Physio-mechanical assessment and process mapping of AlSi10mg/Cu material for automobile application

In this study, copper (Cu) particles were used as a replacement for ceramic particles in an AlSi10Mg matrix to lessen the brittleness often associated with ceramic particles when used as fillers in aluminum matrix. AlSi10Mg was combined with 0, 2, 4, and 6% Cu, and microwave sintering was performed at 300, 450, and 600 °C. The composites produced were subjected to physical tests (porosity, density, shrinkage, and relative density), tensile tests (yield and ultimate strength, elastic modulus, and elongation), and microstructure test. Cu particles were observed to be dispersed at 2% and 4% sintering temperatures and clustered at 6% sintering temperatures, according to the microstructural images. The incorporation of 2% and 4% Cu decreased porosity, leading to increased yield, ultimate tensile strength, and elastic modulus respectively. It was noted that 6% Cu addition resulted in strength reduction owing to particle clusters. Sintering temperatures between 300 and 450 ℃ were favorable for all property investigated; nevertheless, temperatures above 600 °C were detrimental to property responses. The proposed process map revealed diverse response values for varying input combination parameters; hence, a Cu dosage of 4% at a sintering temperature of ≤ 450 °C is recommended.