demonstrate significant improvements in mechanical, thermal, and tribological properties,including higher wear resistance andsuperiorstrength.Despite these advancements,challengessuchasCNT agglomeration,poorwettability,andweakinterfacialbondingremainobstaclestoindustrial-scaleapplications.Thisreview summarizesrecentresearchprogressonsynthesistechniques,microstructuralcharacteristics,andpropertyenhancements ofCNT-Al7075nanocomposites,whilealsohighlightingfutureopportunitiesfortheirdevelopmentinadvancedengineering applications.

Keywords: Al7075 alloy, carbon nanotubes, nanocomposites, mechanical properties, wear resistance, fabrication techniques.

1. INTRODUCTION

Aluminumalloy7075(Al7075)isrecognizedasoneofthe most important high-strength alloys extensively employed in aerospace, automotive, marine, and structural applications. Its widespread use is primarily attributed to its excellent strength-to-weight ratio, superior machinability, and favorable corrosion resistance. Moreover, Al7075 exhibits good fatigue resistance, making it a preferred choice for aircraft structures, defense equipment, and high-performance engineering components where lightweight and reliability are essential. Despite these merits, Al7075 suffers from several limitations that hinder its broader applicability, particularly in advanced and extreme operating environments. Challenges such as insufficient wear resistance, thermal instability at elevated temperatures,andadeclineinfatigueperformanceunder intermediatetohighthermalconditionsrestrictitslongterm service life. These drawbacks often occur simultaneously, especially in aggressive working environments, thus necessitating the exploration of advancedmaterialmodifications[1].

In this regard, the development of metal matrix composites(MMCs)reinforcedwithnanoscale materials has emerged as a promising strategy to overcome the inherent limitations of conventional Al7075. Among the various reinforcements explored, carbon nanotubes (CNTs) have attracted significant attention due to their extraordinary mechanical, thermal, and electrical properties. CNTs possess ultra-high tensile strength, remarkable elasticity,low density,and superior thermal conductivity,makingthemidealcandidatesforimproving the performance of aluminium-based matrices. The

integration of CNTs into the Al7075 matrix offers the possibility ofenhancingloadtransfer efficiency,refining grain structure, and improving resistance to dislocation motion. As a result, CNT-reinforced Al7075 nanocomposites exhibit significant potential for achieving superior wear resistance, enhanced thermal stability,andimprovedfatiguestrengthcomparedtothe base alloy. Nevertheless, the fabrication of CNT-Al7075 nanocompositesisnotwithoutchallenges.Issuessuchas CNTagglomeration,poorwettabilitywiththealuminium matrix, and weak interfacial bonding often limit the full exploitation of their reinforcing potential. To address these obstacles, researchers have investigated various processing routes, including powder metallurgy, stir casting,frictionstirprocessing,mechanicalalloying,and sparkplasmasintering,eachofferingdistinctadvantages in achieving homogeneous CNT dispersion and stronger interfacial adhesion. Continuous advancements in these fabricationmethodshavepavedthewayfortailoringthe microstructural and mechanical properties of CNTAl7075 composites[2]. Thus, the development of CNTreinforced Al7075 aluminium alloy nanocomposites represents a critical research direction for engineering materials with multifunctional properties. These composites are expected to provide a unique balance of strength, toughness, thermal stability, and wear resistance,positioningthemasnext-generationmaterials foraerospace,automotive,anddefenseapplications.This review paper aims to summarize recent progress in the synthesis, characterization, mechanical behavior, and industrial relevance of CNT-Al7075 nanocomposites while also highlighting the challenges and future opportunitiesinthisgrowingfield[3]

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1.1 Carbon Nanotubes (CNT)

A carbon nanotube (CNT) is a carbon-based tube with a nanoscalediameter(inthenanometrerange).(CNTs)are various allotropes of carbon. There are two groups: Single-Walled Carbon Nanotubes (SWCNTs) and MultiWalledCarbonNanotubes(MWCNTs).

1.1.1 Single-Walled Carbon Nanotubes (SWCNTs)

These consist of single layer of atoms, composed of carbonarrangedinahexagonallatticestructurethathas beenrolledupintoacylindricalshape.Thestructureand the number of atoms means that they have outstanding properties from very high electrical conductivity, excellentmechanicalstrengthandflexibility-thesemake SWCNTsidealforuseinnanocomposites,electronics,and molecular sensors [4]. SWCNTs are simply very thin, so they are act like thin layers or shells which means they have unique properties in regard to surface area and reactivity that can be exploited. This has usefulness in energy storage and onboard sensors, drug delivery systems and molecular electronics. Research and development of SWCNTs is particularly complementary for lightweight, very strong materials and for very efficientconductors.

1.1.2 Multi-Walled Carbon Nanotubes (MWCNTs)

Comprisingmultipleradiallayersofgraphenesheetseach in a rolled and cylindrical shape, multi-walled carbon nanotubes (MWCNTs) are, as a result of multiple layers, generallystronger than theirsingly walledcounterparts SWCNTs,asmorelayersneedtobebrokentoyieldfailure ordeformation.Theirelectricalpropertiesmaynotbeas efficientasSWCNTs,however,becauseoftheinteractions between layers. MWCNTs, nevertheless, still have excellentconductivityandthermal stability [5]. The two mainapplicationsforMWCNTsareasareinforcingagent; notably,incomposites,whenhighstrengthandelectrical conductivity must be maintained. The other use for MWCNTs is in various energy storage devices, namely supercapacitorsandbatteries.Otherareasofapplication include sensors, fuel cells, environmental applications, primarilyasaresultoftheirdurabilityandstability.

1.2 Al7075 Aluminum Alloy

Al7075isaheat-treatable,high-strengthaluminumalloy made primarily from aluminum, zinc, copper, and magnesium. Al7075 has a very high strength-to-weight ratio, which makes it suitable for high-performance applicationssuchasaerospace,automotive,andmilitary applications[6].

1.2.1 Properties

Aluminium alloy 7075 (Al7075) is a high-strength heattreatablealloyconsistingofaluminum,zinc,magnesium, copperandislaudedforitshighstrength-to-weightratio, hightensilestrength(upto572MPainT6temper),and decent fatigue resistance. Although Al7075 exhibits corrosionresistance,anditcanbefurtherenhancedwith

protective treatments, that is not where it shines [7]. Al7075hasgoodmachinabilityandcanbemanufactured inavarietyofways.

2. LITERATURE REVIEW

The literature review highlights previous research on Al7075 alloy and CNT-reinforced nanocomposites, focusing on synthesis methods, properties, challenges, andadvancementsinmaterialperformance.

Cardoso-Lozano et al. (2022) studied Al7075 compositesreinforcedwithAl2O3andCNTs,producedby mechanical alloying, and found that al7075 properties liketensilestrength,hardnessandwear,wereimproved with the incorporation of CNTs[8]. Scanning electron microscope (SEM) micrographs showed a homogenous dispersion of the CNTs which improved the mechanical properties of the composites and proved to be successfullyusedasareinforcementforaluminumalloys, but the authors reported challenges to using CNTs includingCNTagglomeration. Gutema et al. (2025) used Al7075 composites with MWCNTs to evaluate hardness and wear resistance. Composites with MWCNTs (0.5%, 1.0%,and1.5%)wereproducedbypowdermetallurgyat various compacting pressures and sintering temperatures[9].RSM and MOGA were usedto optimize the parameters in this study. Increasing compacting pressureresultedinimprovedhardnessandlowerwear; increasingMWCNTcontentimprovedhardnessbutwore atafasterrate.TheuseofMOGAprovidedthemaximum parameter processing conditions that would lead to the best properties. Imanian Ghazanlou & Eghbali (2021) studied the performance of graphene nanoplates (GNP) and carbon nanotubes (CNT) in the Al7075 alloy by introducing GNP and CNT in the Al7075 matrix by stir casting[10]. The results showed that the porosity of the compositeincreasedwithanincreaseinvolumefraction ofreinforcements.X-raydiffractionconfirmedthechange in the crystal orientation of the matrix, as the preferred orientation changed from (002) to (111) as a result of adding reinforcements. The FESEM images also showed theclustereddistributionofreinforcements.Theaddition of 0.52 vol% of GNP resulted in an increase in the hardness of the composite by 44%, ultimate tensile strength by 32%, and uniform elongation by 180%. Conversely, the addition of 0.71 vol% of CNT increased the hardness by 108%, tensile strength by 129%, and elongationby260%. Raja et al. (2022) investigatedused the stir casting method to fabricate Al7075 composites reinforced with boron carbide (B4C), molybdenum disulphide (MoS2), and multi-walled carbon nanotubes (MWCNTs)[11]. The results quantum from the experiment showed that the addition of the reinforcementscontributedtoimprovementofhardness, tensile strength and wear during the composite processing.IncomparisontospecimenCwhichcontained the highest amount of B4C as it's additive, specimen B,

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which was a 50-50 mix equal composition of MoS2 and B4C,containedthehighesthardnessmeasure.Thetensile strength and impact energy measured were the highest for specimen C due to it's contents having a higher B4C amount. MoS2 acted as a solid lubricant reducing the coefficient of friction and improving the tribological characterofthematerials.Thewearlossperformanceof specimen A containing the highest amount of MoS2 compared to B and C indicated that low wear loss occurred. Nurguzhin et al. (2025) summarized the fabrication techniques and properties of Al-CNT composites,whicharebecomingpopularbecauseoftheir excellent mechanical, thermal and electrical properties[12]. The summary explains the different processing methods, such as powder metallurgy, spark plasma sintering (SPS), and diffusion bonding, and how they affect the dispersion of CNTs, quality of interfacial bonding, and properties of the Al-CNT composites. The summary states that issues such as CNT agglomeration and the presence of interfacial reactions will negatively impact the strength and toughness of the composites. Examples of possible solutions being surface modifications of the CNTs or using advanced processing methods which can improve the performance of Al-CNT composites,andprovideashortertimescaletoend-stage preparation. Finally, the summary recommends future research directions that may lower challenges and improve the industrial viability of Al-CNT composites to aerospace,automotive,andelectronicsindustries. Rajj et al. (2024) investigated the properties of Al7075 hybrid compositeswithdifferenttypesofnano-sizedAl2O3and nanographite(Gr).Basedontheirresults,thenano-Al2O3 resultedinhardnessandtensile strength improvements overothercompositesamples,whilenano-Grhadslightly lowerstrengthbutanincreasedwearresistance[13].Ice water quenching of Al7075 was found to have better mechanical properties than conventional water quenching.Icewaterquenchingproducedmoreuniform distribution of the nano-sized particles which aided the overall mechanical properties of the hybrid composite. These improvements are particularly beneficial for automotiveandotheraerospace-industries.

Dr. Nataraja M M et al. (2020) examinedthemechanical properties of Al7075 hybrid composites reinforced with CarbonNanotubes(CNTs)andZirconiumDioxide(ZrO2) using the stir casting method[14]. It was found out that with increasing reinforcement content (0.25%, 0.5%, 0.75%,1%)ofCNTandZrO2,therewasacorresponding increase in tensile strength, compression strength and hardness compared to the base Al7075 alloy. They reported that tensile strength increased significantly 111.56% with the addition of 1% CNT and ZrO2 hybrid reinforcement. The compression strength increased 11.53% and hardness increased 20.49% too. These results demonstrate that the mechanical properties of Al7075are improved with CNTandZrO2 reinforcement and it could be a good candidate for aerospace and automotive applications. Arsun et al. (2021) Studied

Al7075 composites reinforced with hydrothermally synthesized carbon (HTC) made from cellulose using powder metallurgy. Investigated the effect of different HTC contents (0.25, 0.50, and 1.00 wt.%) on the tensile, compressive, wear, and corrosion properties of Al7075[15]. In general terms, the HTC reinforcements improvedthetensilestrength,compressivestrengthand hardness.Theincreaseinwearandcorrosionresistance of the composites was also attributed to the uniform distributionoftheHTCs.HTCrepresentsaninexpensive and environmentally friendly type of reinforcement in aluminum matrix composites. Koria et al. (2023) examined the reinforcement of Al7075 aluminum alloy with micro and nano materials in metal matrix composites (MMCs)[16]. The authors stated Al7075 MMCs exhibited better mechanical properties with reinforcements such as SiC, Al2O3, and B4C. It is important to note that MMCs would be used in aerospace/automotive/defense because of the strengthto-weight ratio, wear resistance, and thermal stability. The authors described processing methods, such as stir casting, and described an eco-friendly way of adding reinforcements. Furthermore, adding nano materials, including carbon nanotubes (CNTs) and graphene, improved Al7075 properties like hardness, tensile strength, and fracture toughness, while the authors mentioned the agitation of particles and processes still neededtoberefined.

2.1 Research Gap

Afterextensiveliteratureobservedwefoundthisgaps

1. Uniform CNT dispersion in Al7075 matrix remainshighlychallenging.

2. Weak CNT–matrix interfacial bonding limits effectiveloadtransfer.

3. Current fabrication methods are costly and lack industrialscalability.

4. Fatigue and thermal stability studies at high temperaturesareinsufficient.

3. PROCESSING TECHNIQUES

ThefabricationofCNT-reinforcedA356nanocomposites presents significant challenges, particularly in achieving uniformdispersionofCNTsinthealuminummatrixand ensuring strong interfacial bonding between CNTs and the matrix [17,18]. Over the years, various processing techniqueshavebeendevelopedandrefinedtoovercome these challenges, each offering specific advantages and limitations.

Stir Casting: This widely employed technique involves the mechanical stirring of CNTs into molten A356 alloy [19,20,21]. It is preferred for its simplicity and costeffectiveness, making it suitable for both research and industrial applications. However, the primary drawback

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remainsnon-uniformCNTdispersionandthetendencyof CNTstoagglomerate.

Compocasting: A semi-solid processing technique that provides better control over CNT distribution and porosityreductioncomparedtoconventionalstircasting [22].Here,CNTsareincorporatedintoasemi-solidA356 slurry, leading to improved dispersion and reduced agglomerationcomparedtofullyliquid-statemethods.

Powder Metallurgy: This approach involves blending A356 powders with CNTs, followed by compaction and sintering [23,24]. Powder metallurgy ensures enhanced control over the microstructure and enables more homogeneousCNTdistribution.However,itismoretimeconsumingandcostlycomparedtoliquid-basedmethods.

Friction Stir Processing (FSP): A solid-state technique utilizingfrictionalheatandsevereplasticdeformationto disperse CNTs and refine the matrix [25]. FSP results in superior dispersion and interfacial bonding but is generally limited to surface modifications rather than bulkproduction.

Squeeze Casting: In this method, the molten A356-CNT mixtureissolidifiedunderhighpressure,whichimproves densification and reduces porosity [26]. Moreover, squeeze casting strengthens CNT–matrix interfacial bonding,thusenhancingmechanicalproperties.

Despite these advancements, the challenges of CNT agglomerationandweakbondingremaincritical.Recent researchemphasizesoptimizationofparameterssuchas stirringspeed,holdingtemperature,andsolidfractionto improvecompositequality[27].

4. CHARACTERIZATION TECHNIQUES

To evaluate the structure and performance of CNTreinforced A356 nanocomposites, various characterizationmethodsareemployed.

Microscopy Techniques: Optical microscopy, SEM, and TEM are used to study CNT dispersion, matrix microstructure,andCNT–matrixinterfacialbonding[28].

X-ray Diffraction (XRD): XRD helps identify crystalline phases,CNTstability,andreactionproductssuchasAl₄C₃ formedduringprocessing[29].

Mechanical Testing: Standardizedtensile,hardness,and weartestsarecarriedouttoassessmechanicalreliability andensurecomparabilityacrossstudies[30].

5. MECHANICAL PROPERTIES

Incorporating CNTs into A356 alloy significantly enhances its mechanical performance [31,32,33]. The

improvementismainlyduetotheinherenthighstrength and stiffness of CNTs, as well as their ability to impede dislocationmotionwithinthematrix.

Tensile and Yield Strength: CNTs act as effective reinforcements, facilitating load transfer and improving strength[34,35].Forexample,a34%increaseinultimate tensile strength was achieved with 1.5 wt% MWCNTs using semi-solid stir casting [36]. Similarly, rheocasting andsqueezecastingreportednearly50%improvements atthesameCNTcontent[37].

Hardness: CNT reinforcement improves hardness by increasing dislocation density and contributing to the formation of hard interfacial phases [38,39]. Studies observedmaximumhardnessatoptimizedsolidfractions duringcompocasting[40].

Wear Resistance: The wear performance of A356 is significantly enhanced by CNTs due to their selflubricatingproperties,whichreducefrictionandprotect thesurface[41,42].Thedegreeofimprovementdepends onCNTdispersion,appliedload,andslidingspeed.

Overall, optimum enhancements are usually achieved at lower CNT contents (<2 wt%), as higher concentrations often result in agglomeration, thereby reducing the effectivenessofreinforcement[43].

6. CONCLUSION

The integration of carbon nanotubes into Al7075 aluminiumalloyhasemergedasapromisingapproachto overcome the inherent limitations of the base alloy and develop advanced nanocomposites with superior performance. CNTs, with their remarkable strength, thermal conductivity, and low density, significantly improvemechanical,thermal,andtribologicalproperties when effectively dispersed within the Al7075 matrix. Research has shown notable enhancements in wear resistance, fatigue performance, and overall durability, making these composites suitable for demanding applications in aerospace, automotive, and structural engineering. However, challenges such as poor wettability,agglomeration,andweakinterfacialbonding betweenCNTsandaluminiumremaincriticalissuesthat limitlarge-scaleindustrialapplication.Continuousefforts in optimizing fabrication methods, surface modification techniques, and dispersion strategies are essential for realizing the full potential of these composites. Overall, CNT-reinforcedAl7075nanocompositesrepresentavital step toward developing next-generation lightweight, high-performance materials for advanced engineering applications.

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