International Research Journal of Engineering and Technology (IRJET) e-ISSN:2395-0056
Volume: 12 Issue: 02 | Feb 2025 www.irjet.net p-ISSN:2395-0072
REVIEW ON DESIGN AND FABRICATION OF CNT REINFORCED A356 NANOCOMPOSITES
Atharv Gajanan Kulkarni1 , Bhagyashri Sagar Kamble2 , Akash Bhimashankar Koli3 , Pradip Narayan
Sabale4 , Umar Bashalal Sharikmaslat5 , Saipratik Dhanpal Admuthe6 .
1,2,3,4,5Students, Department of Mechanical Engineering Sanjay Bhokare Group of Institutes Miraj, India
6 Lecturer, Department of Mechanical Engineering Sanjay Bhokare Group of Institutes Miraj, India
Abstract:
This research explores the enhancement of A356 aluminum alloy properties through carbon nanotube (CNT) reinforcement, targeting improved performance in aerospace, automotive, and electronics applications. While A356 is favored for its castability and corrosion resistance, its inherent limitations in strength and hardness can be mitigated by incorporating CNTs, known for their exceptional strength and lightweight characteristics. A reviewofrecentliteraturerevealssignificantenhancements in tensile strength, hardness, and wear resistance in CNTreinforcedA356compositesachievedviavariousfabrication methods, notably stir casting and compocasting. Despite these improvements, challenges such as CNT agglomeration and poor interfacial bonding remain, hindering uniform dispersionandconsistentperformance.Thisstudyfocuseson optimizing the stir casting process to improve CNT dispersion in A356, thereby maximizing mechanical property enhancements. The results demonstrate notable gains in strength, hardness, and wear resistance, underscoring the potential of CNT reinforcement for highstress applications. Further research is essential to refine processing techniques and ensure uniformity, paving the way for broader industrial adoption of these highperformancematerials.
Introduction:
High-performance applications in modern manufacturing require materials with exceptional strength-to-weight ratios and superior mechanical qualities. A356 aluminum alloy, frequently employed in aerospace, automotive, and electronics fields, boasts favorable castability and corrosion resistance. However, its relatively modest strength and hardness constrain its utilization in highstress environments. Carbon nanotubes (CNTs), recognized for their extraordinary strength, stiffness, and minimal weight, present an optimal solution for reinforcing A356 alloy and enhancing its mechanical properties. This investigation examines the influence of
CNT reinforcement on the microstructure and mechanical characteristicsofA356nanocomposites.
Literature review
Abbasipour et al. (2019) [1] The study examined the wear and friction characteristics of A356 aluminum alloy nanocomposites strengthened with carbon nanotubes (CNTs) and produced using various casting techniques. The research compared traditional liquid casting (stir casting) with semi-solid methods (compocasting and rheocasting), revealing that CNT addition significantly decreased wear loss, wear rate, and friction coefficient in the composite materials. Notably, compocasting improved CNT distribution and reduced void formation, leading to superior wear resistance. The primary wear mechanism differed depending on the manufacturing method: abrasion was predominant in nanocomposites, while adhesion and delamination were observed in monolithic samples.TheresultshighlighttheimportanceofCNTsand semi-solid casting processes in improving the tribological propertiesofaluminum-basedcomposites.
Carneiro & Simões, (2022) [2] This research examines the mechanical characteristics of aluminum/carbon nanotube (Al/CNT) nanocomposites fabricated through powdermetallurgytechniques.Thefocusisondeveloping lightweight, high-strength materials for potential use in automotive and aerospace sectors. Previous studies indicatethatproperlydispersedCNTscanimprovetensile strength and elasticity, although CNT clustering may reduce material ductility. In this investigation, ultrasonication was employed to disperse CNTs, resulting in a 185% enhancement in yield strength, which was attributed to load transfer mechanisms. However, the presence of CNT clusters at grain boundaries led to a decreaseinductility.
El Shalakany et al. (2018b) [3] investigatedtheeffectsof multi-walled carbon nanotubes (MWCNTs) on the mechanical and tribological properties of A356 aluminum
International Research Journal of Engineering and Technology (IRJET) e-ISSN:2395-0056
Volume: 12 Issue: 02 | Feb 2025 www.irjet.net p-ISSN:2395-0072
alloy nanocomposites. The composites, containing varying MWCNT content (0.5, 1.5, and 2.5 wt.%), were fabricated using a combination of rheocasting and squeeze casting techniques.Thestudyfocusedonmicrostructuralchanges, wear behavior, and friction coefficients under dry sliding conditions. The results highlighted that the addition of MWCNTs improved grain refinement, hardness, and mechanical properties, with optimal results observed at 1.5wt.%MWCNTs.Beyondthiscontent,agglomerationled to brittleness and a decline in mechanical performance. Wear testing showed significant improvements in wear resistanceduetotheformationofatribolayerandtheselflubricating effects of carbon. The coefficient of friction decreased with higher MWCNT content, sliding velocity, and applied load, attributed to enhanced dispersion and the formation of protective layers. The study concluded that A356/MWCNT nanocomposites exhibit improved wear resistanceandmechanical properties,particularlyat 1.5 wt.% MWCNTs. These findings demonstrate the potential of these nanocomposites for lightweight applications requiring moderate strength and wear resistance.
Kim et al. (2013) [4] investigatedthefabricationofA356 aluminum alloy hybrid composites reinforced with MWCNTs and Al₂O₃ short fibers using the infiltration method. The study addressed CNT dispersion challenges and demonstrated that hybrid preforms improved reinforcement distribution and mechanical properties. While increasing Al₂O₃ volume enhanced compressive strength, excessive CNTs caused agglomeration and reduced ductility. Microstructural analysis revealed wellintegrated reinforcements supported by Al₂O₃sf. Mechanical tests showed improved high-temperature compression and hardness compared to monolithic A356, with plasma surface modifications suggested for further enhancement. The research highlights hybrid preforms as effectiveforlightweight,high-strengthapplications.
Logesh et al., (2019) [5] This research investigates how Aluminium Nitride (AlN), Multi-Walled Carbon Nanotube (MWCNT), and Graphite additives affect the mechanical characteristics of A356 aluminium alloy. The fabrication processemploysstircastingwithultrasonicvibration.The combination of these reinforcements enhances the alloy's strength, ductility, and fracture resistance through mechanisms such as particle strengthening and crackbridging. The study identifies optimal reinforcement volumes (1% MWCNT, 0.75% AlN), noting that higher quantitiesresultinclusteringanddecreasedperformance. Variousmanufacturingmethods,includingfrictionstirand squeezecasting,arerecognizedfortheirabilitytoprevent
reinforcement agglomeration and improve particle distributionwithinthematrix.
Sajjadi et al. (2011) [6] examinesthemicrostructuraland mechanical enhancements in A356 aluminum alloy compositesreinforcedwithalumina(Al2O3)particles.The study compares stir-casting and compo-casting techniques. Findings indicate that compo-casting, which operates at semi-solid temperatures, provides better particle distribution, lower porosity, and superior mechanical properties compared to stir-casting. Nanosized Al2O3 particles significantly contribute to yield strength,hardness,andtensilestrengththroughprocesses such as Orowan strengthening and grain refinement. The optimal reinforcement is achieved at 3 wt.% nano-Al2O3, with higher concentrations leading to particle agglomerationandreducedductility.
Hadad et al. (2020) [7] examined the influence of graphene nanoplates (GNPs) and carbon nanotubes (CNTs) as reinforcements in A356 aluminum alloy nanocomposites fabricated via stir casting. Reinforcement contents of 0.01, 0.05, and 0.1 wt.% were tested, with optimized parametersof500rpmstirringspeedat740°C. The study reported that both reinforcements significantly improved mechanical properties, with maximum tensile strength and hardness achieved at 0.1 wt.% CNTs, increasingby28%and33%,respectively,comparedtothe base alloy. GNPs demonstrated superior strength enhancements due to their larger volume fraction and greaterimpactondislocationmovement.Compressionand impact energy also improved, with CNTs showing higher compression strength while GNPs enhanced tensile properties more effectively. Microstructural analysis revealed uniform reinforcement distribution and refined grains,contributing to enhanced mechanical performance. The study underscores the potential of both reinforcements for advanced lightweight applications in automotiveandaerospaceindustries
Ujah et al. (2023) [8] incorporating carbon nanotubes (CNTs) as reinforcing agents in nano-composites substantiallyimprovestribological characteristics,suchas increased wear resistance and reduced coefficient of friction (COF). These enhancements are observed across metal,polymer,andceramicmatrixcomposites,stemming from the unique mechanical and thermal properties of CNTs. To prevent CNT clustering, which can negatively impact performance, effective dispersion methods like ultrasonication and functionalization are essential. Strengthening mechanisms, including load transfer and thermal mismatch, further bolster composites, making CNT-reinforced materials suitable for challenging
International Research Journal of Engineering and Technology (IRJET) e-ISSN:2395-0056
Volume: 12 Issue: 02 | Feb 2025 www.irjet.net
applications in aerospace, automotive, and high-wear industrialenvironments.
Yan and Qiu (2016) [9] examined current studies on enhancing aluminum alloy composites with carbon nanotubes (CNTs) to boost mechanical properties, highlighting challenges such as agglomeration and poor wettability with aluminum melts. Prior research indicates that CNTs enhance strength and hardness in metal matrices,although dispersionissuespersist.Totacklethis problem, the researchers employed an Al-CNT master nanocomposite to enhance CNT dispersion in A356 aluminum alloy, promoting the formation of aluminum carbide (Al4C3), which improved CNT wettability. Their results verified that the enhanced dispersion and bonding contributed to microstructure refinement and increased mechanicalstrengthinthecomposites.
Research Gap:
Despite advancements in CNT-reinforced A356 nanocomposites, key research gaps remain. Optimal CNT content for balancing strength, ductility, and wear resistance is still unclear, with inconsistencies across studies. Challenges in CNT dispersion and functionalization persist, requiring improved techniques for uniform distribution. While semi-solid and hybrid reinforcementmethodsshowpromise,stircastingremains the most practical and scalable technique, but further optimization is needed to enhance CNT dispersion and minimize porosity. Tribological performance under diverse conditions, long-term stability, and large-scale manufacturing feasibility remain underexplored. Addressing these gaps will enhance the industrial applicability of CNT-reinforced A356 composites in highperformancesectors.
Conclusion:
The incorporation of CNTs into A356 aluminum alloy significantlyenhancesitsmechanical properties,including strength,hardness,andwearresistance.Thedispersionof CNTs improves load transfer, resulting in superior performance under high-stress conditions. Additionally, the composite demonstrates better thermal stability, making it suitable for high-temperature applications. Whilethematerialshowsgreatpotentialforindustrieslike automotiveandaerospace, challengesremain inachieving uniform CNT distribution and optimizing processing techniques. Future research should focus on refining fabrication methods to fully exploit the benefits of CNT reinforcementinA356alloy.
Reference
p-ISSN:2395-0072
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