Fabrication of Functionally Graded Materials Using Aluminum Alloys via Hot Extrusion

Abstract

In this study, we have attempted to manufacture functionally graded materials (FGMs) using aluminum alloys 3003 and 6063 via a hot extrusion process to realize multifunctionality through achieving high strength and low weight. The FGMs were fabricated using Al3003 powder and Al6063 bulk to improve the interfacial properties. Particle size analysis and X-ray fluorescence of the Al3003 powder were used to analyze the composition of general Al3003; microstructure analysis revealed improved hardness with almost no defects, such as cracks at the interface between the two materials. The experimentally determined tensile strength of the composite was observed to be higher than the theoretical value calculated using the rule of mixtures; the strengthening mechanisms considered for the calculations were grain size reduction and precipitation hardening. In particular, we attempted to predict the strengthening effect resulting from the fine grain size of the powder and grain size reduction due to the extrusion process using the Hall–Petch equation. The Kelly–Tyson equation was also used to calculate the theoretical strength in the presence of the strengthening phases. Based on these results, it was confirmed that FGMs can be successfully produced using the hot extrusion process.

Effect of Intermetallic Compounds on the Thermal and Mechanical Properties of Al–Cu Composite Materials Fabricated by Spark Plasma Sintering

“…As a result, alloy or composite-related studies have been conducted owing to the demands for various functions in a single material. Low-density aluminium has a relatively lower hardness than other metals; thus, materials such as Fe, Mg, SiC, B, Ti, V, diamond, and carbon nanotubes (CNT) are added as composites to increase the hardness [17,18,19,20,21,22,23,24,25,26,27,28,29,30,31,32,33]. Kwon et al [34] fabricated Al–CNT composites through a combination of spark plasma sintering and a hot extrusion process.…”

Metals Powders: Synthesis and Processing

“…Magnetic properties are studied by Sun et al [9] in cold pressed Fe-Si-B alloys. Kim et al [6] studied the fabrication of functionally graded Al-based materials by hot extrusion. Civantos et al [1] processed Ti by the space holder technique to be used as medical implants.…”

“…Several manuscripts [1][2][3][4]6,10] deal with crystalline materials, whereas other works [5,[7][8][9] use amorphous powders. According to the country of the corresponding author, three papers come from China [7][8][9], another three from Korea [2,3,6], two from Spain [5,10], one from USA-Spain [1], and one from Portugal [4]. In addition, authors from the United Kingdom, Germany, Mexico and Romania have contributed to the different papers.…”

“…Hot extrusion process is studied in [6] to fabricate functionally graded Al-base materials. Functionally graded materials improve the interfaces to prevent cracks coming from residual stresses in a heterogeneous material.…”

Microstructural, mechanical and tribological characterization on the Al based functionally graded material fabricated powder metallurgy

“…In order to eliminate the mentioned limitations, plenty of new aluminum-based materials are arisen in many sectors such as automobiles, aerospace, construction,anddefense, because of the evolution of material science [3]. Aluminumbased alloys and composite materials are prominently utilized in automobiles and aircraft, but, those have some limitations such as low susceptibility, strength and wear resistance [4]. For achieving the multiple characteristics within a single material, FGMs introduced as the alternatives for the composite and alloy materials.…”