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Mechanical properties investigation of composite FGM fabricated from Al/Zn

  • Al-hadrayi Ziadoon Mohammed Rahi EMAIL logo , Ahmed Naif Al-Khazraji and Ahmed A. Shandookh
Published/Copyright: December 2, 2022
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Open Engineering
From the journal Open Engineering Volume 12 Issue 1

Abstract

This article investigates the novel mechanical behavior of metal–metal gradients (Al/Zn) of the functionally graded materials (FGM) type. The experimental work includes the manufacture of three different models (FGM 1, FGM 2, and FGM 3) with various proportions of volume fraction and gradation as (100% Al–50% Al–50% Zn–50% Zn–50% Al–100% Zn), (100% Al–30% Zn–70% Al–70% Zn–30% Al–100% Zn) and (100% Al–70% Zn–30% Al–30% Zn–70% Al–100% Zn), respectively. The annealing process was carried out to eliminate the casting problems of the FGM. Mechanical tests such as tensile and hardness were performed using different parameters of the gradient of properties for each model. Hardness tests for each model were carried out by the circumferential method along the rod made of the FGM and in the radial direction from the core of the models and at different distances. In the third model, the modulus of elasticity and ultimate strength were 79 and 377 MPa, respectively. The densities of the three models were measured experimentally and theoretically. The results show that model FGM 3 has a tensile strength of 6, which is 10% more than that of models FGM 1 and FGM 2. The results showed a significant improvement of 22% in the tensile strength on average compared to the aluminum–zinc alloy. The circumferential method of hardness testing gives variant results than the radial type due to the properties of FGMs.

Keywords: functionally gradient material; casting process; metal–metal composites; mechanical test

1 Introduction

In the progress of science and innovation, materials have played a significant role. The engineering of modern composite materials has significantly influenced technology. The concept of functionally graded material (FGM) describes the development of advanced materials with continuously changing material properties (such as mechanical and thermal properties) over time, eliminating stress concentrations in laminated composites [1,2]. FGMs are preferred over monolithic alloys in the automotive and engineering industries. In comparison with monolithic alloys, FGMs offer numerous advantages. FGM was developed out of a desire to produce a material with both microstructural and mechanical properties that varied along their axes. Compared to FGMs, conventional alloys focus on the even distribution of reinforcement within a matrix rather than on the measured distribution of reinforcement in varying concentrations within the matrix [3]. Because of the advantages that this class of materials possesses, FGMs are increasingly used in various engineering applications [4,5]. The most common applications of FGMs include energy, aerospace, automobiles, biochemistry, bioengineering, electrical/electronics, marine, optoelectronics, sports, and thermoelectrics. Figure 1 illustrates the various types of FGM and their types of applications [6].

Figure 1 Application areas for each type of FGM [6].
Figure 1

Application areas for each type of FGM [6].

FGMs have been manufactured with a variety of manufacturing methods over the years. One of those is casting. Manufacturers have often favored the casting process when it comes to producing FGMs composed of metal–metal compositions or metal–ceramic compositions due to the processing flexibility, ease of operation, and cost-effectiveness of the material fabrication [6]. Using the vertical centrifugal casting technique to manufacture structural components enhances their mechanical properties [7,8]. Centrifugally cast composite pistons made of Al–Si alloy reinforced with SiC particles were manufactured. Centrifugal casting of aluminum alloy-based composite pistons partially reinforced with SiC particles was successful [8,9]. Commercially, the casting process is considered the most effective method of producing FGMs. It discusses the aluminum–silicon carbide FGM disc manufacturing process simulation using ANSYS Fluent. The casting process can be simulated to visually monitor the progress of the solidification of molten metal without having to conduct costly and lengthy experiments [10]. Functionally graded polymer nano composites were fabricated by mixing alumina (Al2O3) nanoparticles with epoxy through five layers of 1.2 mm thickness per layer and by hand lay-up technique. The experimental and numerical results for the flexural modulus of FGM 1 loaded from the composite side showed good agreement [11,12]. One of the essential methods of manufacturing functionally gradient materials is 3D printing. FGMs are manufactured from porous, functionally graded polymeric materials. This method is costly for functionally graded metal fabrication [13,14]. The casting method was also suitable for making hollow cylinders of aluminum alloy and titanium oxide. The method gave a homogeneous structure and acceptable proportions in an excellent manner [15,16,17]. The literature has documented the effects of the various processing parameters involved in the manufacture of FGM by the casting process. An aluminum matrix material with 12% mass fractions of reinforcing materials was cast as hollow cylindrical functionally rated materials by centrifugal casting [18]. The current study aims to design, manufacture, and characterize an FGM consisting of aluminum and zinc alloy. Three models are designed with different ratios, weights, and densities. The manufacturing method is the casting method by a metal mold, and it is called the permanent casting method. It was distinguished by engineering tests, such as tensile and hardness tests, and comparing them in terms of satisfactory results.

2 Samples preparation

Alloys (aluminum and zinc) were supplied from the local market for this research, and the chemical components (spectrophotometer) of each alloy were examined, as shown in Figure 2 and Table 1, were approximately 1050 and 1060 aluminum alloys, while zinc alloys were approximately (Zamak 3). After that, tensile and hardness tests were conducted for each alloy to compare it with the FGMs made by the permanent casting method through a thermal furnace and the design of a metal mold installed on a base. Figure 3(a) shows the design shape and dimensions of the mold (21 cm in length × 2 cm in diameter). Figure 3(b) represents the mold in which the samples were cast, made of high-temperature iron, and greased from the inside. Figure 4 represents the FGMs scheme for three manufactured models. They were placed inside the melting pots after melting the ingots inside the furnace, as shown in Figure 5.

Figure 2 Chemical composition analysis (spectrophotometer).
Figure 2

Chemical composition analysis (spectrophotometer).

Table 1

Chemical compositions of alloys

Alloys Si% Fe% Cu% Mn% Mg% Cr% Ni% Zn% Ti% P% Pb% Al%
Al alloys 0.166 0.625 0.0878 0.0058 0.0012 0.0214 0.0093 0.017 0.0307 0.0015 0.0036 99
Alloys Al% Mg% Cu% Fe% Pb% Cd% Sn% Ni% Zn%
Zn alloys 3.8 0.03 0.25 0.1 0.005 0.004 0.003 — 95.8
Figure 3 (a) The sketch of mold; (b) mold for sample casting.
Figure 3

(a) The sketch of mold; (b) mold for sample casting.

Figure 4 Models of FGMs’ layout.
Figure 4

Models of FGMs’ layout.

Figure 5 (a) Furnace; (b) melting pots; (c) molds; and (d) samples of FGMs (e) Controller of temperature.
Figure 5

(a) Furnace; (b) melting pots; (c) molds; and (d) samples of FGMs (e) Controller of temperature.

The mechanical properties of the alloys that were used in the manufacture of the FGM are presented in Table 2.

Table 2

Mechanical properties of alloys

Alloys Elastic modulus (GPa) Ultimate strength (MPa) Yield strength (MPa) Density (mg/m3) Poisson’s ratio Melting temperature (°C)
Al 70.5 ± 2 340 ± 5 265 ± 5 2.66 ± 0.2 0.33 640 ± 5
Zn 85 ± 2 320 ± 5 225 ± 5 7.14 ± 0.2 0.25 422 ± 5

Depending on the thickness or size of the product, FGMs can be categorized into thin and bulk FGMs: thin FGMs consist of relatively thin sections or thin surface coatings, which can be created by self-propagating high-temperature synthesis, plasma spraying, chemical or physical vapor deposition, etc., and bulk FGMs can be produced using many different technologies, including centrifugal casting, powder metallurgy, permanent molds, and solid freeform technology [19]. Therefore, this article adopts the permanent casting method to produce functionally graded metal. Molds for permanently, such as in Figure 5, are generally made from metals with a higher melting point than the metals they contain. No external pressure is used to pour liquid metal into the mold. It is essential that permanent cores can be easily removed from finished castings to be reused.

The annealing and machining operations were performed on the samples made by the casting method. Figure 6 represents the annealing process for functionally graded samples at 380°C, which was approved according to the study in the literature review [20].

Figure 6 Annealing process: (a) furnace and (b) samples.
Figure 6

Annealing process: (a) furnace and (b) samples.

The machining operations were carried out on the samples manufactured by the casting method to form the samples to complete the requirements of the tests and according to the standards as shown in Figure 7.

Figure 7 Machining operations and ASTM standards (E8M and E18-05): (a) an isometric view; (b) top view; (c) side view; (d) sample; (e) sketch of the standard; and (f) cutting tools.
Figure 7

Machining operations and ASTM standards (E8M and E18-05): (a) an isometric view; (b) top view; (c) side view; (d) sample; (e) sketch of the standard; and (f) cutting tools.

3 Characterizations

By varying the constituents of multiphase materials in a predetermined manner, FGM can be produced. Nonuniform microstructures with continuously graded macro properties are one of the most distinctive features of an FGM. Volume fraction variation can be used to identify an FGM. The characterizations of FGMs are categorized into two majors that are mechanical and physical characterizations.

3.1 Mechanical characterization

3.1.1 Tensile and hardness test

When the local volume fraction g(z) is determined, it can be used to determine the material properties by the rule of mixture (ROM) [21]:

(1) E ( z ) = g ( z ) E Zn + ( 1 − g ( z ) ) E Al ,

where E Zn is the elastic modulus of zinc alloys, and E Al is the elastic modulus of aluminum alloys.

As shown in Figure 8, the tensile test has been carried out on the WDW-100E universal testing machine. The tests were conducted using the American Society for Testing and Materials (ASTM) E8M [22] and had a crosshead speed of 0.1 mm/min, by dividing the tensile stress on the strain in the linear part of the stress–strain curve between different strain values depending on the type of FGMs used.

Figure 8 (a) Tensile machine and (b) samples tested.
Figure 8

(a) Tensile machine and (b) samples tested.

An instrument that measures Rockwell hardness follows the Rockwell principle. Hardness testing is commonly carried out on carbon steels, alloy steels, cast iron, nonferrous metals, and machinery plastics. In addition, it boasts high accuracy, wide usage, automatic loading and unloading of the main force, printing of the test results, and computer connectivity. In this article, the hardness was tested in two ways: on the circumferential length of the rod made of the FGM and diagonally according to ASTM E18-05, as shown in Figure 9 [23].

Figure 9 Rockwell hardness and samples tested: (a) circumference hardness (front view); (b) isometric view; (c) core hardness; and (d) core sample.
Figure 9

Rockwell hardness and samples tested: (a) circumference hardness (front view); (b) isometric view; (c) core hardness; and (d) core sample.

3.2 Description of the physical property (density)

According to the ROM, the theoretical density (ρ th) of the composites was calculated as follows [21]:

(2) ρ th = V Al ρ Al + V Zn ρ Zn ,

where V Al, V Zn, ρ Al, and ρ Zn are the fractions of volume and densities of Al and Zn alloys, respectively.

Experimentally determined densities of the alloys and the FGMs were obtained by applying the Archimedes principle, as shown in Figure 10. This formula was used to compute the composite density [21]:

(3) ρ c = W a ( W a + W w ) .

Figure 10 The Archimedes principle to determine the densities.
Figure 10

The Archimedes principle to determine the densities.

The composite density is determined by ρ c, and W a and W w, respectively, determine the weights of air and water.

4 Results and discussion

The results conducted as tensile, hardness tests, and statistical calculations showed acceptable results for the FGMs and the different behavior, which shows the effect of volume fraction of different manufactured models. As well as the different values of the modulus of elasticity and hardness along the circumference of the samples.

4.1 Tensile test

Figure 11 represents the stress–strain behavior shown by the curves of alloys and FGMs (the three manufactured models). The stress–strain curves of the FGM are different from the alloys from which it was made. The FGM showed an improvement in the elastic modulus value compared with the original alloys that it was the best density, and the highest value of the elastic modulus was 79 GPa at FGM 3. As well as the ultimate stress of the FGMs of the third type, its value was 377 MPa; the results show that model FGM 3 has a tensile strength of 6, which is 10% more than that of models FGM 1 and FGM 2, respectively. The results showed a significant improvement of 22% in the tensile strength as an average compared to the aluminum–zinc alloy.

Figure 11 Stress–strain curves and behavior of FGMs.
Figure 11

Stress–strain curves and behavior of FGMs.

From Figure 12, it can be seen that the value of the elastic modulus changes by changing the fractional volume ratio. It has been given a nonlinear behavior, and the value depends on the amount of change in the volume fraction. The comparison was between the experimental results and the theoretical calculations based on equation (1). The ratio of the gap for the highest value of the elastic modulus values (theoretically and experimentally), especially in FGM 3, is 6%. The tensile test results also showed that the highest yield strength was for the third type, about 260 MPa, and the lowest strength for the second type was about 230 MPa. In addition, the ultimate strength was also the highest at the third type, about 377 MPa, as shown in Figure 13, which shows the values of the yield strength and the ultimate strength for each FGM.

Figure 12 Elastic modulus via distance along the FGM rod.
Figure 12

Elastic modulus via distance along the FGM rod.

Figure 13 Yield and ultimate strength for each FGM.
Figure 13

Yield and ultimate strength for each FGM.

4.2 Hardness

The hardness of the functional grade material layers varies for each type and according to the mixing ratio and the distribution of the material for each layer. The hardness tests were carried out for the FGM in two types. The first was on the outer surfaces of the rod manufactured as an FGM, as shown in Figure 14, and the second was for the core and according to ASTM E18 and along the length of the rod with different distances according to the mixing ratio of the FGM, as shown in Figure 15. The hardness test results showed variable values on the outer surface and nonlinear behavior, and the highest value of hardness was 90.5 HR in FGM 3 from the proximal side of the zinc alloy. At the same time, the lowest value of hardness was in FGM 1, which is 70.5 HR, which is close to the side of the aluminum alloy. The rate of hardness improvement of the FGM is about 12% compared to the alloys, and at the same time, it gives the impression that the hardness is variable at each point. In addition, the hardness values differ from the core to the outer surface, and this reason is due to the FGM property.

Figure 14 Circumference hardness (outer surface).
Figure 14

Circumference hardness (outer surface).

Figure 15 Core hardness.
Figure 15

Core hardness.

The density of manufactured materials was calculated theoretically and experimentally, as shown in Table 3. The results showed a remarkable convergence between theoretical and experimental calculations.

Table 3

Experimental and theoretical densities for each FGM

Composites Theoretical density (g/cm3) Experimental density (g/cm3)
FGM 1 3.45 3.356
FGM 2 4.35 4.283
FGM 3 3.22 3.163

The results showed that the highest density value was at FGM 2. After cutting the FGM and calculating the density according to distance and mixing ratio for the alloys and each type of the three models, it was shown that the density was variable at each point, as shown in Figure 16.

Figure 16 Experimental and theoretical densities of FGMs and the FGM rod’s distance.
Figure 16

Experimental and theoretical densities of FGMs and the FGM rod’s distance.

5 Conclusions

This article included the manufacturing of three models of FGM composed of aluminum and zinc alloy. The manufacturing process was the permanent die-casting method. The behavior of this FGM has been studied, and the manufacturing method is among the available possibilities. The main points of this study have been summarized as follows:

  1. The manufacturing process was very suitable and included the manufacture of three different models, and the results showed an effect according to the mixing ratio of the molten alloys.

  2. The modulus of elasticity and ultimate strength appeared in the third model as having the highest value, which amounted to 79 and 377 MPa, respectively. This is due to the mixing ratio adopted for this model. It increased by about 11%, and the ductility of FGM 1 appeared to be greater than that of FGM 2 and FGM 3. The results show that model FGM 3 has a tensile strength of 6, which is 10% more than that of models FGM 1 and FGM 2. The results showed that there is a significant improvement of 22% in the tensile strength on average compared to the aluminum–zinc alloy.

  3. The hardness test also showed the third model, which is the hardest of the first and second, and the test was taken in a circumferential and core configuration.

  4. The calculations of densities were close, both theoretically and experimentally.

  5. The properties were variable at each point, which distinguishes the FGM.

Acknowledgement

This work was supported by the University of Technology (Mechanical Engineering Department) and the University of Kufa (Lab of Materials Engineering, Faculty of Engineering, Iraq).

  1. Conflict of interest: Authors state no conflict of interest.

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Received: 2022-03-24
Revised: 2022-05-31
Accepted: 2022-06-17
Published Online: 2022-12-02

© 2022 the author(s), published by De Gruyter

This work is licensed under the Creative Commons Attribution 4.0 International License.

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https://doi.org/10.1515/eng-2022-0347
Keywords for this article
functionally gradient material; casting process; metal–metal composites; mechanical test
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