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Advanced processing techniques are required to produce functionally graded metal matrix composites due to the metallurgical conditions required during production. In this study, we developed a novel approach for this task by using a combination of two different methods to produce functionally graded 7075 Al/SiCp (5–20 wt.%) composites. The first process was direct semisolid stirring, which was used to prevent particle agglomeration, brittle reaction products, floating or settling of the reinforcements, and poor wettability. The second process was sequential squeeze casting, which enabled liquid diffusion between the two composite layers that were used to produce a functionally graded aluminum matrix composite. Thus, a method was developed to eliminate the problems encountered in the production of particle-reinforced metal matrix composite materials using liquid stirring methods and to produce composite materials with the desired functionally graded structure. The resulting functionally graded material was subjected to spectrometer analyses, density measurements, and metallographic examinations to determine the characteristics of its layers and interfacial zones, as well as to assess the formation of the graded structure. The results indicate the potential of using this new combined manufacturing method, which is efficient and controllable, to produce functionally graded metal matrix composites.

In this study, concurrent enhancements in both strength and ductility of the Al-2Li-2Cu-0.5Mg-0.2Zr cast alloy (hereafter referred to as Al-Li) were achieved through an optimized forming process comprising ultrasonic treatment followed by squeeze casting, coupled with the incorporation of Sc. Initially, the variations in the microstructure and mechanical properties of the Sc-free Al-Li cast alloy (i.e., alloy A) during various forming processes were investigated. The results revealed that the grain size in the UT+SC (ultrasonic treatment + squeeze casting) alloy was reduced by 76.3% and 57.7%, respectively, compared to those of the GC (gravity casting) or SC alloys. Additionally, significant improvements were observed in its compositional segregation and porosity reduction. After UT+SC, the ultimate tensile strength (UTS), yield strength (YS), and elongation reached 235 MPa, 135 MPa, and 15%, respectively, which were 113.6%, 28.6%, and 1150% higher than those of the GC alloy. Subsequently, the Al-Li cast alloy containing 0.2 wt.% Sc (referred to as alloy B) exhibited even finer grains under the UT+SC process, resulting in simultaneous enhancements in its UTS, YS, and elongation. Interestingly, the product of ultimate tensile strength and elongation (i.e., UTS × EL) for both alloys reached 36 GPa•% and 42 GPa•%, respectively, which is much higher than that of other Al-Li cast alloys reported in the available literature.

Three-dimensional reinforcements can improve overall mechanical and wear properties of matrix material. However, the structure of traditional three-dimensional reinforcement is difficult to control. In this work, the 316L honeycomb structure were fabricated by selective laser melting, and ZA8 alloy were added to prepared 316L/ZA8 alloy composites using squeeze casting. The tribological behavior of ZA8 alloy and composites at different temperatures was studied through pin-on-disc wear tests. The results show that the addition of honeycomb reinforcements can reduce the friction coefficient and improve the stability of ZA8 alloy after running-in stage at room temperature. At high temperatures, the reinforcements can restrain the plastic deformation of ZA8 alloy. The wear rate of the composite decreases with the increase of honeycomb apertures at both room temperature and 120 °C. The reinforcements have effect on the wear mechanisms of ZA8 alloy at different temperatures. The wear mechanism of ZA8 at different temperatures is mainly adhesive wear, while the plastic deformation on the surface of ZA8 is more severe at 120 °C. The composites with small honeycomb aperture exhibit adhesive wear and severe abrasive wear at both room temperature and 120 °C, accompanying with significant oxidative wear at 120 °C. The wear mechanism of composites with larger honeycomb aperture at different temperatures is mainly adhesive wear. [ABSTRACT FROM AUTHOR]

In just one step, a squeeze casting process was applied to produce aluminium foam sandwich panels. NaCl particles with mean sizes of 4.75 and 6.35 mm were used as space holders in different proportions. In-situ face sheet manufacturing was conducted through previously placed steel meshes in the mould. The effect of NaCl particle sizes and the proportion of each size on porosity, microstructure, and mechanical properties were investigated. Results showed a decline from 59.8% to 43.8% in the porosity amount of samples with increasing the proportion of larger NaCl particles. Accordingly, an increase in compression yield stress (from 3.2 to 6.1 kgf/mm2) and the absorbed energy were observed. Also, at the elevated densities of the sandwich panel core, the plateau stress was enhanced. The presence of Cu, Ni, Fe, and Si elements leads to the formation of brittle intermetallic compounds in the microstructure of cell walls. [ABSTRACT FROM AUTHOR]

Multiwall carbon nanotube buttressed aluminium 7075 metal matrix composite was synthesized through an amended liquid metallurgy method, which consisted semisolid stirring, ultrasonic treatment and squeeze casting. Aim was to investigate its machinability and surface morphology during electrical discharge machining. Variable machining factors were peak current, pulse‐on time and gap voltage, whereas the responses under investigation were electrode wear rate, material removal rate and average surface roughness. Results revealed electrode wear rate, material wear rate and average surface roughness increased on increasing peak current and pulse‐on time, but all these responses behaved inversely with the increase of gap voltage. Average surface roughness reduced by around 44 % on reducing the peak current from 10 A to 4 A and increasing gap voltage from 55 V to 80 V at constant pulse‐on time of 300 μs; however, it increased by around 25 % on reducing the gap voltage from 80 V to 55 V and increasing the pulse‐on time from 100 μs to 300 μs at constant peak current of 10 A. Significance of the process parameters were verified, regression models were developed and morphology of the machined surfaces was studied. Finally, multiple response optimization was conducted following grey relational approach. [ABSTRACT FROM AUTHOR]

The technology of casting with crystallization under pressure-squeeze casting belongs to unconventional pressure-casting methods. The melt or material in a semi-solid state is pressed under pressure until the casting solidifies completely. The input parameter, whose influence was mainly observed in this paper, is the state of the material entering the filling process. The alloys were in a molten and semi-solid state. The influence of casting thickness from 3.15 mm to 8 mm was also observed. Alloy AlSi7Mg0.3 was used because of the wide solidification interval and the significant influence of pressure during solidification. Consequently, alloy AlSi12 was subjected to experimental work because processing in the semi-solid state is not sufficiently examined for this material. A significant influence of the cooling rate in different cross-sections on the structure and mechanical properties of castings made using squeeze casting technology was confirmed. The difference in mechanical properties was approximately 35% for both eutectic and hypoeutectic alloys. When processed in a semi-solid state, it was confirmed that the network of dendrites has a significant influence on the filling of the mold cavity. The paper also focuses on the effect of input material morphology on the final product properties. The change in morphology was achieved by metallurgical intervention, thermal and technological processing. [ABSTRACT FROM AUTHOR]

Magnesium alloys are still attractive materials for applications that necessitate light weight due to their low density, moderate strength, and good corrosion resistance. AZ91 is one of the widely applied magnesium alloys due to its very good castability and strength. However, one of the drawbacks of magnesium alloys is the low elastic modulus. So, reinforcing AZ91 with carbon short fibers with the aim of further increasing the strength and improving the elastic modulus is investigated in this study. Squeeze cast AZ91-23 vol.% carbon short carbon (AZ91-C) and the unreinforced AZ91 are deeply examined by tensile testing at different temperatures (20, 100, 150, 200, 250, and 300 °C). Tensile stress–strain curves are measured and the tensile parameters (yield stress, ultimate tensile strength and strain) are defined and presented against the test temperature. Yield stress of AZ91 at 20 °C (109 MPa) is doubled (226 MPa) in the reinforced AZ91-C. Yield stress is found to slightly decrease with increasing the test temperature. Ultimate tensile strength of AZ91 at 20 °C (198 MPa) is increased (262 MPa) in the reinforced AZ91-C. The improvement of the ultimate tensile strength due to reinforcing increases with increasing the test temperature. Flow curves are determined and described by a modified Mecking–Kocks relationship and the flow parameters are determined and described as a function of the test temperature. Microstructure investigation was undertaken of the fractured tensile specimens at the grain boundaries rich in eutectic structure formed at the grain boundaries. Mixed brittle/ductile fracture mode is detected on the fracture surface of unreinforced AZ91, while the SEM investigations show matrix/carbon fiber detachment and fiber fracture as main fracture modes. [ABSTRACT FROM AUTHOR]

In the present work, the effect of squeezing at 100 MPa during AZ91 Mg alloy casting has been studied, where the microstructure, texture, and mechanical properties of gravity die-cast (GC) and squeeze cast (SC) AZ91 alloy samples have been compared. Also, the effect of the combined addition of calcium (Ca) and strontium (Sr) on microstructure and mechanical properties of AZ91 alloy fabricated by SC has been investigated. The SC AZ91 alloy samples exhibited weaker texture than that of GC AZ91 alloy with a reduction in maximum texture intensity. The squeeze casting resulted in the refinement of the secondary phase (β-Mg17Al12) in the microstructure by reducing its segregation at the grain boundaries. The volume fraction of β-Mg17Al12 was more suppressed with Ca and Sr alloy addition due to the formation of new Al2Ca and Al4Sr intermetallics. The tensile properties of SC AZ91 samples were found to be better than that of GC AZ91 samples. Further improvements in mechanical properties were obtained after alloying with Ca and Sr, and the best combination of all tensile properties was obtained at (1% Ca + 0.9% Sr) addition. Higher Sr addition than 0.9% Sr degraded the strength as it induced brittleness in the material. [ABSTRACT FROM AUTHOR]

A strontium-modified experimental Al20Si3Cu alloy was processed using the squeeze casting/high pressure die casting universal metallurgical simulator and analyzer (SC/HPDC UMSA) under impact and cyclic loading. Sample pressure and temperature vs. time were monitored during solidification, allowing thermal analysis to identify key solidification parameters. The application of pressure to the melt region improves the contact between the melt and the steel mold, which increases the initial melt cooling rate to ~100 °C/s and heat extraction by 40%. Metallographic analysis techniques including LOM, SEM/EDS, STEM/EDS were used to characterize the as-cast microstructure and microchemistry of selected samples. Metallographic data were collected from the polished and deep-etched surfaces as well as from STEM thin foils. This data allowed for the gathering of complementary information for determination of the relationship between the process and the thermal analysis parameters. The best processing parameters produced as-cast composite colonies that had a high fraction (~38 vol. %) dispersion of nanosized, individual, amorphous, Si-rich SiAl clusters and whiskers in a face-centered cubic (FCC) α-Al matrix. The clusters and whiskers had an average diameter of 220 nm with a standard deviation of 48 nm and whiskers were ~2 µm long. This nanocomposite structure was in the form of ~500 µm cauliflower-florets-shaped colonies of radial cells of ~30 µm in diameter that accounted for >85% of the material volume. We describe the process of formation of these newly discovered glassy SiAl nanophase clusters and whiskers in an FCC α-Al matrix. This ultrafine phase is a main, dominant feature of the as-cast ultrafine microstructure of Sr-modified, hypereutectic Al20Si3CuX alloy solidified under non-equilibrium conditions controlled by rapid heat extraction. [ABSTRACT FROM AUTHOR]

The present study attempts to promote the quality of squeeze casting components by a two-stage study which includes experimental research of virtual casting based on response surface method (RSM) and experimental research of actual production casting. In the first stage, the critical parameters determined by the numerical model of casting procedure indicate that the qualities of castings, including casting solidification time, secondary dendrite spacing and porosity, are highly affected by the die temperature, pouring temperature and filling velocity. The input–output relationship developed, based on Box–Behnken experimental design (BBD), is found to be statistically adequate and yielded better prediction accuracy. NSGA-II algorithm performs multi-directional search in multi-dimensional space simultaneously combining with the data optimization software ISIGHT. In the second stage, the trial production test was carried out on the squeeze casting machine to verify the optimal parameters. X-ray inspection, metallographic structure testing and mechanics performance testing show that the casting has no casting defects and has good mechanical properties. [ABSTRACT FROM AUTHOR]

In this study, an enclosed cooling slope channel (ECSC) was used to produce a semi-solid slurry of the 7075 aluminum alloy. The effects of the pouring temperature and the rate of cooling water on the microstructure of the semi-solid slurry were studied. The microstructure, solidification behavior, mechanical properties, and fracture mechanism of rheological squeeze casting (Rheo-SC) and liquid squeeze casting (LSC) samples were compared. The results indicate that lowering the pouring temperature and increasing the rate of cooling water can refine the crystals of the semi-solid slurry. The best process is a pouring temperature of 670 °C and a rate of cooling water of 200 L/h. The microstructure of the LSC samples was made up of coarse dendritic crystals, but the microstructure of the Rheo-SC samples was made up of almost spherical primary α1-Al and refined secondary α2-Al under this method. The ultimate tensile strength, yield strength, and elongation of the Rheo-SC samples were 238 MPa, 151 MPa, and 5.2%, respectively, which were 10%, 10.5%, and 44.4% higher than those of the LSC sample. The key factor contributing to the increased performance of the Rheo-SC samples is the combination of decreased casting flaws, strengthened grain refinement, and improved segregation. [ABSTRACT FROM AUTHOR]

In this study, near-liquidus squeeze casting AZ91D alloy was used to prepare differential support, and the microstructure and mechanical behavior under different applied pressure were investigated. Under the preset temperature, speed, and other process parameters, the effect of applied pressure on the microstructure and properties of formed parts was analyzed, and relevant mechanism was also discussed. The results showed that the ultimate tensile strength (UTS) and elongation (EL) of differential support can be improved by controlling real-time precision of the forming pressure. The dislocation density in the primary phase increased obviously with the pressure increasing from 80 MPa to 170 MPa, and even tangles appeared. When the applied pressure increased from 80 MPa to 140 MPa, the α-Mg grains were gradually refined, and the microstructure changed from rosette to globular shape. With increasing the applied pressure to 170 MPa, the grain could not be further refined. Similarly, its UTS and EL gradually increased with the applied pressure increasing from 80 MPa to 140 MPa. With increasing to 170 MPa, the UTS tended to be constant, but the EL gradually decreased. In other words, the UTS (229.2 MPa) and EL (3.43%) of the alloy reached the maximum when the applied pressure was 140 MPa, and the comprehensive mechanical properties were the best. [ABSTRACT FROM AUTHOR]

The current study is an attempt made to synthesize nano B4C/Graphite reinforced AluminumZincMagnesium alloy composites by altering the weight %age of B4C (2%, 4%, and 6%). SEM was used to examine the morphology and mechanical behaviour was done in accordance with ASTM standards (ASTM E8, E9, E23, and D790). The microstructure displays a nearly uniform dispersion of reinforcement particles in the matrix alloy, with no residual pore visible. From the XRD analysis it is identified that interfacial phases between the base material and ceramic strengthening particulates are identified as Al3BC, AlB12, Mg2Si, SiAl2 and it strive as strengthening mechanism of synthetic composites. The interfacial phases identified as Al3BC, AlB12, Mg2Si, and SiAl2, and serve as a strengthening mechanism for synthetic composites, according to XRD. When compared to the base material, intermixtures had higher hardness (28.07%), ultimate tensile strength (69.31%), compressive strength (18.58%). The flexural strength is improved (29.32%) due to higher dislocation density in the matrix and wider variations in the elastic modulus. The impact strength improved significantly (72%) due to a reduction in porosity and grain refinement. [ABSTRACT FROM AUTHOR]

In this study, steel particles were used to reinforce the magnesium matrix. To fabricate the magnesium-steel particle composite, steel particle preforms were made in different sizes; some were sintered at 1000 - 1200 °C and some without sintering. These preforms were preheated at 750 °C and then infiltrated with melted magnesium with the squeeze casting method. The microstructure of the preforms and the composites were investigated by SEM and optical microscope. Microhardness and compression tests were performed to investigate the mechanical behavior of the composites. The microstructure study showed the rigid connectivity between the steel particles in the interpenetrating phase composites. Also, hardness and compression test results showed higher hardness (61 VHN) and strength (218 MPa) for the composites with 1mm steel particle size sintered at 1200 °C. Hence, the composites with 3D-dimensionally interconnected steel particles show significant changes in their mechanical properties. [ABSTRACT FROM AUTHOR]

Polymer Injection Pyrolysis (PIPs) can be adopted to synthesize in-situ ceramic particles within molten metal by stir-casting process. This paper investigated the effect of pyrolysis temperatures on microstructural and strength properties of in-situ aluminum matrix composites containing 2.5 vol% of SiCNO particles. In-situ composites were synthesized by stir-mixing of cross-linked polysilazane at four different pyrolysis temperatures (675-850°C) at which in-situ pyrolysis occurred and then followed by ultrasonic agitation and squeeze casting process. Microstructural data reveals that grain size and the particle size of SiCNO particles decreases with increasing the temperature of the melt at which polymer was introduced into the melt. The increase in the strength properties of the fabricated composites as compared to pure aluminum is almost 210% for the composites fabricated at 850°C while it is marginally 17% for the composites fabricated at 720°C. Fractography studies suggest that composite fabricated at 675°C exhibits a better combination of yield strength and ductility. [ABSTRACT FROM AUTHOR]

The squeeze casting process blends the features of casting, forging, and also helps in achieving better manufacturing abilities; attain smooth uniform surface, high productivity, superior mechanical properties, and refined microstructure. The precise control of process variables is the most feasible solution to obtain a defect-free casting. In the squeeze casting process, surface roughness, hardness, ultimate tensile strength, and yield strength are influenced by process variables. Hence, this paper deals with the new intelligent-based squeeze casting process using LM-20 alloy. Aluminium is commonly employed in automobile and aerospace applications. The proposed casting process considers the input parameters such as squeeze pressure, pressure duration, pouring temperature, and Die preheats temperature. The output variables such as Yield strength, hardness, Ultimate tensile strength, and Surface roughness is artificially computed using the regression equations obtained for different responses using the non-linear regression models based on Central Composite Design (CCD). Initially, the considered process variables are trained in a Neural Network (NN). Further, the employed parameters are optimised to attain the best solution within the concerned limit using an improved meta-heuristic algorithm called Modified Coefficient based DHOA called MC-DHOA. The fitness evaluation of parameter optimisation depends on NN for prediction, and the objective function intends to minimise the error between optimised and target value. The analysis proves that the implemental model helps to select the most influential process parameters in the squeeze casting process within less duration. The overall performance of the proposed MC-DHOA is 16.5% better than PSO, 1% better than FF, 11% better than GWO, 4.6% better than WOA, and 2.15% better than DHOA. [ABSTRACT FROM AUTHOR]

Aluminum metal matrix composites (AAMC) play a vital role in many fields due to their exceptional properties compared to monolithic aluminum alloys. While fabricating the AMMC, there are several problems including poor wettability between the matrix melt and reinforcements, low interfacial bond strength, and undesirable reactions in the interface. To overcome these problems, the surface of the reinforcements needs to be modified appropriately, often using coatings. This paper critically reviews the coatings used on reinforcements during the processing of aluminum-based composites. Nickel has been one of the most common coatings on reinforcements. Nickel coating promotes wetting between the melt and reinforcements, restricts unwanted interfacial reactions including carbide formation, and releases nickel in the matrix while dissolving with an exothermic reaction. Copper coating behaves similar to nickel, and in addition, avoids the initiation of fracture at the interface due to its ductile nature. Coating ceramics, including SiO2, on reinforcements, improves the wetting with molten aluminum and increases the oxidation resistance of the composite. SiC-coated reinforcements avoid the formation of porosity and increase the wettability, enhancing the stability of the composite; however, the strength of the composite decreases if the thickness of the coating increases above a critical value. Coating nanocrystalline 5083 aluminum on reinforcement makes the composite more ductile than uncoated reinforcement. Mg coating on reinforcements promotes wetting but reduces the melting point of the matrix. While coatings on reinforcements have to lead to improved properties in aluminum composites, there is a need for further research on optimizing the composition and thickness of coatings, understanding how the coatings change during processing, and how they influence the properties of aluminum composites. [ABSTRACT FROM AUTHOR]

2 wt.% TiB2 (mean particle size: 400 nm) reinforced Al 7075 metal matrix composites (MMCs) fabricated through mechanical stirring and ultrasonic agitation integrated squeeze casting process were subjected to electrical discharge machining (EDM) after determining the physical and mechanical properties. EDM was conducted with Cu electrode tools to investigate influence of machining factors, i.e. peak current (IP), pulse on time (TON) and gap voltage (VG) on the tool wear rate (TWR), material removal rate (MRR) and average surface roughness (ASR) of the machined surfaces. All the three responses increased on increasing IP and TON, but reduced on increasing VG. The machined surfaces were studied through scanning electron microscope (SEM). Significance of the EDM parameters on the individual responses were studied using analysis of variance (ANOVA) and regression models for the responses were developed using response surface method (RSM). The responses under consideration were optimized simultaneously using Taguchi embedded weighted principal component analysis (WPCA), which resulted the parametric combination of 4A (current), 100 µs (pulse duration) and 75V (voltage) was the optimal setting for the multi-criteria decision problem. Finally, the result of optimization was validated by conducting some confirmatory experiments. [ABSTRACT FROM AUTHOR]

In order to solve the problems of low yield and easy shrinkage cavity and porosity in the traditional sand casting process of cast iron glass mold, the liquid die forging process was adopted, and the graphite shape of the casting was distributed in gradient by different cooling conditions. The temperature field and solidification field of liquid die forging process were simulated by Procast, shrinkage cavity and porosity defects were predicted, and the key process parameters such as pouring temperature, cooling mode and gate size were adjusted and optimized, and the microstructure of different parts of the casting was predicted according to the view of thermal analysis. The results show that liquid die forging can effectively reduce shrinkage defects. [ABSTRACT FROM AUTHOR]

Squeeze casting is a well-established and reliable process for fabricating high-integrity metallic alloys, bimetals, and composites. The quality and high performance of squeeze cast components are dependent on optimum casting conditions. Inappropriate selection of parameter values may adversely affect the quality of the casting. The squeeze cast components are generally subjected to secondary processing such as heat treatment, extrusion, and other bulk deformation processes to improve the microstructural features and mechanical properties. Heat treatment further refines the grains and reduces porosity, consequently improving tensile strength, and hardness; however, ductility decreases. This paper provides a comprehensive review on studies concerning the influence of processing parameters on porosity, density, percentage elongation, strength, hardness, wear, and fracture of squeeze casting alloys, aiming to provide sufficient information on the squeeze casting process and the effects of processing parameters on product quality. [ABSTRACT FROM AUTHOR]

In this study, the heat treatment process of a high-chromium cast iron (HCCI) alloy prepared via 128 MPa squeeze casting at different subcritical quenching temperatures was investigated. The results showed that subcritical heat treatment can change the martensite content, the carbide type and size of the squeeze casting HCCI microstructure. Furthermore, it was revealed that the subcritical quenching heat treatment can improve the hardness of the liquid-forged HCCIs. When the quenching temperature increased from 500 °C to 530 °C, the hardness of the alloy increased significantly, reaching a maximum value of 57 HRC. Thereafter, if the temperature continued to rise to 630 °C, the hardness decreased rapidly. For impact toughness, when the quenching temperature was 500 °C, the toughness of alloy increased by 0.9 J/cm2 than that of the no heat treatment group. If the quenching temperature continued to increase, the toughness was reduced. Taking hardness and toughness into account, the microstructure evolution diagram of the optimal process-500 °C subcritical quenching process was established, various characterisation techniques were used to gain insights into the optimal heat treatment process. Compared with high temperature heat treatment, subcritical heat treatment can improve the performance of the HCCI alloy and reduce costs. [ABSTRACT FROM AUTHOR]

The creep behavior of a binary Mg-15 wt.% Gd alloy was investigated over the temperature range from 523 K to 743 K, i.e., in both the single-phase region (the hexagonal close-packed solid solution of Gd in Mg) and the two-phase region (the solid solution plus Mg5Gd precipitates). The alloy was prepared by the squeeze casting technique. In the higher temperature range, at 723 and 743 K, the specimens were solution treated by in situ annealing prior to testing. At the temperature of 673 K and below, the alloy was tested in the cast state. In the higher temperature range, the behavior was interpreted in terms of the viscous glide, where the dislocation motion was constrained by the presence of solute atmospheres. The dislocation motion was controlled by the rate of the cross slip from the basal to the prismatic planes. At the temperatures of 623 K and 673 K, the creep behavior was rationalized by introducing the threshold stress concept. At the temperatures of 523 K and 573 K, the stresses required to achieve experimentally measurable creep rates were such that dislocations broke away from the atmospheres of foreign atoms. Comparison with a series of magnesium alloys prepared by squeeze casting and creep-tested by the same technique showed that gadolinium can be a favorable creep-resistance enhancing element. [ABSTRACT FROM AUTHOR]

The need for lightweight materials towards aerospace has increased prominently. This paper focuses on introducing a novel reinforcement mixture of graphene with Al 2014 powder synthesised through ball milling technique. The synthesized powder was utilized as a reinforcement to fabricate Al 2014 based MMCs through squeeze casting technique. The results exhibited that Al 2014 mixture with embedded and interlocked 2D-Grnp (2.517 g/cm3) matched the density of the matrix metal (2.771 g/cm3) that facilitated homogeneous dispersion of 2D-Grnp and solved the dispersion problems during stir casting. As a result, AA 2014 embedded with 2D-Grnp acted as a carrier to homogeneously disperse combined with the squeeze casting process leading to the production of homogeneously reinforced MMC. This can be considered as a potential fabrication route for the launch vehicle super lightweight fuel tank (SLWT) structural application. The final casted plate after T6 heat treatment with 0.5 wt% 2D-Grnp exhibited an improved tensile strength of 361 MPa (52% higher than the monolithic 2014 aluminium alloy) with total elongation of 21% and improved hardness of 119 HRB (45.5 % increase). Furthermore, SEM and TEM results exhibited that squeeze casting led to enhanced interfacial bonding between the 2D-Grnp and Al 2014.

Titanium carbide particles (TiCp) is one of the most commonly used ceramic particles in ceramic- particle-reinforced metal matrix composites. The study prepared TiCp/Cr8Mo2VSi composites using the squeeze casting technique and investigated the effects of different TiCp volume fractions on the mechanical properties, including bending strength and impact toughness. Additionally, the study added tungsten carbide particles (WCp) powder to the preform to examine its effect on the mechanical properties of the composites. The study found that as the volume fraction of TiCp increased, the bending strength of the composites decreased gradually. The highest bending strength of 642.7 MPa was observed at 35% volume fraction. The impact toughness showed a small change, approximately 1.7 J cm ^−2 . Upon the addition of WCp powder (with a mass fraction of 5.0 wt% and TiCp volume fraction of 50%), the bending strength and impact toughness of the composites were 375.2 MPa and 2.1 J cm ^−2 , respectively. Compared to the composites without WCp powder (105.4 MPa, 1.7 J cm ^−2 ), the addition of WCp powder resulted in a 256.0% increase in bending strength and a 23.5% increase in impact toughness.

In this work, squeeze casting experiments of flywheel housing components with a large wall thickness difference and a complex shape were carried out with AlSi9Mg aluminum alloy. The defects, microstructures, and mechanical properties under different process parameters were investigated. Furthermore, the local pressurization process was applied to the thick-walled positions to force-feed the cast defects. The mechanical properties and microstructures at these positions were analyzed. The results showed that the surface quality of formed components was good and that local pressurization could effectively reduce the shrinkage cavity and shrinkage porosity in thick walls, but the scope and effect of forced feeding were limited. The optimum process parameters were a pouring temperature of 650 °C, a specific pressure of 48 MPa, a mold temperature of 220 °C, a local pressurization of 800 MPa, and pressure delay times of 15 s (side A) and 17 s (side B). The ultimate tensile strength, yield strength, and elongation of the formed component under validation experiments of the optimum process parameters were 201 MPa, 103 MPa, and 5.1%. Meanwhile, the fine grains of primary α-Al were mainly rosette and equiaxed grains, and the average grain size was about 40 μm. The microstructure of the eutectic silicon was acicular and was prone to segregation under pressure. According to profile morphology, the positions after pressurization were divided into a deformation zone, a direct action zone, and an indirect action zone. The coexistence of as-cast and plastic deformation microstructures was observed. The effect of local pressurization mainly involved a change in the solidification process, plastic deformation, and forced feeding.

In this study, the effects of Ni content on the microstructure and mechanical properties of Al-5.0Cu-1Mn-based alloys were investigated. The results demonstrate that Ni alloying refines the grain size and enhances castability. At low Ni content, some of Ni atoms participate in forming Al7Cu4Ni at the grain boundaries. The rest Ni segregates to the interface between α-Al and AlCu3Mn2 phase, which inhibits AlCu3Mn2 growth. The amount of Ni-rich phase at grain boundaries increases significantly as Ni concentration increases at the expense of the decline precipitates. After T6 treatment, the lamellar Ni-rich phase spheroidized into discrete particles that were uniformly distributed along the grain boundaries. Ni-rich phase of particles can effectively pin grain boundaries and prevent grain rotation. The optimum mechanical property is achieved with 1% Ni addition, predominantly due to the synergistic strengthening of eutectic strengthening and precipitation strengthening. The ultimate tensile strength, yield strength and elongation reach 505 MPa, 348 MPa and 16.5% respectively, which far exceed the current commercial cast aluminium alloys. With increasing Ni concentration, the fracture mode of the alloy changes from ductile fracture to brittle-ductile mixed fracture, because the high amount of Ni-rich phase intermetallic compounds increase the sites for localized brittle fractures.

Al6061 alloy is most commonly used in automotive, marine, and aerospace applications to lighten the composite and increase its strength. Al6061 alloy is a precipitation-hardened aluminum alloy used as a matrix material. Beef bone is a biowaste that has polluted the environment and the people who live in the vicinity of its manufacturing and disposal sites. Biowaste has been used in a variety of ways by researchers in recent years, including activated carbon, water purification, reinforcement in composites, fillers, additives, etc. Beef bones that had been abandoned as waste were collected, cleaned, and grounded into a fine powder with a particle size of 50–100 nm and used as reinforcement. Squeeze casting process is used to create the newly created aluminum composite (Al6061 + 0%, 5%, 10% of bone powder). The aluminum composite was fabricated and three samples were successfully obtained for further testing and analysis. The prepared Al composites with nanopowder reinforcement are analyzed for surface morphology, elemental identification, hardness, porosity, tensile strength, and compression strength. The percentage of porosity in the composite is improved by 36.7% when compared to the Al6061 alloy. Similarly, the tensile strength of the produced composite is increased to 5.59%. A significant improvement is observed in the wear resistance and hardness of the composite as 54.55% and 48.65%, respectively. [ABSTRACT FROM AUTHOR]

The recent shoot-up in demand for lightweight materials with tailored properties has increased the interest of researchers, metallurgical and materials engineers towards aluminium matrix composites (AMCs). AMCs are light and rich in properties like corrosion, strength and wear. Moreover, AMCs are among the most economical compared to their counterparts due to the low cost and availability of aluminium. AMCs are gaining employment in many engineering sectors including power, construction, automobile and aerospace. Selection of suitable base materials and compatible reinforcement is of prime importance. Therefore, in the current study, an attempt has been made to develop an effective and economical silicon carbide-reinforced AMCs through stirring-assisted squeeze casting. Mechanical, metallurgical and wear investigations were done on the developed AMCs to determine the influence of ceramic addition on the base matrix. Microstructural investigations revealed grain refinement with even dispersion of silicon carbide in aluminium matrix. The ceramic reinforcement has also led to an increase of about 62% in ultimate tensile strength and 30% in microhardness of composites over the base matrix. Improvement in properties and microstructure can be attributed to grain refinement, reduction in porosity and strengthening of the aluminium matrix by the reinforcement particles. In addition, the tribological behaviour of the fabricated composites showed significant improvement with a reduction in wear rate and friction coefficient. [ABSTRACT FROM AUTHOR]

The role of silicon in Al-Si alloy is to enhance its thermodynamic and mechanical properties. Silicon is an eco-friendly source that lowers the melting temperature and enhances the fluidity of alloys. Low-cost synthesis, abundant natural resources, and mass production are other merits of silicon. Silicon possesses excellent properties such as good photoconductivity, ideal thermal expansion, high corrosion resistance, and long-term durability, which improve the system's overall efficiency. In this study, the matrix used in the composite was Al-Si alloy and lemongrass ash (LGA) as the agro-waste reinforcement (2%-10%). The agro-waste composite produced by the stir casting cum squeeze casting method exhibited exceptional physical and tribological characteristics owing to improved bonding between the composite constituents. Thermogravimetric and differential Thermal Analysis (TG–DTA) deduced the maximum weight loss of 81% for the LGA particles. Other tests performed on the composite specimens helped determine the physical, mechanical, tribological, and microstructural properties like density, porosity, hardness, impact, tensile, compressive strength, wear rate, and coefficient of friction. These inferences were compared with ADC12. With the addition of the mass fraction of LGA particles, the density and toughness decreased at the rate of 2.43 g·cm−3 and 11.9 J, respectively. 6% of reinforced LGA particles in the composite have a high hardness of 61.8 HRB and 113 HV, Tensile strength of 192.3 MPa, and Compressive Strength of 535.6 MPa. Further increase in reinforcement reduced the mechanical strength. A linear reciprocating Tribometer (LRT) was used to find the composite's wear rate and friction coefficient. The rate of wear of fabricated composites decreased gradually on adding LGA particles. The composite with 8wt% of LGA reinforcement exhibited a better anti-wear property of 0.0079 mm3/m and 0.0084 mm3/m on applying a load of 20 N and 40 N. Increasing the reinforcement content reduced the coefficient of friction (CoF) to 0.72 and 0.74 on applying various load. The distribution of reinforcement in the matrix was studied using an Upright Optical microscope (OM) and Scanning Electron Microscope (SEM) with EDAX techniques. Micrographs disclosed the homogeneous distribution and effectively bonded in the composites with a clear interface of LGA reinforcement. [ABSTRACT FROM AUTHOR]

This paper presents the new route of fabrication of H-AlSi24Cu3.8Mg0.8 alloy, assisted by ultrasonic vibration stirring and squeeze casting (UVSS). The primary objective of this investigation is to establish the tribological characteristics of the prepared aluminium alloy under dry, lubricated, and coated sliding conditions. Oil SAE20W40 is used as a lubricant and diamond-like carbon (DLC) is used as a coating. Under a load between 20 N and 50 N, a linear reciprocating tribometer (LRT) with a ball-on-plate geometry is used. Alloy was examined using an optical microscope, scanning electron microscope with EDS, 3D surface profilometer, Brinell hardness tester, and tensometer for pre- and postcharacterization of alloy, surface, and worn tracks. The DLC-coated condition yields the lowest wear and coefficient of friction. [ABSTRACT FROM AUTHOR]

The smooth particle hydrodynamics (SPH) method is advantageous in tracking a free surface and a moving interface. This paper uses the SPH method to simulate the filling process of squeeze casting. The simulated temperature field at the end of filling was input into a finite element model (FEM) program to simulate the solidification process after squeeze casting. Due to the existence of a liquid phase, a solid phase, and a two-phase mushy zone in the solidification process after squeeze casting, the deformation behavior in the solidification process was modeled with a thermoelasto–viscoplastic constitutive model representing these different phases. In the RDG thermal cracking criterion based on the principle of dendrite gap complement, there are a strain rate term, a secondary dendritic spacing term, and a pressure term. These terms accurately describe the squeeze casting process. Therefore, the RDG criterion was used to predict thermal cracking. The strain rate term in the RDG criterion was calculated by the FEM. For the calculation of the secondary dendritic spacing, the temperature field during the solidification process is locally refined by the FDM method to complete the transition from the macroscale to the mesoscale; then the refinement results are imported into the phase field method for dendritic growth simulation. The results show that the method based on multi-model coupling has satisfactory prediction accuracy for the thermal cracking in the squeeze casting process. The combination of the phase field method and the RDG criterion provides a new approach to the simulation of thermal cracking defects. The prediction results show that the thermal cracking tendency increases with an increase in strain rate. However, the local position C of the bracket sample had a higher strain rate of 7.15/s, and a lower cooling rate of 2.96 K/s offset the effect of the high strain rate. As a result, a low thermal cracking tendency level of 1.13729 was obtained. [ABSTRACT FROM AUTHOR]

The current study investigated the effect of adding La and Nd on the microstructural evolution and corrosion response of AZ91 magnesium alloy. Mg–Al–Zn–La–Nd alloys with different WLa/WNd ratios were developed by the squeeze casting process. Typical characterization was conducted using scanning electron microscopy (SEM), transmission electron microscopy (TEM), X-ray diffraction (XRD), scanning Kelvin probe force microscopy (SKPFM), electrochemical impedance spectroscopy (EIS), and potentiodynamic polarization (PDP) tests to analyze the effect of WLa/WNd on the corrosion performance of Mg–Al–Zn–La–Nd alloys. AZLN alloys showed better corrosion resistance, mainly due to the microstructure refinement of RE addition and the protective effect of RE oxide films. In addition, the acicular Al11RE3 phase acts as a barrier against corrosion and is more effective than the granular Al2RE phase. As a result, the Mg–Al–Zn–La–Nd alloy with a WLa/WNd ratio of 3/2 is more corrosion resistant than other alloys due to its finer morphology and more uniform distribution of secondary phases. [ABSTRACT FROM AUTHOR]

Robust optimization of injection mechanism can improve the stability of injection process control. A novel multiobjective six-sigma (6σ) robust optimization method that considers key indices based on Bayesian Kriging metamodel was proposed in this study. The deformation and temperature of the injection mechanism were studied, and the stability was characterized using the clearance rate. By combining a Kriging metamodel and Bayesian hypothesis testing, an approximate system exhibiting high reliability was established. Based on the approximate system, a robust optimization design of the injection parameters was proposed under the 6σ framework. The optimization results of multiobjective particle swarm optimization and NSGA-II with different population sizes and generations numbers are compared. Results showed that NSGA-II (population size = 32; generations number = 60) gave the better performance. Robust optimization on this basis reduced the average clearance rate and standard deviation of the injection mechanism by 11.38% and 30.8%, respectively. [ABSTRACT FROM AUTHOR]

A comprehensive study on Sn macrosegregation behavior in ternary Al-Sn-Cu alloys was carried out by comparative analysis between gravity casting and squeeze casting samples. The microstructure and Sn distribution of the castings were characterized by metallography, scanning electron microscopy (SEM), energy-dispersive X-ray (EDX) spectroscopy, and a direct reading spectrometer. Results show that there are obvious differences in Sn morphology between gravity casting and squeeze casting alloys. Under squeeze casting condition, the grain size of the casting is smaller and the distribution of ß(Sn) is uniform. This effectively reduces the segregation of triangular grain boundary as well as the segregation of Sn. The segregation types of Sn in gravity casting and squeeze casting samples are obviously different. The upper surfaces of gravity casting samples show severe negative segregation, while all the lower surfaces have positive segregation. Compared with gravity casting, squeeze casting solidifies under isostatic pressure. Due to the direct contact between the upper surface of the casting and the mold, the casting solidifies faster under higher undercooling degree and pressure. Consequently, the uniform distribution of Sn reduces the segregation phenomenon on the surface of the casting. [ABSTRACT FROM AUTHOR]

Magnesium-based biomaterials have been in extensive research for orthopedic applications for decades due to their optimal mechanical features and osteopromotive nature; nevertheless, rapid degradation restricts their clinical applicability. In this study, pristine magnesium was purified (P-Mg) using a melt self-purification approach and reinforced using indigenously synthesized nanohydroxyapatite (HAP, 0.6 wt.%) and strontium substituted nanohydroxyapatite (SrHAP, 0.6 wt.%) using a low-cost stir assisted squeeze casting method to control their degradation rate. Using electron back-scattered diffraction (EBSD) and X-ray diffraction (XRD) examinations, all casted materials were carefully evaluated for microstructure and phase analysis. Mechanical characteristics, in vitro degradation, and in vitro biocompatibility with murine pre-osteoblasts were also tested on the fabricated alloys. For in vivo examination of bone formation, osteointegration, and degradation rate, the magnesium-based alloys were fabricated as small cylindrical pins with a diameter of 2.7 mm and a height of 2 mm. The pins were implanted in a critical-sized defect in a rat femur shaft (2.7 mm diameter and 2 mm depth) for 8 weeks and evaluated by micro-CT and histological evaluation for bone growth and osteointegration. When compared to P-Mg and P-MgHAP, micro-CT and histological analyses revealed that the P-MgSrHAP group had the highest bone formation towards the periphery of the implant and hence maximum osteointegration. When the removed pins from the bone defect were analyzed using GIXRD, they displayed hydroxyapatite peaks that were consistent with bio-integration. For P-Mg, P-MgHAP, and P-MgSrHAP 8 weeks after implantation , in vivo degradation rates derived from micro-CT were around 0.6 mm/year, 0.5 mm/year, and 0.1 mm/year, respectively. Finally, P-MgSrHAP possesses the requisite degradation rate as well as sufficient mechanical and biological properties, indicating that it has the potential to be used in the development/fabrication of biodegradable bioactive orthopaedic implants. [ABSTRACT FROM AUTHOR]

Aluminium metal matrix composites have been shown to make significant contributions to the area of new materials and have become widely accepted in high-tech structural and functional applications such as those in the aircraft, automobile, marine, mineral, defence, transportation, thermal management, automotive, and sports and recreation fields. Metal matrix composites are manufactured using a variety of manufacturing processes. Stirring casting, powder metallurgy, squeezing casting, in situ processes, deposition techniques, and electroplating are part of the manufacturing process used in the manufacture of aluminium-metal matrix composites. Metal matrix composites that use friction stir processing have a distinct advantage over metal matrix composites that use other manufacturing techniques. FSP's benefits include a finer grain, processing zone homogeneity, densification, and the homogenization of aluminium alloy and composite precipitates. Most metal matrix composite investigations achieve aluminium-metal matrix composite precipitate grain refinement, treated zone homogeneity, densification, and homogenization. This part of the work examines the impact of reinforcing particles, process parameters, multiple passes, and active cooling on mechanical properties during the fabrication of 5000-series aluminium-metal matrix composites using friction stir processing. This paper reports on the available literature on aluminium metal matrix composites fabricated with 5xxx series marine grade aluminium alloy using FSP. [ABSTRACT FROM AUTHOR]

In this research, aluminum matrix composites reinforced with continuous carbon fibers (CFs) were fabricated using A356 aluminum alloy and PAN-based CFs by squeeze casting. For this purpose, CFs were first coated with a nickel layer using the electroless method and then the microstructure of the nickel–phosphorus (Ni–P) electroless coating was investigated. In the next step, composite samples reinforced with volume fractions of 5, 10, and 15 vol.% CFs coated with Ni–P coating were fabricated by squeeze casting at 60 MPa, and then microstructure and mechanical properties were examined. The results of the bending test on the composite samples indicated that the nickel coating had a significant effect on the flexural strength of the composite and increased the flexural strength by up to 30%. In addition, with the increase in the volume percentage of the fibers, the hardness of the samples increased while both the wear rate and the coefficient of friction decreased. Moreover, the best wear resistance was observed in the sample containing 15 vol.% as-coated carbon fibers. The Ni coating led to the formation of a mechanically mixed layer (MML) containing a fine mixture of metallic oxides and carbon thus enhancing the wear resistance. [ABSTRACT FROM AUTHOR]

Strengthening, heat treating, or rolling these alloys with different reinforcement particles positively affects the physical, mechanical and tribological properties. In this study, materials were produced by squeeze casting method by adding B4C particle to Al7075 alloy matrix in 4 different reinforcement ratios (4%, 8%, 10%, 12%). The physical, mechanical, and tribological properties of B4C/Al7075 composites were compared to the Al7075 alloy. In addition, aging and rolling processes were applied to B4C reinforced composite and Al7075 alloy, where the best mechanical properties were obtained, and the effects of these processes on hardness, tensile and flexural strengths, and tribological properties were investigated. The fracture and wear surfaces of the samples were investigated by SEM. When the effect of reinforcement ratio was examined, the highest hardness value was seen at 12% reinforcement ratio. The highest tensile and flexural strength was obtained from 10% reinforcement. Tensile strength of 10% B4C/Al7075 composite material was determined as 249 MPa and flexural strength as 494 MPa. As in the hardness value, the best value in wear resistance was obtained from 12%. B4C reinforcement increased the wear resistance of the Al7075 alloy. When the effect of aging was examined, it was observed that the determined properties of the materials were considerably improved depending on the aging period, but they partially decreased after a certain aging period. The rolling process also improved the determined properties of the materials, but this effect was not as high as in the aging process. [ABSTRACT FROM AUTHOR]

In this paper, the electroless Ni–P-coated SiC and Al2O3 reinforcements are doped with scrap Al alloy wheel to fabricate the new AMMCs using the squeeze casting process. The primary objective of this research is to use electroless Ni–P-coated SiC and Al2O3 to improve the wear behaviour and thermal stability of AMMCs. In addition, the use of waste material as matrix reduces the production cost, environmental pollution and mining of minerals from the earth crust. To analyse the properties, the composites are fabricated in four different variations, i.e. scrap Al alloy with uncoated SiC (5 wt%) and scrap Al alloy with coated SiC (5 wt%), scrap Al alloy with uncoated Al2O3 (5 wt%) and scrap Al alloy with coated Al2O3 (5 wt%). Thermogravimetric analysis is used to study the thermal stability of composites. From the findings of this research, it is observed that the specific wear rate in composite reinforced with coated SiC is 5.7% lesser than the composite reinforced with uncoated Al2O3. Porosity in reinforced composite with coated Al2O3 is 17.5% lesser than the uncoated Al2O3. A noteworthy improvement in the hardness value is observed in the reinforced composites with coated particles compared to uncoated particles. All composite samples under consideration are thermally stable as the variation in weight gain of composite samples is less than 0.1% with increased temperature. Finally, morphological study is carried out using Scanning Electron Microscope (SEM) and elemental analysis and elements present in the composite are studied using Energy-Dispersive X-Ray analysis (EDAX). [ABSTRACT FROM AUTHOR]

In this study, highly stable aluminium silicate (Al2SiO5) particles were spatially dispersed with tungsten disulphide (WS2) particles, making aluminium alloy (AA7075) composites suitable for tribological applications. The composite fabrication was done through the squeeze casting technique by dispersing aluminium silicate (Al2SiO5) particles with 5–15% weight percentages and WS2 particles with weight percentages of 5% in the aluminium alloy. Optical microscopy and X-ray diffraction (XRD) techniques were employed to study the distribution of particles and phase analysis. Hardness and tensile strength tests were conducted to assess the mechanical strength of composites. Dry sliding wear behaviour of aluminium alloy and composites was studied using a pin-on-disc tribometer. Wear performance was evaluated over a load range of (20, 40, 60, and 80 N) at a sliding velocity of 2.0 m/s with a sliding distance of 3000 m. SEM, XRD, and Energy Dispersive Spectroscopy (EDS) were used to investigate the particles' effects on the wear mechanism. The 3D surface topography was used to characterise the worn surface map, and wear depth has been analysed. The experimental results revealed that both particle dispersed conditions show a synergetic effect on reducing wear rate and friction coefficient better than alloy and monodispersed particle composite. The higher wear resistance on the AA7075/10 wt.% Al2SiO5/5 wt.% WS2 coordinate was shown by the combined effect of reinforcement particles through the formation of a stable and compacted tribo lubricating layer consisting of mixed SiO2 and WO3, which retains wear resistance properties of the composites. [ABSTRACT FROM AUTHOR]

In order to explore the optimal combination of process parameters for the extrusion casting of A356 aluminum alloy flywheel housing, the application of casting numerical simulation and BP neural network optimized by genetic algorithm and particle swarm algorithm. The minimum shrinkage porosity defect volume value was taked as the optimization goal to select and optimize the four parameters of casting temperature, mold preheating temperature, specific pressure and pressure holding time. The results show that the optimized combination of process parameters is the pouring temperature of 676.2 °C, the mold preheating temperature of 280 °C, the specific pressure of 66.5 MPa, and the pressure holding time of 40 s. The above optimized parameters combination can effectively improve the casting quality and mechanical properties. [ABSTRACT FROM AUTHOR]

In this paper, ZL205A (AlCu5Mn alloy) castings were prepared by squeeze casting. The effects of solution and ageing treatment on the microstructure and mechanical properties of ZL205A castings were studied by metallography, scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS) and mechanical properties tests. The results showed that most of the θ(Al2Cu) and T(Al12CuMn2) phases in squeeze-cast ZL205A dissolved into the α(Al) matrix after solution treatment for 15 h. The fine precipitates gradually increased with the ageing time. The ultimate tensile strength of the specimen aged for 6 h was the highest of 467 MPa and the elongation was up to 15.1%, showing good comprehensive mechanical properties. [ABSTRACT FROM AUTHOR]

In this research, the effects of nanodiamond (ND) addition at different loadings on the compressive and wear properties of the interpenetrating phases hybrid aluminum/alumina (Al/Al 2 O 3) composite were investigated. The samples were fabricated in a two-step process. First, the Al 2 O 3 -ND preforms were fabricated via the replica method. Second, the squeeze casting route was employed to infiltrate the molten pure Al. The ceramic preforms were made by immersing a polyurethane foam with 17 ppi pores in a slurry containing α-Al 2 O 3 powder (1 μm), ND particles (0–10 vol%), and natural egg white. After sintering at 1500 °C for 4 h, the preheated preforms were infiltrated with molten Al. The microstructural evaluations of the preforms and composites revealed a proper distribution of the ND particles in the preform, as well as the formation of the ND agglomerates at higher volume percentages. Also, the hardness of the samples enhanced with an increase in the ND loading, reaching a maximum of 263.8 Vickers for the 10 vol% ND-loaded composite. The compressive strength of the samples enhanced up to 3 vol% ND addition and then decreased due to the agglomeration. The wear test results indicated that the best behavior was related to the 3 vol% ND-loaded composite. Embedding the 3 vol% ND decreased the weight rate and friction coefficient of the interpenetrating phases hybrid Al/Al 2 O 3 composite by 16 % (from 8.2396×10−3 to 6.9269×10−3 mm3/m) and 12 % (0.8165 to 0.7238), respectively. The study of the worn surfaces of the samples after wear testing revealed that the dominant wear mechanisms were abrasive and adhesive for the higher and lower volume fractions of the ND, respectively. [Display omitted] • The interpenetrating phases hybrid Al/Al 2 O 3 -ND composite were fabricated. • The microstructural evaluations revealed a proper distribution of the ND particles in the composite. • Increasing the volume percentage of diamond nanoparticles increased the hardness of the composites. • The maximum compressive strength was observed in the composite with 3 vol.% ND particles. [ABSTRACT FROM AUTHOR]