Recycling Aluminium AA6061 Chips with Reinforced Boron Carbide (B4C) and Zirconia (ZrO2) Particles via Hot Extrusion

Abstract

Compared to the recycling process by remelting, hot extrusion significantly reduces the energy consumption and CO2 emission and ensures good mechanical and microstructural properties. This study investigates the effects of reinforcing aluminium AA6061 chips with mixed boron carbide (B4C) and zirconia (ZrO2) particles by employing a design of experiment (DOE) under 550 °C processing temperature and three hours preheating time. The findings showed that compressive strength (CS) and hardness increased with up to 5% added particles, and beyond 5%, the yielded values decreased because of materials agglomeration. However, the decreasing density was dependent on the addition of ZrO2 particles. The distribution of particles with different volume fractions of mixed particles was investigated by employing SEM, AFM, and EDS tests. Thus, the process can produce a net shape structure that utilises material-bonding consolidation to provide sufficient support to reuse the recovered materials in engineering applications, such as in the automotive industry.

Response surface methodology and machine learning optimisations comparisons of recycled AA6061-B4C–ZrO2 hybrid metal matrix composites via hot forging forming process

“…Al/5 % B 4 C + 5 % ZrO 2 show higher UTS strength compared to other amounts mixing quantities and this value increases to 178 MPa for Al/5 % B 4 C + 5 % ZrO 2 hybrid materials. Adding reinforced particles causes elastic modulus strength which is attributed to a strong bonding interface between the matrix and the reinforcements [ 54 , 55 ]. Further improvements are because of the interfacial strength dispersion that is achieved under preheating during the forming process.…”

“…Where according to Eqs. (20) , (21) [ 55 ]. Where, λ is the distance of reinforced particles, r is the radius of ceramic particles, and f is the volume fraction of ceramic particles.…”

Recent Advancements in Material Waste Recycling: Conventional, Direct Conversion, and Additive Manufacturing Techniques

“…They studied the microstructure and analyzed the fracture mechanism as a function of the volume fraction of phosphor bronze chips in fabricated composite. Alimi et al [267] studied the effects of reinforcing aluminum AA6061chips mixed with boron carbide and zirconia particles. The results indicate that hardness and compressive strength increased with up to 5% added particles and beyond 5% the yield values decreased.…”

“…Aluminum alloys [260][261][262][263][264][265]267], bronze [266], reinforced magnesium matrix composite [275].…”

Forming limit diagram and optimization of process parameters in SPIF of Inconel 625 aviation-grade superalloy

“…Hence, Inconel 625 is extensively used for aerospace, automotive, chemical processing and marine engineering applications (Shoemaker, 2005). Response surface methodology (RSM) is a precise statistical approach for scheming experiments and analyzing data to establish the link between process parameters and response variables (Bahloul et al , 2014; Sindhu et al , 2020; Al-Alimi et al , 2022). Researchers have conducted numerous experimental studies to improve formability in single-point incrementally formed parts.…”