Manufacturing of Low Cost Composites with Porous Structures from Scrap Aluminium (AA2014) Chips
In this study, aluminium matrix composites, (AMCs) have been created with porous structures reinforced with brown sugar, BN, graphite powders, boron and also fine glass bubbles. These composites are produced as sponge structures with low thermal and elect
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Manufacturing of Low Cost Composites with Porous Structures from Scrap Aluminium (AA2014) Chips L.F.P. Ferreira, F. Gatamorta, E. Bayraktar, and M.H. Robert Abstract In this study, aluminium matrix composites, (AMCs) have been created with porous structures reinforced with brown sugar, BN, graphite powders, boron and also fine glass bubbles. These composites are produced as sponge structures with low thermal and electrical conductivity. The process comprises a simple mixture of aluminium powders obtained from scrap aluminium chips (A2014) and glass bubbles with fresh scrap organic sugar coming from the excess of the production and their blending and finally followed by compacting of the mixture. Addition of the wax is variable from 0 up to 10 %. Sintering is carried out in two steps. First of all, the green compact is heated to eliminate entirely the sugar after that classical sintering of the structure is made under the inert atmosphere. Glass bubbles added at the beginning of the green compact create a net of interconnected porosity. Basically, drop weight test were applied to measure the impact behaviour of these sponge composites and acoustic emission capacity was measured. Microstructural and fracture behaviour were evaluated by Scanning Electron Microscopy (SEM). Keywords Recycle of aluminium • Hybrid-porous composites • Impact test • Damage analysis • Clean energy
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Introduction
Hybrid composites have unique structures that can be used to bring together various design requirements in a more economical way than conventional composites. Aluminium metal matrix composites (AMMCs) find many advanced materials application thanks to new manufacturing techniques and application of new particulate reinforcements. Today, through the combined methods of sintering and thixoforging/forging, many new composites especially hybrid composites are successfully used for the main manufacturing processes in aerospace and automotive industry. They are known high strength, lightweight materials very often called absorbed materials with high wear resistance, etc. Increasingly, the demands for lightweight materials having a high strength and a high toughness capacities have attracted a lot of attention to the development of composite porous structures and/or composite reinforced with light reinforcements as nonconventional organic materials such as sugar, wax boron nitrate and/or porous ceramic oxides etc. [1–5]. The Powder Metallurgy (PM) route is known as most commonly used method for the preparation of discontinuous reinforced AMMCs. This method is generally used as low–medium cost to produce small objects, the high strength and resistant materials. For this reason, in the present work, a simple idea was established on the production of porous composites by using a low cost method (mixture of aluminum matrix with wax and/or with organic sugar and also addition of small size glass bubbles and finally cold compaction followed by sintering in two stages). Therefore, a new process was applied for the manufacturing of these comp
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