Impact of reinforcement proportions on mechanical properties and micro-structure of modified Al2O3-LM6 cast composites synthesize at self-pouring temperature: optimization through mixture design of experiment (DoE)

Abstract

Purpose The purpose of this study is to investigate and evaluate the impact of varying proportions of reinforcement on the mechanical properties of a modified Al2O3-LM6 cast composite under self-pouring temperature conditions. This study aims to determine the optimal mixture proportion of fine powders of Al, Si and xAl2O3 (with x values of 2%, 3% and 4%) through the application of design of experiment (DoE) and statistical analysis using the Minitab software. This study also involved evaluating the microstructural estimation and other physical properties of the cast composite to understand the combined effect of the reinforcement proportion on the material’s properties. Design/methodology/approach The researchers initially mixed the powders through ball milling and then compacted the moisture-free powder mix in a closed steel die. The resulting preforms were heated at the self-pouring temperature in an inert environment to fabricate the final cast composite. By applying DoE and performing an analysis of variance (ANOVA), the researchers sought to optimize the mixture proportion that would yield the best mechanical properties. Findings The experimental results indicated that a mixture combination of 83.5% Al blended with 12.5% Si and 4% Al2O3 led to the greatest improvement in mechanical properties, specifically in terms of increased density, hardness and impact strength. The ANOVA further supported the interaction effect of each processing parameter on the observed results. The results of this study offer valuable insights for the fabrication of modified Al2O3-LM6 cast composites under self-pouring temperature conditions. The identified optimal mixture proportion provides guidance for manufacturing processes and material selection to achieve improved mechanical properties in similar applications. Originality/value This study focuses on a specific composite material consisting of modified Al2O3 and LM6. Although Al2O3 and LM6 have been studied individually in various contexts, the combination of these materials and their impact on mechanical properties under self-pouring temperature conditions is a novel aspect of this research. The researchers use DoE methodology, along with statistical analysis using Minitab software, to optimize the mixture proportion and analyze the data. This systematic approach allows for a comprehensive exploration of the parameter space and the identification of significant factors that influence the mechanical properties of the composite.