Impact of Yellow Oil Fly Ash Content and Particle Size on the Mechanical Performance of Sintered Cu-Gr Hybrid Composites
الشريط الجانبي للمقالة
محتوى المقالة الرئيسي
الملخص
In the present work, copper hybrid composites reinforced with graphite (Gr) and yellow oil fly ash (YOFA) are fabricated by powder metallurgy. Incorporating yellow oil fly ash (YOFA) improves sustainability as well as mechanical and tribological properties, making it a potential green reinforcement. Pure copper powder was mixed with 3% graphite and YOFA at various concentrations, i.e. 0, 3, 6, 9, and 12 vol.%, as well as particle sizes, i.e., <53, 53–80, 80–125, and 125–150 μm. The mechanical and physical properties, i.e., microhardness, radial compressive strength, wear resistance, density, and porosity, were tested. The results showed that as YOFA concentration and particle size increased, density decreased while porosity decreased despite the large particle size. Microhardness increased significantly with YOFA after its initial decrease due to graphite addition. Radial compressive strength reduced due to graphite and declined further with YOFA; however, it improved considerably at 12 vol.% YOFA. Wear tests (5–20 N, 20 min) showed load-dependent wear behavior, and the best performance was achieved at 9 vol.% YOFA with small particles, suggesting higher load-bearing capacity and more stable tribological properties. YOFA was an excellent reinforcement in terms of improving the tribo-mechanical performance of Cu-Gr composites. A full factorial design was employed to maximize the wear test conditions. ANOVA showed that YOFA content, YOFA particle size, and applied stress were the most significant parameters, supporting the experiment’s robustness. The best performance was achieved at 9 vol.% YOFA content across all particle sizes and applied loads, minimizing wear loss.
تفاصيل المقالة
القسم
هذا العمل مرخص بموجب Creative Commons Attribution 4.0 International License.
THIS IS AN OPEN ACCESS ARTICLE UNDER THE CC BY LICENSE http://creativecommons.org/licenses/by/4.0/
كيفية الاقتباس
المراجع
Annaz AA, Irhayyim SS, Hamada ML, Hammood HS. Comparative Study of Mechanical Performance Between Al-Graphite and Cu-Graphite Self-Lubricating Composites Reinforced by Nano-Ag Particles. AIMS Materials Science 2020; 7(5): 534–551.
Mahdi FM, Razooqi RN, Irhayyim SS. The Influence of the Graphite Content and Milling Time on the Hardness, Compressive Strength and Wear Volume of Copper - Graphite Composites Prepared Via Powder Metallurgy. Tikrit Journal of Engineering Sciences 2017; 24(3): 38–44.
Irhayyim SS, Hammood HS, Meteab MM. Gravel Powder Effect in Reinforced Aluminum Alloy Matrix Composite. Materials Today: Proceedings 2020; 20: 548–554.
Deng Z, Zhou X, Zhang J, Li Y, Wang H, Chen X, Liu Y. Microstructure and Mechanical Properties of Cu–12Al–xNi Alloy Prepared Using Powder Metallurgy. Materials Science and Engineering: A 2019; 759: 241–251.
Meignanamoorthy M, Ravichandran M. Synthesis of Metal Matrix Composites Via Powder Metallurgy Route. Mechanics and Mechanical Engineering 2018; 22(1): 59–69.
Surekha K, Els-Botes A. Development of High Strength, High Conductivity Copper by Friction Stir Processing. Materials & Design 2011; 32(2): 911–916.
Narayanasamy P, Balaji AN, Vettivel SC. Microstructural, Electrical, Thermal, and Tribological Studies of Copper-Fly Ash Composites Through Powder Metallurgy. Bulletin of the Polish Academy of Sciences: Technical Sciences 2018; 66(6): 935–940.
Guo MX, Shen K, Wang MP. Effect of In Situ Reaction Conditions on the Microstructure Changes of Cu–TiB2 Alloys by Combining in Situ Reaction and Rapid Solidification. Materials Chemistry and Physics 2012; 131(3): 589–599.
Mun YS, Jo JH, Park GD, Kang YC. Copper–Antimony–Red Phosphorus Composites as Promising Anode Materials for Sodium-Ion Batteries. Journal of Power Sources 2017; 362: 115–122.
Ahn BW, Kim JH, Hamad K, Jung SB. Microstructure and Mechanical Properties of a B4C Particle-Reinforced Cu Matrix Composite Fabricated by Friction Stir Welding. Journal of Alloys and Compounds 2017; 693: 688–691.
Irhayyim SS. Effect of Graphite/WC Additions on Physical, Mechanical, and Wear Properties of Aluminum. Diyala Journal of Engineering Sciences 2017; 10(1): 72–86.
Razooqi RN, Razej KH, Abdulhameed AT, Irhayyim SS. The Physical and Mechanical Properties of a Shape Memory Alloy Reinforced with Carbon Nanotubes (CNTs). Tikrit Journal of Pure Science 2018; 23(9): 80–88.
Liu Q, Castillo-Rodríguez M, Galisteo AJ, Guzmán de Villoria R, Torralba JM. Wear Behavior of Copper–Graphite Composites Processed by Field-Assisted Hot Pressing. Journal of Composites Science 2019; 3(1): 29.
Mahdi AD, Irhayyim SS, Abduljabbar SF. Mechanical and Wear Behavior of Al7075-Graphite Self-Lubricating Composite Reinforced by Nano-WO3 Particles. Materials Science Forum 2020; 1002: 151–160.
Chen K, Zhang L, Xie T, Wei X. Study on Graphite Motion Law of Copper-Based Graphite Composites During Friction. Journal of Advanced Mechanical Design, Systems, and Manufacturing 2024; 18(3): 2024jamdsm0026.
Rajesh R, Balaji AN, Narayanasamy P, Vettivel SC. Study on Conventional and Microwave-Assisted Sintering of Cu-FA Composites. Materials Today: Proceedings 2021; 39: 1677–1681.
Dinaharan I, Albert T. Effect of Reinforcement Type on Microstructural Evolution and Wear Performance of Copper Matrix Composites Via Powder Metallurgy. Materials Today Communications 2023; 34: 105250.
da Motta CAO, dos Santos CA, Garcia A, Spim JA. Enhancing Composite Materials Through Fly Ash Reinforcement Through Powder Metallurgy. Materials Chemistry and Physics 2023; 307: 128124.
Zou H, Ran X, Zhu W, Wang Y, Zhan S, Hao Z. Tribological Behavior of Copper–Graphite Composites Reinforced with Cu-Coated or Uncoated SiO2 Particles. Materials 2018; 11(12): 2414.
Dinaharan I, Albert T, David Raja Selvam J. Microstructure and Wear Performance of Fly Ash-Reinforced Copper Matrix Composites Prepared Via Powder Metallurgy. Journal of Materials Engineering and Performance 2024; 33(24): 14161–14176.
Balamurugan P, Uthayakumar M, Niemczewska-Wójcik M. Wear Studies of Copper-Fly Ash Composite Under Dry Sliding Conditions. Materials Research Express 2019; 6(10): 1065d5.
Rajan STK, Balaji AN, Raghav GR, Vettivel SC. Compression and Corrosion Behaviour of Sintered Copper-Fly Ash Composite Material. Materials Research Express 2019; 6(4): 046524.
Influence of Concentration and Particle Size of Yellow Oil Fly Ash on Thermal and Mechanical Properties of High-Density Polyethylene. Jordan Journal of Mechanical and Industrial Engineering 2025; 19(1): 129–146.
ASTM B962-08. Standard Test Methods for Density of Compacted or Sintered Powder Metallurgy (PM) Products Using Archimedes’ Principle. ASTM International, West Conshohocken, PA; 2008.
Horath L. Fundamentals of Materials Science for Technologists: Properties, Testing, and Laboratory Exercises. 3rd ed., Waveland Press, Inc.; 2019.
Huang SJ, Abbas A, Ballóková B. Effect of CNT on Microstructure, Dry Sliding Wear and Compressive Mechanical Properties of AZ61 Magnesium Alloy. Journal of Materials Research and Technology 2019; 8(5): 4273–4286.
Zeng F, Dong X, Wang Q, Zhang C, Wu Y, Ding W. Fabrication and Mechanical Properties of Mesoporous Silica Nanoparticles Reinforced Magnesium Matrix Composite. Journal of Alloys and Compounds 2017; 728: 413–423.
AlGharagoly HSH. Effect of Pressing Pressure on Properties of Copper–10% Graphite Composites Prepared by Powder Metallurgy Technique. Tikrit Journal of Engineering Sciences 2016; 24(2): 28–34.
ASTM E384-22. Standard Test Method for Microindentation Hardness of Materials. ASTM International, West Conshohocken, PA; 2022.
Irhayyim SS, Hammood HS, Mahdi AD. Mechanical and Wear Properties of Hybrid Aluminum Matrix Composite Reinforced with Graphite and Nano MgO Particles Prepared by Powder Metallurgy Technique. AIMS Materials Science 2020; 7(1): 103–115.
Irhayyim SS, Hammood HS, Abdulhadi HA. Effect of Nano-TiO2 Particles on Mechanical Performance of Al–CNT Matrix Composite. AIMS Materials Science 2019; 6(6): 1124–1134.
Irhayyim SS, Ahmed SR, Annaz AA. Mechanical Performance of Micro-Cu and Nano-Ag Reinforced Al-CNT Composite Prepared by Powder Metallurgy Technique. Materials Research Express 2019; 6(10): 105071.
ASTM G99-95a. Standard Test Method for Wear Testing with a Pin-on-Disk Apparatus. ASTM International, West Conshohocken, PA; 2017.
Hammood HS, Mahmood AS, Irhayyim SS. Effect of Graphite Particles on Physical and Mechanical Properties of Nickel Matrix Composite. Periodicals of Engineering and Natural Sciences 2019; 7(3): 1318–1328.
Xiao Y, Zhang Z, Yao C, Wang Y, Kadochkin A, Zhang Y. Investigation on Speed-Load Sensitivity to Tribological Properties of Copper Metal Matrix Composites for Braking Application. Metals 2020; 10(7): 889.
Ning H, Wang Z, Zhao X, Liu Y, Zhang S, Lu Y. Modeling and Prediction of Tribological Properties of Copper/Aluminum-Graphite Self-Lubricating Composites Using Machine Learning Algorithms. Friction 2024; 12(6): 1322–1340.
Radhika N, Sam M. Tribological and Wear Performance of Centrifuge Cast Functional Graded Copper-Based Composite at Dry Sliding Conditions. Journal of Central South University 2019; 26(11): 2961–2973.
Balamurugan P, Uthayakumar M. Influence Study of Manufacturing Constraints and Percentage of Reinforcement on Copper-Fly Ash Composite by Full Factorial Design. International Journal of Computer Aided Engineering and Technology 2018; 10(6): 673–683.
Li H, Zhang Z, Dong C, Wu G, Yang H. On the Tribological Behaviors of Cu Matrix Composites with Different Cu-Coated Graphite Content. Journal of Materials Research and Technology 2023; 25: 83–94.
Santhosh MS, Sasikumar C, Natarajan E, Kumar RS. Mechanical and Wear Behaviour of Nano-Fly Ash Particle-Reinforced Mg Metal Matrix Composites Fabricated by Stir Casting Technique. Journal of Nanomaterials 2022; 2022: 5465771.
Shankar KV, Sharma S, Verma A. Investigating the Effect of Fly Ash Addition on the Metallurgical and Mechanical Behavior of Al-Si-Mg-Cu Alloy for Engine Cylinder Head Application. Materials 2022; 15(15): 5462.
Sai NV, Komaraiah M, Raju AVSR. Preparation and Properties of Sintered Copper–Tin Composites Containing Copper Coated or Uncoated Fly Ash. Materials and Manufacturing Processes 2008; 23(7): 651–657.
Chew PY, Zahi S, You AH, Lim PS, Ng MC. Preparation of Cu and Fly Ash Composite by Powder Metallurgy Technique. AIP Conference Proceedings 2011; 1328(1): 208–210.
Balamurugan P, Uthayakumar M. Influence of Process Parameters on Cu–Fly Ash Composite by Powder Metallurgy Technique. Materials and Manufacturing Processes 2015; 30(3): 313–319.
Balamurugan P, Uthayakumar M. Wear Studies on SiC and Fly Ash Reinforced Copper Based Composites by Grey Relational Analysis. Advanced Materials Research 2014; 984-985: 304–312.
Haiter Lenin A, Vettivel SC, Raja T, Belay L, Singh SCE. A Statistical Prediction on Wear and Friction Behavior of ZrC Nano Particles Reinforced with Al Si Composites Using Full Factorial Design. Surfaces and Interfaces 2018; 10: 149–161.
Gangatharan K, Selvakumar N. Optimizing the Dry Sliding Wear Behavior of Copper Hybrid Nano Composites Reinforced with MWCNTs and Nano B4C Using Full Factorial Design. Transactions of the Indian Institute of Metals 2016; 69(3): 717–732.