Al Matrix Nano Composites Reviewed

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 6, Issue 1, January (2015), pp. 01-19 © IAEME
1
ANALYSIS OF MECHANICAL AND MICRO
STRUCTURAL BEHAVIOUR OF AL BASED METAL
MATRIX COMPOSITE REINFORCED WITH BALL
MILLED NANO PARTICLES: A REVIEW
Amit Raturi1
, Anil Dhanola2
, Dr. K. K. S. Mer3
, Pradeep Kothiyal4
1, 2
M.Tech scholar, Department of Mechanical Engineering,
G.B.Pant Engineering College, Pauri Garhwal
3
Associate Prof., Department of Mechanical Engineering,
4
Ph.D scholar, Department of Mechanical Engineering,
ABSTRACT
In recent years Metal matrix composites have been considered as one of the most important
materials which offer excellent wear resistance and stiffness, low weight, economic and high
strength to weight ratio. Metal matrix composites (MMCs) reinforced with ball milled nano particles
,also called metal matrix –nano composite, are spreading rapidly in worldwide due to their various
demands in the field of engineering and science like automobiles, aerospace, energy, defence,
materials, electronics and bio technology. Ball milling is a technique of production of nano particles
and can enhance the base material in terms of damping properties, mechanical strength, wear
resistance and prevent from clustering. Reinforcement of ball milled nano particles with aluminium
metal matrix yields excellent physical and mechanical properties. This review reveals that various
fabrication techniques are recently used for the production of Al based MMC such as powder
metallurgy, high energy ball milling, ultrasonic assisted casting, stir casting, compo casting. The
microstructure and mechanical properties of the composite were evaluated by X-ray diffraction
(XRD), scanning electron microscopy (SEM).
Key Words: Aluminium Metal Matrix, Ball Milled Nano Particles, Mechanical Properties,
Microstructure.
INTERNATIONAL JOURNAL OF MECHANICAL ENGINEERING AND
TECHNOLOGY (IJMET)
ISSN 0976 – 6340 (Print)
ISSN 0976 – 6359 (Online)
Volume 6, Issue 1, January (2015), pp. 01-19
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1. INTRODUCTION
Composite materials are the materials in which the desirable properties of different materials
are combined to form a single material system. Composite material is a combination or mixture of
two or more materials. The composite material is usually better than its individual elements or
components as regards their properties or characteristics such as stiffness and strength etc.
[G.R.Nagpal, material science khanna book publication, (2000)]. Composite posses excellent
stiffness and strength, high strength to weight ratio (high tensile strength, low density), high creep
resistance, high tensile strength, high toughness, low in weight. Among different composites, metal
matrix composite are promising new materials for recent engineering application having high
specific strength, stiffness and their high temperature stability and widely used in bio-medical,
aerospace and automotive industries. [Dandekar CR, et.al. (2011)].
Metal matrix composite is the engineered combination or mixture of a metal as a matrix and
some reinforcing material in the matrix. The matrix material can be aluminum, nickel, titanium,
super alloy, copper, magnesium and the reinforcing fiber may be graphite, alumina, silicon carbide,
and silicon nitride or boron carbide as well as wires of tungsten, titanium, molybedenum, beryllium
and stainless steel. [Degarmo et.al. (2006)]. In Aluminium matrix composite (AMC) the matrix
phase is of pure aluminium or an alloy of it and the reinforcement used is a non-metallic ceramic
such as Sic, Al2O3, SiO2, B4C, Al-N. Commercial aluminium matrix composite posses much higher
specific strength, good corrosion resistance, high damping capacity, good thermal and electrical
conductivities. Aluminium matrix composite have been tested and proved useful in different
engineering sector including structural and functional application. The main limitation of these type
of composite high production cost, complex fabrication technique for fiber-reinforced system.
[Himanshu kala, et.al. (ICMP 2014)]. Generally MMC can be classified into four types- (1) Particle
reinforced MMC. (2) Laminated MMC. (3) Fibre-reinforced composite. (4) Whisker-reinforced
MMC. [Krieder K.G., MMC, (Academic Press Inc, USA.)]
Aluminium Metal matrix composites reinforced with ball milled (nano particle), also called
metal matrix nano-composite, are being investigated in recent years, due to their promising
properties suitable for large number of structural and functional application.[Zhang, et.al.(A2008)]-
[Zhang, et.al.(Scripta Mater.2006)]. Ball milling technique can be successfully used for converting
the reinforcing particle into nano materials and improve the base material in terms of damping
properties, mechanical strength and wear resistance by distributing the ball milled reinforced particle
uniformly. Particulate reinforced aluminium metal matrix composite is recently used due to their cost
effective and isotropic properties and researchers are working on this field. The availability of a large
variety of reinforcing particle and the development of recently processing methods like high energy
ball milling, powder metallurgy, friction stir casting, and ultrasonic assisted casting are recently
being used for the production of Aluminium matrix nano composite. This paper reviews recent
studies on mechanical properties, processing and microstructure of aluminium- matrix composite
reinforced with ball milled nano particles.
2. PROCESSING TECHNIQUES OF ALUMINIUM MATRIX COMPOSITE
The processing techniques of Al matrix composite can be categorized into two main groups
(a) Liquid State processes: This process include Stir casting, compo casting, ultrasonic assisted
casting, squeeze casting, and spray casting.
(b) Solid state processes: This process include powder blending followed by consolidation (powder
metallurgy), high energy ball milling, diffusion bonding, and friction stir process.

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976
ISSN 0976 – 6359(Online), Volume
2.1 Stir casting: In a stir casting process particulate reinforcement (usually in powder form) are
distributed into molten Al matrix by mechanical stirring.
S.Ray. S.Ray. (1968) introduced alumina particle into a
Mechanical stirring in furnace is the key element of this process.
Su et al. (2012) designed a new three step stir casting method for fabrication of nano particle
reinforced composite. First the reinforcement and Al particles are mixed
initial clustering of nano particles. The composite powder is then incorporated into the melt with
along with mechanical stirring. After adequate stirring the composite slurry is sonicated using an
ultrasonic probe or transducer in order to improve the distribution of
Hamid Reza Ezatpour et
casting process through injection of Al
stirring using a mechanical stirrer and fabrication of nano composites with reasonable distribution of
Al2O3 in the matrix alloy with low agglomeration and low porosity.
Abhishek Kumar et al. (2013) used a 3 phase induction motor for electromagnetically stirring
the aluminium melt and showed improvement in particle matrix interface bonding with a small grain
size structure.
A recent development in stir c
process. In this technique, initially
The melt is then cooled down to a temperature between the liquidus and solidus points to a semi
solid state. At this point the preheat
is heated to a fully liquid state and mixed thoroughly. In double stir casting
microstructure has been found to be more uniform as compared with conventional stirring. The
potency of this two-step mixing method is mainly due to its ability to break the gas layer around the
particle surface which otherwise impedes wetti
mixing of the particles in the semi
action due to the high melt viscosity.
low cost, simple and applicable to mass production of MMC.
2.2 Compo Casting: stir casting is one of the best
however it suffers from poor distribution and incorporation of the reinforcement particles in the Al
matrix due to which wettability is reduced of the particles with melt. To
problems development of recent techniques for addition of
melt which showed that better incorporation and uniform distribution of reinforcement particle into
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976
6359(Online), Volume 6, Issue 1, January (2015), pp. 01-19 © IAEME
3
In a stir casting process particulate reinforcement (usually in powder form) are
distributed into molten Al matrix by mechanical stirring. This process was initiated in 1968 by
roduced alumina particle into a molten Al matrix by mec
Mechanical stirring in furnace is the key element of this process.
2012) designed a new three step stir casting method for fabrication of nano particle
reinforced composite. First the reinforcement and Al particles are mixed using ball mills to break the
er in order to improve the distribution of reinforced particles.
et al. (2013) Al6061/nano Al2O3 composites were fabricated by stir
casting process through injection of Al2O3 particles into the molten Al alloy by argon gas along with
in the matrix alloy with low agglomeration and low porosity.
013) used a 3 phase induction motor for electromagnetically stirring
A recent development in stir casting technique is a double stir casting
technique, initially the matrix material is heated to above its liquidu
The melt is then cooled down to a temperature between the liquidus and solidus points to a semi
solid state. At this point the preheated reinforcement particles are mixed and added
is heated to a fully liquid state and mixed thoroughly. In double stir casting technique
step mixing method is mainly due to its ability to break the gas layer around the
particle surface which otherwise impedes wetting between the particles and molten metal. Thus the
mixing of the particles in the semi-solid state helps to break the gas layer because of the abrasive
action due to the high melt viscosity. The major characteristics of stir casting process are relatively
low cost, simple and applicable to mass production of MMC.
Fig.1 process of stir casting
stir casting is one of the best technique of producing Al matrix composite
matrix due to which wettability is reduced of the particles with melt. To overcome these
pment of recent techniques for addition of milled particles (powder form) to metallic
© IAEME
In a stir casting process particulate reinforcement (usually in powder form) are
This process was initiated in 1968 by
molten Al matrix by mechanical stirring.
2012) designed a new three step stir casting method for fabrication of nano particle
using ball mills to break the
reinforced particles.
composites were fabricated by stir
particles into the molten Al alloy by argon gas along with
013) used a 3 phase induction motor for electromagnetically stirring
is a double stir casting or two-step mixing
l is heated to above its liquidus temperature.
The melt is then cooled down to a temperature between the liquidus and solidus points to a semi-
added. Again the slurry
technique the resulting
step mixing method is mainly due to its ability to break the gas layer around the
ng between the particles and molten metal. Thus the
solid state helps to break the gas layer because of the abrasive
of stir casting process are relatively
of producing Al matrix composite
overcome these type of
milled particles (powder form) to metallic

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matrix. Compo casting is a liquid state process in which reinforcement particles are added to
solidifying melt while being vigorously agitated. [Flemings M C. (Metallurgical transactions, 1991)].
This technique will result in better distribution of reinforcement particles and low volume shrinkage
of metal matrix alloy.
Fig.2 Process of compo casting
2.3 Squeeze casting: This process was introduced in the United States in 1960. Squeeze casting,
also known as liquid metal forging, is a combination of casting and forging process. The molten
metal is poured into the bottom half of the pre-heated die. As the metal starts solidifying, the upper
half closes the die and applies pressure during the solidification process. The applied pressure and
instantaneous contact of molten metal with die surface produces rapid heat transfer that yields a
porous free casting.
The squeeze casting process has been widely used to produce quality castings and offers
excellent surface finish, high metal yield, minimum shrinkage, porosity and low operating cost.
Aluminum, magnesium, and copper alloy components are readily manufactured using this
process. Squeeze casting is capable of producing light weight, high integrity automotive component
such as engine block, brake disc, piston etc. [R.S.Rana et al. (IJSER 2012)].
Fig.3 Process of squeeze casting [http://www.substech.com]

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2.4 Powder Metallurgy: Powder metallurgy is the technique of blending fine powders of metals or
ceramic materials, pressing them into a desired shape and then heating the compressed material in a
controlled atmosphere to bond the material (sintering). Ball milling technique can be used to achieve
mechanical alloying of powder mixtures for enhances the mechanical properties. Powder metallurgy
is the most economical technique for fabrication of Al MMCs and can prevent from agglomeration
and segregation of the reinforcing particles. In powder metallurgy homogeneity of mixture is better
controlled, component is produced with good dimensional stability, good ductility and provides a
better blend homogeneity.
Certain metals that are difficult to manufacture by other technique can be shaped by powder
metallurgy such as tungsten filaments for incandescent, lamp bulbs, oil-impregnated bearings, gears
and filters. [John Wiley & Sons, Inc. (M. P. Groover2002)].
Fig.4 Process of powder metallurgy. [R.S.Rana et al. (IJSER2012)]
2.5 High energy ball milling: High energy ball milling technique which is used to produce various
nanocrystal powders in high energy planetary, vibratory mills and ball. This technique is used
producing metallic and ceramic nano materials. Ball mill is a type of grinder which is used in mixing
materials like ceramic, ores, paints, and chemical. These balls rotate around a horizontal axis. These
balls can be made from ceramic, stainless steel, silicon carbide. Ball mills are widely used in
mechanical alloying. [Florez-Zamora et.al (2008)]. Mechanical alloying could successfully to
produce uniform distribution of oxide particles (Al2O3) and fine particles. It has several advantages
such as cost effective, grinding medium and power is low. Suitable for continuous and batch
production. Uniform distribution of narrow particle which improves mixing of sample. Ball milling
technique is used for nano grinding, mechanical alloying, homogenizing, size reduction and colloidal
milling. It has several applications in the field of engineering and science such as agriculture,
chemistry, metallurgy, ceramics, medicine, pharmaceuticals, and construction materials.
[www.restech.com]

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Fig.5 Process of motion of the balls and powder mixture and set up of ball milling. [http://al-
chemist.info/node/10].
3. COMPRASION OF DIFFERENT PROCESSING TECHNIQUE
Table 1. Comparison of various processing technique
Process Advantages Limitations
Stir casting
Stir casting is one of the most economical
techniques of processing Al MMC. The
major advantages of stir casting process are
its applicability to mass production, easier
control of matrix structure, simplicity and
good matrix-particle bonding.
Difficulties with geometry of
mechanical stirrer and position
of stirrer in melt. It is difficult
to distribute and dispersion of
ball milled nano particles
uniformly in metal melts.
Compo casting
This technique will result in better
distribution of reinforcement particles and
low volume shrinkage of metal matrix
alloy. In the compo castings has been
attributed to the better wettability between
the matrix and the reinforcement particles.
Costly than the stir casting
Squeeze casting
The major advantages of squeeze casting
process are to produce quality castings and
offers excellent surface finish, high metal
yield, minimum shrinkage and porosity.
High tooling and equipment
cost.
Powder Metallurgy
Powder metallurgy is the most economical
technique for fabrication of Al MMCs and
can prevent from agglomeration and
segregation of the reinforcing particles and
component is produced with good
dimensional stability, good ductility and
provides a better blend homogeneity.
In processing technique of
Hydroxide and Aluminium
oxide films coating the
powder.[Dinesh Kumar koli et
al.(ICMPC2014)]
High energy ball
milling
Ball milling technique can be used to
achieve mechanical alloying of powder
mixtures for enhances the mechanical
properties. It has several advantages such as
cost effective, grinding medium and power
is low.
Ball milling technique produce
crystal defects and shape of
nano material can be irregular.

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4. MECHANICAL PROPERTIES
The mechanical properties of a Metal matrix composite depend on many factors such type of
reinforcement, shape, size, quantity of reinforcement etc. The actual knowledge of the mechanical
behaviour is thus necessary as they are employed in different fields.
Ruixiao Zheng et al. (2013) evaluated the mechanical properties of Al-2024 matrix composite
were fabricated by using powder metallurgy method. To evaluate the mechanical properties of the
composites, compression tests were conducted at room temperature under uniaxial compressive
loading and the stress–strain curves are shown in (Fig.6.) Shown that, the compression strength value
of MMCs is significantly higher than that of the matrix alloy, suggesting that the Fe based metallic
glass particle (FMG) can strongly enhance the mechanical strength of the Al matrix. In particular,
MMCs exhibit yield strength of about 403 MPa and fracture strength of about 660 MPa combined
with an appreciable plastic strain at fracture of about 12%. Metallic glass particles significantly
improve the mechanical behaviour of the MMCs.
Fig.6 Stress strain curve of the composite and the Al-2024 alloy prepared by milled powder and as
atomized powder. [Ruixiao Zheng et al. (2013)]
Hamid Reza Ezatpour et al.(2014) Fabricated Al6061/nano Al2O3 composite by stir casting
process through injection of Al2O3 particle into the molten Al alloy by argon gas along with stirring
by the help of mechanical stirrer. The mechanical properties of Al6061 were investigated. To
investigate the mechanical behaviour of the composites the tensile tests were carried out using Zwick
760 testing machine according to ASTM: B557M – 10. The crosshead speed was set at 3 mm/min on
the round specimens. In (Fig.7 a) shown that the influence of nano particle content on hardness
represent in the as –cast state and in the extruded condition. The effect of nanoparticles on the
increasing of hardness mainly due to Hall–Petch mechanism, particle strengthening and grain
refinement. In the as-cast state, hardness increases with increasing reinforcement content up to 1 wt.
% Al2O3 but thereafter the hardness decreases. This is due to the heterogeneous dispersion of
nanoparticles and high porosity content. However, after applying hot extrusion process, hardness of
all samples increases continuously with increasing Al2O3 content. By the help of stress strain curve
the yield stress and tensile strength increase while fracture strain decreases with increasing particle
content. (Fig.7 b) shows the variation of 0.2% yield strength of the composite with different nano-
Al2O3 weight fractions before and after extrusion. It is clear that all composites provide higher
strength than that of the Al alloy in the as-cast and extruded states. This is because of the grain
refinement and particles strengthening.

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Fig.7(a) Hardness variation of composites
with nano Al2O3 Content in as –cast state and
in extruded condition.[Hamid Reza Ezatpour
et al.(2014)]
Fig.7(b). 0.2% variation in yield strength of
the composite with nano Al2O3 Content as-
cast state and in extruded condition.
(Fig.7 b) also shows that in the as-cast state, with increasing Al2O3 particle content up to 1
wt. %, yield strength increase continuously but with more adding of particles, 1.5 wt. %, they
decrease. In fact, hot extrusion process causes uniform dispersion of particles in the matrix, lowering
porosity, and refinement of grain, thus can improve the yield and ultimate strength. [Ezatpour HR et
al. (2013:23:1262-8)]-[Alizadeh A et al.(sci technol 2011:528:8765-71)]
Hai Su et al. (2012) produced Al 2024 composite reinforced with nano Al2O3 particles by the
help of solid-liquid mixed casting combined with ultrasonic treatment. The author observed the
tensile properties of Al 2024. The better tensile properties were attributed to the uniform distribution
of reinforcement and grain refinement of aluminum matrix. (Fig.8) shows the yield strength, ultimate
tensile strength and elongation of as-cast 2024 alloy and nano-Al2O3/2024 composites. At the
optimal amount of nano-Al2O3 particulates (1 wt.%), the ultimate tensile strength and yield strength
of the composite were enhanced by 37% and 81%, respectively, compared with the alloy matrix.
However, with increasing the mass fraction of nanoparticles, the tensile strength of the composites
decreases. It is also found from (Fig.8) that the elongation decreases gradually with increasing the
mass fraction of nanoparticle.
Fig.8. Tensile properties of as-cast 2024 alloy and nano-Al2O3/2024 composite. [Hai Su et al.
(2012)]

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Hwa-Jung Kim et al. (2012) worked on wear properties of recently developed Al-Mg-Si-
CoNi alloy by the addition of ball milled CoNi powders. The wear properties of the Al–Mg–Si–CoNi
alloy have been compared to a commercial A6061 (Al–Mg–Si) alloy under dry sliding conditions.
The Al–Mg–Si–CoNi alloys shows better wear properties than the A6061 alloy for all test conditions
in this investigation. (Fig.9) shows the variation of the wear rate with the applied load for Al–Mg–
Si–CoNi and A6061 alloys. The wear rate increases rapidly with the applied load for the A6061
alloy, whereas the wear rate increases smoothly with an applied load up to 300 N for the as-cast and
T6-treated Al–Mg–Si–CoNi alloys.
Fig.9 Variation of wear rate with applied load for Al6061 alloy and the Al-Mg-Si-CoNi alloy. [Hwa-
Jung Kim et al. (2012)]
K.Kalaiselvan et al. (2011) produced Al (6061-T6)/B4C composite and analysed its
mechanical properties. They observed that the hardness (Fig. 10 a) and the tensile strength (Fig. 10
b) of the composite are linearly increasing with increasing weight percentage of the B4C particulate.
Fig 10 (a) Variation of hardness with Fig 10(b) Variation of UTS with B4C content.
B4C content. [K.Kalaiselvan et al. (2011)] [K.Kalaiselvan et al. (2011)]

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Abhishek Kumar et al. (2013) fabricated A359/ Al2O3 composite by the help of
electromagnetic stir casting technique. The author revealed that the hardness values increased to 72.8
HRC compared to pure alloy (46HRC). Also the tensile strength of the composite increased to
148.7N/mm2
as compared to pure alloy (103.7N/mm2
).
Mahboob et al. (2008) has worked on synthesis of Al- Al2O3 composite by mechanical
alloying and evaluate the effect of ball milling on mechanical properties. Author used commercial Al
powders with particle size smaller than 63 µm and nanosized α-alumina powder with 99.5% purity
and average size of about 27-43 nm have been provided. High energy planetary ball mill with
stainless steel balls with different diameters (8.5-10 mm) were employed. Rotary velocity of the mill
and ball to powder weight ratio were 250 rpm and 15, respectively. The aluminum and 5wt%
alumina nano powders were milled at different times, i.e., 0, 4, 8 and 12 hours. Strength and
hardness were increased by increasing of milling time but the elongation was almost constant. Al-
5%wt. Al2O3 composite strength was appreciably increased by 12 hours milling, due to the uniform
dispersion of nano-size alumina particles.
Tavoosi et al. (2009) fabricated Al–Zn/Al2O3 nanocomposites prepared by reactive milling
and hot Pressing technique and evaluate the hardness. Author has taken a mixture of commercial Al
of 99.7% pure and size of particles (50-70 µm) and 15.8% ZnO powders (99.9% pure and size of
particles 250nm) was milled in planetary ball mill in order to produce Al–13.8 wt%Zn/5 vol%Al2O3
nanocomposites. Rotation of planetary ball mill has been carried out at a speed of 600 rpm and a
ball-powder mass ratio of 15:1. It was found after 60 h milling and hot pressing at 500°C under 400
MPa pressure. The result cleared that the hardness value for Al–13.8 wt%Zn/5vol% Al2O3
nanocomposites (relative density about 99.6% and crystallite size about 40 nm) was about 180 HV
and for Al–13.8 wt%Zn (relative density 99.8% and crystallite size of about 40 nm) was about 150
HV. The variation of hardness vs. annealing time at different temperatures showed that the produced
nanocomposites had a good thermal stability at temperatures below 400°C.
Mazahery et al. (2009) worked on fabrication of A356 alloy matrix composite reinforced with
nano- Al2O3 particles by stir casting. The author has revealed that the values of the yield strength
(Fig.11 a), the ultimate tensile strength (Fig.11 b) of the composite increased with the increase in
volume percentage of the nano particles. Also the hardness (Fig.11 c) of the composite improved
compared to pure alloy.
Fig. 11(a) Variation of yield strength with Fig.11 (b) Variation of UTS with Al2O3 content.
Al2O3 content. [Mazahery et al. (2009)] [Mazahery et al. (2009)]

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Fig.11 (c) Variation of Hardness with Al2O3 content. [Mazahery et al. (2009)]
M. karbalaei Akbari et al. (2014) fabricated Al metal matrix composite (A356 alloy metal
matrix) reinforced with nano-sized aluminum oxide by commercial casting technique and evaluated
wear resistance, hardness, compressive strength. The evaluation of mechanical properties showed
that mechanical properties decrease with increase in porosity content of composite. In his
experimental work nano Al2O3 particles were individually milled with Cu and Al powder and take in
into Al alloy by stir casting technique to fabricate A356/1.5 vol% nano alumina composites.
Hardness, wear resistance and compressive strength enhanced with mixing with nano Al2O3 particles
in A356 as a matrix. The minimum of wear rate and maximum of hardness and compressive strength
were seen in Al2O3-Cu reinforced specimen. Porosity content was the main controller factor, which
affect the mechanical properties of materials manufactured at different stirring time.
M.Hiller et al. (2006) analysed the mechanical properties and compared with that non
reinforcement Al. AA6061 aluminium powder and nano sized powder were mechanically alloyed
with ball milling technique. In his experimental work sub micron scale clusters of aluminum oxide
particles were investigated in the matrix after mechanical alloying. In comparison to the not
reinforced AA6061 the nano metal matrix composite evaluated the mechanical properties: according
to rule of mixture the young’s modulus was increased to 13% (percent) and yield strength is about
31% lower and UTS is almost same.
A.Baradeswarn et al. (2013) worked on Influence of B4C on the tribological and mechanical
properties of Al 7075- B4C composite. Author studied the mechanical behaviour of B4C reinforced
AL-7075 matrix composite and has revealed that the compressive strength (Fig. 12 a), tensile
strength (Fig. 12 b), and the hardness (Fig. 12 c) of the composite increased linearly with increase in
volume percentage of B4C.
(a) (b)
Fig.12 (a) and (b) Variation of compressive strength and tensile strength with B4c content

12
(c)
Fig.12 (c) Variation of hardness with B4c content. [A.Baradeswarn et al. (2013)]
5. MICROSTRUCTURAL PROPERTIES
Micro structural properties play a very important role in the field of engineering and science.
These micro structural observations can be done by some different techniques, such as SEM, XRD,
Optical, TEM, and XRD. Micro structure can be defined as it is the structure of a finished surface or
a thin layer of a material as revealed by microscope above 25× magnification. The microstructure of
a material can be further categorized into polymeric, metallic, ceramic and metallic and can enhance
the physical properties such as Hardness, toughness, strength, corrosion resistance. [American
Society of Metals (1985)]
M.S.Aboraia et al. (2013) Fabricated Al MMC reinforced with nano-sized Al2O3 by
commercial casting. The Uniform dispersion of Al2O3 and Al2O3-ZrO2 in the Al matrix was
confirmed by characterizing these nanocomposites powders by SEM and XRD process. SEM process
was successfully applied on the milled powders to check the uniform dispersion of the reinforcement
particles in the Al matrix. Author analysed the samples at the different milling time. (Fig. 13) shows
the SEM snapshot of Al- Al2O3 particles before milling (0 hours). The author observed the
agglomerated Al2O3 particles. Agglomeration can be removed by increasing the milling time.
Fig.13 SEM images of Al- Al2O3 particles before milling (0 hours) [M.S.Aboraia et al. (2013)]

13
In a work of M.S.Aboraia et al. (2013) (Fig.14 a) shows the SEM images of Al- Al2O3
particles at different milling times for 300 rpm speed. (Fig. 14) shows after 7 hours milling time the
agglomerations of Al2O3 particles are still observed, but smaller in size. (Fig. 14 a) shows flattened
Al particles were formed. (Fig. 14 b) shows after 30 h milling time a change in particles morphology
from flattened to flake. Fragmentation of particles occurred with particle size reduction. Layers of Al
and Al2O3 were obviously observed at this stage and there are alumina clusters surrounded by
aluminum particles as shown in (Fig. 14 b). (Fig. 14 c) shows the resulted microstructure, at this
milling time alumina clusters have been disappeared and distributed homogeneously. Nano size of
alumina particles are covered by Al particles. The author analysed the powder particles which are
shown in (Fig.14 c) is more uniform in size compared to the previous phases of milling.
Fig.14 (a) Flattened Al (b) Fragmented Al2O3 (C) Al particles spitted- Al2O3 cluster
disappeared and homogeneously distributed
Fig.14 SEM images of Al- Al2O3 powders 300 rpm after (a) 7h (b) 30h (c) 45h [M.S.Aboraia et al.
(2013)].
M.S.Aboraia et al. (2013) worked on structure analysis by XRD technique. At the time of
powder milling process the changes in peak shape are related to changes in micro structure. This
technique is used to evaluate the lattice strain and the crystallite size. The XRD patterns of the Al-
Al2O3 powder milled with 300 rpm rotation speed for different periods of time are shown in
(Fig.15). Author has observed that line broadening increases with milling time. Decrease in the
broadening of diffraction peaks and intensity are the strain of the lattice and grain size.
Fig.15 XRD patterns of Al- Al2O3 powder milled for different times 7, 12, 15, 21, 30, 38 and 45 h.
[M.S.Aboraia et al. (2013)]

14
H. Mahboob et al. (2008) used commercial aluminium particles with particle size smaller
than 63 µm and nanosized α-alumina powder with 99.5% pure and average size of about 27-43 nm
have been provided. (Fig.16 a) and (Fig. 16 b) show microstructure of Al and α-Al2O3 particles
captured by SEM and TEM, respectively. Author analysed that the Al particles are irregular and α-
Al2O3 particles.
Fig.16 (a) Aluminium particle Fig.16 (b) α-Al2O3 particle [H. Mahboob
et al. (2008)]
Ruixiao Zheng et al. (2014) investigated the micro structural properties of Al alloy matrix
composite reinforced with Fe – based metallic glass particles (FMG) by SEM and XRD. Powder
morphological evolution and microstructure of the extruded samples were analysed by SEM cam
scan 3400. The morphological characteristics and distribution of particle size of initial powder are
shown in (Fig. 17 a) and (b) for Al-2024 and (Fig.17 c) and (d) for Fe based metallic glass particle.
The initial Al-2024 powders are spherical in shape. The author also shows in (Fig.18) the XRD
pattern of initial powder. Author has been viewed that the Aluminium 2024 alloy powder has sharp
peaks which correspond to the face cantered cubic (FCC) structure.
Fig.17 (a) Fig 17(b)
Fig.17 (a) Morphology and particle size distribution Fig.17 (b) of initial powder for Al-2024.
[Ruixiao Zheng et al. (2014)]

15
Fig 17 (c) Fig.17 (d)
Fig.17 (c) Morphology and particle size distribution Fig.17 (d) of initial powder for FMG.
[Ruixiao Zheng et al. (2014)]
Fig.18 XRD patterns of initial powders. [Ruixiao Zheng et al. (2014)]
In a work of Ruixiao Zheng et al. (2014) shows the morphological characteristics of 24h
milled composite powders. The author shows in (Fig.19 a) particles are changed from spherical to
Flaky but the size of powders is almost same. (Fig. 19 b) exhibits the cross sectional morphology
characteristics of powders. It can be examined that after milling the size of Fe based metallic glass
particles is less than 5 µm and homogeneous dispersion in the Al alloy matrix. Author also shows in
(Fig. 20) XRD patterns of mixed powders and mechanical alloyed powder. These patterns show that
mech. alloying causes the peak broadening and intensity reduction with increasing in milling time.

16
Fig.19 (a) Fig.19 (b)
Fig. 19 (a) SEM morphology of 24h milled Fig.19 (b) cross section morphology of powder
Composite powder. [Ruixiao Zheng et al. (2014)]
Fig.20 XRD patterns of 24h milled powder composite. [Ruixiao Zheng et al. (2014)]
Hamid Reza Ezatpour et al. (2013) worked on Al 6061- nano composite reinforced with
alumina particles by stir casting. Author investigated the micro structural property of nano composite
by scanning electron microscopy. (Fig. 21 a) SEM snapshots of nano Al2O3 powder are shown and
completely analysed that the big cluster are formed in raw alumina nano particles. When nano
alumina powder is added into melt it is very difficult to break the cluster by mechanical stirrer. (Fig.
21 b) shows SEM snapshots of Al/ Al2O3 composite powder After 6h milling. Author examined that
Al2O3 nano particles are uniformly dispersed into the soft Al particles and clusters are effectively
broken.

17
Fig. 21(a) Fig. 21(b)
Fig.21 (a) SEM images of nano Al2O3 powders, and (b) Al/ Al2O3 powders after 6h ball milling time.
[Hamid Reza Ezatpour et al. (2013)]
6. CONCLUSION
The above review on various processing techniques, mechanical, and micro structural
properties of Al based MMCs reinforced with ball milled nano particles leads to the following
conclusions.
Ball milling process can be successfully applied for converting the reinforced particles into
nano particles and enhance the base material in terms of damping properties, mechanical
strength, and wear resistance by dispersing the ball milled nano particles homogeneously.
From the various processing techniques which are discussed in this paper the Stir casting is
one of the most economical techniques of processing Al MMCs. The major advantages of stir
casting process are its applicability to mass production, easier control of matrix structure,
simplicity and good matrix-particle bonding.
Uniform distribution of Al2O3 nano particle improves the tensile properties.
The aluminum and 5wt% alumina nano powders were milled at different times. Strength and
hardness were increased by increasing of milling time but the elongation was almost constant.
In Al Metal matrix reinforced with alumina, SiC, B4C etc. particle Improves the tensile
strength, hardness and yield strength
SEM process was successfully applied on the milled powders to check the uniform dispersion
of the reinforcement particles in the Al matrix. Increase in milling time alumina clusters have
been disappeared and distributed homogeneously.
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