Fabrication of Low Friction Al-Based Metal Matrix Composites and Its Machinability Study

Metal matrix composites (MMCs) have established themselves as a bright, intriguing, and significant group of materials that have captured the interest of numerous researchers and scientists worldwide. The most recommended structural materials for automotive, electrical, and aerospace applications are aluminum-based metal matrix composites due to their superior corrosion and wear resistance, high specific modulus, thermal stability, and low weight. An attempt has been made to study the various effects of different reinforcement particles on Aluminum Alloy 6063 (Al6063). Al6063 is a significant member of the 6000 series, known for its better formability, wettability, and high strength-to-weight ratio, owing to the presence of magnesium (Mg) and silicon (Si) as the primary constituents. The reinforcement is an essential part of MMCs, as it profoundly impacts the composite material's mechanical, microstructural, and tribological properties, as well as its cost-effectiveness. Based on desired specifications and processing considerations, the following reinforcements were taken into account: Graphite (Gr) and molybdenum disulfide (MoS₂). Among the numerous processes, stir casting stands out as one of the best liquid-state processing techniques for the fabrication of MMCs. In stir casting, the dispersed phase (reinforcing particles) is incorporated into a molten matrix metal, followed by its solidification. This versatile and effective manufacturing method allows for the production of MMCs with tailored properties, making them invaluable in industries where lightweight, corrosion resistance, and enhanced mechanical properties are essential. After the fabrication, a comparative study of the different physical properties and machinability study of the MMCs is done using the Wire-EDM process.