AGRO-BIO-WASTE AND NANO CERAMIC COMPOUND INCORPORATED ALUMINUM MATRIX HYBRID NANO COMPOSITES

Abstract

ABSTRACT “AGRO-BIO-WASTE AND NANO CERAMIC COMPOUND INCORPORATED ALUMINUM MATRIX HYBRID NANO COMPOSITES” The present invention provides Agro-bio-waste and nano ceramic compound incorporated Aluminum matrix hybrid nano composites. The composite comprises an Al 7075 alloy matrix reinforced with 3.75 wt.% rice husk ash, 1.25 wt.% egg shell ash, and 0.5-2.5 wt.% nano silicon carbide (SiC) particles. The manufacturing process, performed under inert gas, combines mechanical and ultrasonic mixing to achieve uniform reinforcement dispersion, eliminating harmful degassing agents. Squeeze casting solidifies the composite, followed by T6 heat treatment, resulting in enhanced tensile strength, impact resistance, and corrosion resistance. This environmentally friendly nanocomposite is suitable for automotive, aerospace, marine, defense, and electronics applications, offering improved durability and surface properties. No Figure.

Specification

Description:TECHNICAL FIELD
[0001] The present invention relates to the field of agriculture, and more particularly, the present invention relates to the agro-bio-waste and nano ceramic compound incorporated Aluminum matrix hybrid nano composites.
BACKGROUND ART
[0002] The following discussion of the background of the invention is intended to facilitate an understanding of the present invention. However, it should be appreciated that the discussion is not an acknowledgment or admission that any of the material referred to was published, known, or part of the common general knowledge in any jurisdiction as of the application's priority date. The details provided herein the background if belongs to any publication is taken only as a reference for describing the problems, in general terminologies or principles or both of science and technology in the associated prior art.
[0003] Aluminum Matrix Composites (AMCs) are increasingly replacing traditional metal materials due to their enhanced mechanical and wear properties, making them ideal for use in industries such as aerospace, maritime, automotive, sports, and biomedical applications. The strength of these composites can be enhanced by various techniques, including the addition of insoluble reinforcement materials to the base alloy. AMCs typically consist of multiple insoluble phases, often exhibiting superior properties compared to their individual components. Recently, nano-sized particulate reinforcements in AMCs have been studied for their superior mechanical properties compared to traditional micro-sized reinforcements. This is attributed to grain refinement, strong thermal stress at the matrix/nano particle interface, the small size and uniform distribution of nano particles, and reduced porosity, which facilitates the efficient transfer of applied tensile loads to the nano particulates. The strength of these composites is influenced by factors such as dislocation density, interactions between dislocations, and the resistance to plastic flow imposed by the nano particles. Overall, the improved performance of these composites relies on the effective integration of nano and micro-sized particulates working together synergistically. The current study focuses on the impact of nano-ceramic particulate reinforcements on the physical, microstructural, mechanical, and tribological properties of various hybrid aluminum matrix composites.
[0004] Available Solutions:
- Material and method for producing metal nanocomposites, and metal nanocomposites obtained thereby (Patent No. CN109996625B)
- High-entropy alloy particle reinforced aluminum-based composite material and magnetic field auxiliary preparation method (Patent No. CN112899531A)
- Composites of aluminum oxide and cerium/zirconium mixed oxides (Patent No. US10766018B2)
- Nanomatrix metal composite (Patent No. CA2806714C)
[0005] In light of the foregoing, there is a need for Agro-bio-waste and nano ceramic compound incorporated Aluminum matrix hybrid nano composites that overcomes problems prevalent in the prior art associated with the traditionally available method or system, of the above-mentioned inventions that can be used with the presented disclosed technique with or without modification.
[0006] All publications herein are incorporated by reference to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies, and the definition of that term in the reference does not apply.
OBJECTS OF THE INVENTION
[0007] The principal object of the present invention is to overcome the disadvantages of the prior art by providing Agro-bio-waste and nano ceramic compound incorporated Aluminum matrix hybrid nano composites.
[0008] Another object of the present invention is to provide Agro-bio-waste and nano ceramic compound incorporated Aluminum matrix hybrid nano composites that enhance the metallurgical properties of Al7075 hybrid composite.
[0009] Another object of the present invention is to provide Agro-bio-waste and nano ceramic compound incorporated Aluminum matrix hybrid nano composites that serve as nucleation sites during the aluminum matrix's solidification. Their small size and large surface area create more nucleation points, resulting in finer grains. This refinement improves various metallurgical and mechanical properties, such as increased strength, driven by the Hall-Petch effect.
[0010] Another object of the present invention is to provide Agro-bio-waste and nano ceramic compound incorporated Aluminum matrix hybrid nano composites that enhances the strength of the Al7075 hybrid composite through several mechanisms:
[0011] Another object of the present invention is to provide Agro-bio-waste and nano ceramic compound incorporated Aluminum matrix hybrid nano composites that reduce the stress on the softer aluminum matrix and improving the composite's overall strength.
[0012] Another object of the present invention is to provide Agro-bio-waste and nano ceramic compound incorporated Aluminum matrix hybrid nano composites that generates dislocations around the reinforcements, leading to strain hardening and enhanced mechanical strength.
[0013] Another object of the present invention is to provide Agro-bio-waste and nano ceramic compound incorporated Aluminum matrix hybrid nano composites that helps reduce porosity in the composite by filling voids, creating a denser structure and minimizing casting defects like shrinkage porosity.
[0014] Another object of the present invention is to provide Agro-bio-waste and nano ceramic compound incorporated Aluminum matrix hybrid nano composites that contributes to better wear resistance by acting as hard barriers against abrasion, reducing material loss during use.
[0015] Another object of the present invention is to provide Agro-bio-waste and nano ceramic compound incorporated Aluminum matrix hybrid nano composites that help the composite retain its mechanical properties at higher temperatures.
[0016] Another object of the present invention is to provide Agro-bio-waste and nano ceramic compound incorporated Aluminum matrix hybrid nano composites that enhance the composite's ability to absorb and dissipate vibrational energy, which is crucial in reducing noise and vibrations, especially in aerospace and automotive applications.
[0017] Another object of the present invention is to provide Agro-bio-waste and nano ceramic compound incorporated Aluminum matrix hybrid nano composites that help refine and control these phases, leading to better corrosion resistance by minimizing galvanic coupling effects and improved toughness by preventing the formation of brittle zones.
[0018] Another object of the present invention is to provide Agro-bio-waste and nano ceramic compound incorporated Aluminum matrix hybrid nano composites wherein when used alongside other reinforcements like rice husk ash and egg shell ash, nano SiC particles create a synergistic effect, balancing strength and ductility. The combination of micro and nano-sized reinforcements results in optimized mechanical properties, producing a more versatile, high-performing material.
[0019] The foregoing and other objects of the present invention will become readily apparent upon further review of the following detailed description of the embodiments as illustrated in the accompanying drawings.
SUMMARY OF THE INVENTION
[0020] The present invention relates to Agro-bio-waste and nano ceramic compound incorporated Aluminum matrix hybrid nano composites.
[0021] To address the issues of low ductility and low impact strength in the hybrid Al7075 metal matrix composite, which was created by adding 3.75 wt. % rice husk ash and 1.25 wt. % egg shell ash, experimental trials were conducted by incorporating nano-sized ceramic SiC particles (in increments of 0.5 wt. % ranging from 0.5 wt. % to 2.5 wt. %) into the melt. This was done using a stir casting process, combining mechanical and ultrasonic mixing, followed by squeeze casting. The detailed steps of the melting process are as follows:
[0022] The stir casting process starts by placing an empty crucible and AA 7075 alloy ingots, cut into circular saw discs, weighing around 1.2 kg, into the muffle.
[0023] Initially, the heater temperature is set to 500 °C and then gradually increased to 800 °C.
[0024] The melting process is carried out at 760 °C.
[0025] Once the alloy is fully melted, slagging is performed. The melt is maintained at 740 °C, followed by degassing using argon gas bubbling (1.5 liters/min) for 10 minutes to refine the aluminum melt and remove slag. Surface scum is removed with a slagging spoon.
[0026] The primary reinforcements (rice husk ash and egg shell ash) and secondary reinforcement (nano SiC) are preheated to 500 °C for 1 hour to eliminate moisture and improve wettability with the molten matrix.
[0027] The alloy is reheated to 750 °C, and the preheated primary reinforcements (rice husk ash and egg shell ash) with 1 wt. % preheated magnesium powder (to improve wettability with the molten alloy) are gradually added at 750 °C using a hopper, while maintaining continuous mechanical stirring at 400 rpm for 10 minutes to prevent particle coagulation and segregation.
[0028] The temperature is then lowered to 720 °C, and the preheated nano SiC reinforcement is introduced, along with simultaneous argon gas bubbling and mechanical stirring at 400 rpm for another 10 minutes.
[0029] The temperature is raised again to 750 °C, and ultrasonic mixing is applied for 5 minutes under argon gas. The ultrasonic horn is preheated to 720 °C for 5 minutes before the UV generator is turned on, and the probe is submerged to three-quarters of the depth of the liquid metal to vibrate at ultrasonic frequencies.
[0030] The molten alloy is poured into a preheated (400 °C) steel mold and subjected to squeeze casting at 50 MPa for 3-6 minutes to allow solidification and then cooled to room temperature.
[0031] The cast ingot is processed using wire electro-discharge machining, cut into four longitudinal sections, and subjected to a T6 heat treatment cycle (Solutionising at 483 °C for 4 hours, quenching in running cold water, and then artificially aging at 122 °C for 24 hours, followed by air cooling).
[0032] The machined mechanical samples are tested for tensile strength, compression strength, elongation percentage, impact strength, and flexural strength.
[0033] The current invention stands out from existing solutions for several reasons:
- It incorporates agro-bio-waste materials like rice husk ash and egg shell ash as primary reinforcements in hybrid aluminum matrix composites.
- It uses nano-sized synthetic compounds, such as SiC, as secondary reinforcement materials.
- The melt is prepared using a stir casting process, involving both mechanical and ultrasonic mixing, followed by squeeze casting.
- The resulting aluminum matrix hybrid nanocomposites exhibit enhanced mechanical strength, improved microstructural characteristics, and superior surface properties.
[0034] While the invention has been described and shown with reference to the preferred embodiment, it will be apparent that variations might be possible that would fall within the scope of the present invention.
BRIEF DESCRIPTION OF DRAWINGS
[0035] So that the manner in which the above-recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may have been referred by embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
[0036] These and other features, benefits, and advantages of the present invention will become apparent by reference to the following text figure, with like reference numbers referring to like structures across the views, wherein:
[0037] No Figure.
DETAILED DESCRIPTION OF THE INVENTION
[0038] While the present invention is described herein by way of example using embodiments and illustrative drawings, those skilled in the art will recognize that the invention is not limited to the embodiments of drawing or drawings described and are not intended to represent the scale of the various components. Further, some components that may form a part of the invention may not be illustrated in certain figures, for ease of illustration, and such omissions do not limit the embodiments outlined in any way. It should be understood that the drawings and the detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the scope of the present invention as defined by the appended claim.
[0039] As used throughout this description, the word "may" is used in a permissive sense (i.e. meaning having the potential to), rather than the mandatory sense, (i.e. meaning must). Further, the words "a" or "an" mean "at least one" and the word "plurality" means "one or more" unless otherwise mentioned. Furthermore, the terminology and phraseology used herein are solely used for descriptive purposes and should not be construed as limiting in scope. Language such as "including," "comprising," "having," "containing," or "involving," and variations thereof, is intended to be broad and encompass the subject matter listed thereafter, equivalents, and additional subject matter not recited, and is not intended to exclude other additives, components, integers, or steps. Likewise, the term "comprising" is considered synonymous with the terms "including" or "containing" for applicable legal purposes. Any discussion of documents, acts, materials, devices, articles, and the like are included in the specification solely for the purpose of providing a context for the present invention. It is not suggested or represented that any or all these matters form part of the prior art base or were common general knowledge in the field relevant to the present invention.
[0040] In this disclosure, whenever a composition or an element or a group of elements is preceded with the transitional phrase "comprising", it is understood that we also contemplate the same composition, element, or group of elements with transitional phrases "consisting of", "consisting", "selected from the group of consisting of, "including", or "is" preceding the recitation of the composition, element or group of elements and vice versa.
[0041] The present invention is described hereinafter by various embodiments with reference to the accompanying drawing, wherein reference numerals used in the accompanying drawing correspond to the like elements throughout the description. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiment set forth herein. Rather, the embodiment is provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those skilled in the art. In the following detailed description, numeric values and ranges are provided for various aspects of the implementations described. These values and ranges are to be treated as examples only and are not intended to limit the scope of the claims. In addition, several materials are identified as suitable for various facets of the implementations. These materials are to be treated as exemplary and are not intended to limit the scope of the invention.
[0042] The present invention relates to Agro-bio-waste and nano ceramic compound incorporated Aluminum matrix hybrid nano composites.
[0043] Features of the present invention:
- A minor addition of nano SiC particles, ranging from 0.5 wt.% to 2.5 wt.%, to the Al 7075 melt containing 3.75 wt.% rice husk ash and 1.25 wt.% egg shell ash significantly enhances the mechanical properties of the composite, making it suitable for potential applications in automotive, aerospace, and defense industries.
- This innovation opens up the possibility for large-scale use of agro and bio-waste materials, such as rice husk ash and egg shell ash, in aluminum metal matrix hybrid composites, with the addition of nano synthetic compounds like SiC for improved properties.
- The melting process can be carried out entirely under an inert gas cover, eliminating the need for harmful chemicals like degasser tablets and chlorine gas, making the process environmentally friendly.
- The combination of ultrasonic mixing with mechanical mixing is an innovative feature that helps prevent the coagulation of nano particles in the composite.4o
[0044] With these property improvements, aluminum alloys reinforced with nano SiC are ideal for high-performance applications such as:
- Automotive Components: Engine parts, chassis elements, and crash management systems that demand high strength, toughness, and enhanced corrosion resistance.
- Aerospace Structures: Airframe components and other structural parts where lightweight materials with high strength are critical.
- Marine Applications: Boat hulls and marine fittings that benefit from increased corrosion resistance.
- Defense: Structural components and armor requiring high strength, toughness, and durability.
- Electronics: Heat sinks and electronic packaging, where thermal stability and reduced thermal expansion are advantageous.
[0045] The present invention relates to Agro-bio-waste and nano ceramic compound incorporated Aluminum matrix hybrid nano composites.
[0046] To address the issues of low ductility and low impact strength in the hybrid Al7075 metal matrix composite, which was created by adding 3.75 wt. % rice husk ash and 1.25 wt. % egg shell ash, experimental trials were conducted by incorporating nano-sized ceramic SiC particles (in increments of 0.5 wt. % ranging from 0.5 wt. % to 2.5 wt. %) into the melt. This was done using a stir casting process, combining mechanical and ultrasonic mixing, followed by squeeze casting. The detailed steps of the melting process are as follows:
[0047] The stir casting process starts by placing an empty crucible and AA 7075 alloy ingots, cut into circular saw discs, weighing around 1.2 kg, into the muffle.
[0048] Initially, the heater temperature is set to 500 °C and then gradually increased to 800 °C.
[0049] The melting process is carried out at 760 °C.
[0050] Once the alloy is fully melted, slagging is performed. The melt is maintained at 740 °C, followed by degassing using argon gas bubbling (1.5 liters/min) for 10 minutes to refine the aluminum melt and remove slag. Surface scum is removed with a slagging spoon.
[0051] The primary reinforcements (rice husk ash and egg shell ash) and secondary reinforcement (nano SiC) are preheated to 500 °C for 1 hour to eliminate moisture and improve wettability with the molten matrix.
[0052] The alloy is reheated to 750 °C, and the preheated primary reinforcements (rice husk ash and egg shell ash) with 1 wt. % preheated magnesium powder (to improve wettability with the molten alloy) are gradually added at 750 °C using a hopper, while maintaining continuous mechanical stirring at 400 rpm for 10 minutes to prevent particle coagulation and segregation.
[0053] The temperature is then lowered to 720 °C, and the preheated nano SiC reinforcement is introduced, along with simultaneous argon gas bubbling and mechanical stirring at 400 rpm for another 10 minutes.
[0054] The temperature is raised again to 750 °C, and ultrasonic mixing is applied for 5 minutes under argon gas. The ultrasonic horn is preheated to 720 °C for 5 minutes before the UV generator is turned on, and the probe is submerged to three-quarters of the depth of the liquid metal to vibrate at ultrasonic frequencies.
[0055] The molten alloy is poured into a preheated (400 °C) steel mold and subjected to squeeze casting at 50 MPa for 3-6 minutes to allow solidification and then cooled to room temperature.
[0056] The cast ingot is processed using wire electro-discharge machining, cut into four longitudinal sections, and subjected to a T6 heat treatment cycle (Solutionising at 483 °C for 4 hours, quenching in running cold water, and then artificially aging at 122 °C for 24 hours, followed by air cooling).
[0057] The machined mechanical samples are tested for tensile strength, compression strength, elongation percentage, impact strength, and flexural strength.
[0058] The current invention stands out from existing solutions for several reasons:
- It incorporates agro-bio-waste materials like rice husk ash and egg shell ash as primary reinforcements in hybrid aluminum matrix composites.
- It uses nano-sized synthetic compounds, such as SiC, as secondary reinforcement materials.
- The melt is prepared using a stir casting process, involving both mechanical and ultrasonic mixing, followed by squeeze casting.
- The resulting aluminum matrix hybrid nanocomposites exhibit enhanced mechanical strength, improved microstructural characteristics, and superior surface properties.
[0059] Various modifications to these embodiments are apparent to those skilled in the art from the description and the accompanying drawings. The principles associated with the various embodiments described herein may be applied to other embodiments. Therefore, the description is not intended to be limited to the 5 embodiments shown along with the accompanying drawings but is to be providing the broadest scope consistent with the principles and the novel and inventive features disclosed or suggested herein. Accordingly, the invention is anticipated to hold on to all other such alternatives, modifications, and variations that fall within the scope of the present invention and appended claims.
, Claims:CLAIMS
We Claim:
1) A hybrid aluminum matrix nanocomposite, the nanocomposite comprising:
- an aluminum alloy matrix,
- a primary reinforcement consisting of agro-bio-waste materials including rice husk ash in an amount of about 3.75 wt.% and egg shell ash in an amount of about 1.25 wt.%, and
- a secondary reinforcement consisting of nano-sized silicon carbide (SiC) particles in an amount ranging from 0.5 wt.% to 2.5 wt.%, wherein the combination of said primary and secondary reinforcements enhances the mechanical properties of the aluminum alloy matrix.
2) The nanocomposite as claimed in claim 1, wherein the manufacturing process comprises:
- performing a melting process under an inert gas atmosphere, eliminating the need for chemical degassing agents,
- subjecting the aluminum alloy matrix to a stir casting process incorporating both mechanical and ultrasonic mixing to enhance dispersion of reinforcements within the matrix.
3) A method for manufacturing a hybrid aluminum matrix nanocomposite, the method comprising:
- melting an aluminum alloy at a temperature of about 760°C under an inert gas cover,
- performing degassing of the molten alloy by argon gas bubbling at a rate of 1.5 liters per minute for approximately 10 minutes,
- preheating rice husk ash, egg shell ash, nano SiC particles, and magnesium powder to about 500°C to eliminate moisture,
- introducing the preheated primary reinforcements (rice husk ash and egg shell ash) and 1 wt.% magnesium powder to the molten alloy under continuous mechanical stirring at approximately 400 rpm for about 10 minutes,
- introducing preheated nano SiC particles to the molten alloy with simultaneous argon bubbling and mechanical stirring, and
- applying ultrasonic mixing at about 750°C for approximately 5 minutes, followed by pouring the molten alloy into a mold preheated to approximately 400°C and subjecting it to squeeze casting.

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