Claims:WE CLAIM:
1. A process for synthesizing nano-reinforced aluminium metal matrix composite, comprising:
providing one of melting treatment and powdering treatment to one or more pure metals and one or more master alloys to obtain a melt,
wherein the one or more pure metals are selected from a group comprising aluminium (Al), magnesium (Mg), and Silicon (Si),
wherein the one or more master alloys comprises one or more aluminium alloys;
nano-reinforcing the melt, wherein a nano-reinforcement being carried using at least one of hybrid carbide and carbonaceous powder comprising at least one of spherical shape and plate shape;
ultra-sonicating a nano-reinforced melt for duration of 10 minutes;
producing a nano-reinforced billet from a ultrasonicated nano-reinforced melt via top pouring technology;
extruding the nano-reinforced billet into a rod shape using extrusion ratio >9;
forging an extruded rod using a forging press to obtain a nano-reinforced aluminium metal matrix composite; and
providing a T6 heat treatment to the nano-reinforced aluminium metal matrix composite to increase hardness and mechanical properties.
2. The process as claimed in claim 1, wherein the melting treatment comprises melting of the one or more pure metals and the one or more master alloys at 680 °C to 730 °C in a gas fired furnace to obtain the melt.
3. The process as claimed in claim 1, wherein the powdering treatment comprises
powdering of the one or more pure metals and the one or more master alloys using ball mill for duration of 2 hours to obtain powdered one or more pure metals and the one or more master alloys, and
preheating the powdered the one or more pure metals and the one or more master alloys at 200 to 300 °C to obtain the melt.
4. The process as claimed in claim 1, wherein the one or more aluminium alloy comprises at least one of silicon, copper, titanium, zirconium, iron, chromium and manganese in combination with aluminium.
5. The process as claimed in claim 1, wherein the nano-reinforcing the melt comprises
reinforcing the melt using nanoparticles via a stirrer inlet, and
stirring the nano-reinforced melt at 500 to 600 rpm for duration of 10 to 15 minutes.
6. The process as claimed in claim 1, wherein preheating the at least one of hybrid carbide and carbonaceous powder at 200°C before the nano-reinforcing the melt.
7. The process as claimed in claim 1, wherein the nano-reinforced billet being preheated at a temperature of 480°C before the extruding.

Dated this 20th day of April 2020


Vidya Bhaskar Singh Nandiyal
Patent Agent (IN/PA-2912)
Agent for applicant
, Description:FIELD OF INVENTION
[0001] Embodiments of a present invention relates to aluminium based metal matrix composite, and more particularly to a process for synthesizing nano-reinforced aluminium metal matrix composite.

BACKGROUND
[0002] Nanocomposites reinforced particles being used in the automotive industry due to their ability to withstand high pressures and temperatures. The nanocomposites have various applications in structural and operating parts in automotive industry and thus stimulate the growth of the market. The advantage of using nanocomposites in external components and luxury cars have a positive impact on demand in the market.

[0003] Several manufacturing methods being used to produce nanocomposites. In order to produce aluminum metal matrix nanocomposites, two common methods being employed which are reinforced by particles on a large scale: One is powder metallurgy process (solid state), and another one is casting (liquid state).

[0004] Aluminium 6082 metal matrix is a medium strength alloy with excellent corrosion resistance and manganese present in it controls the grain structure, which results into a stronger alloy and its application are in the field of high stress application, bridges, trusses, cranes, transport application, etc.

[0005] The main disadvantage of these metal matrix is a lack of homogeneity in the dispersion of the particles and weak links between the matrix and the particles.
[0006] Hence, in order to overcome the aforementioned shortcomings, there is a need for a process to produce high strength and lightweight nano-reinforced metal matrix of Aluminium 6082 of 6xxx series with modified composition to increase endurance and durability of the component.

SUMMARY
[0007] In accordance with an embodiment of the invention, a process for synthesizing nano-reinforced aluminium metal matrix composite is provided. The process includes providing one of melting treatment and powdering treatment to one or more pure metals and one or more master alloys to obtain a melt. The one or more pure metals are selected from a group comprising aluminium (Al), magnesium (Mg), and Silicon (Si). The one or more master alloys comprises one or more aluminium alloys. The process also includes nano-reinforcing the melt. A nano-reinforcement being carried using at least one of hybrid carbide and carbonaceous powder comprising at least one of spherical shape and plate shape. The process includes ultra-sonicating a nano-reinforced melt. The process includes producing a nano-reinforced billet via top pouring technology. The process includes extruding the nano-reinforced billet into a rod shape. The process includes forging an extruded rod using a forging press to obtain a nano-reinforced aluminium metal matrix composite. The process further includes providing a T6 treatment to the nano-reinforced aluminium metal matrix composite to increase hardness and mechanical properties.

[0008] To further clarify the advantages and features of the present disclosure, a more particular description of the disclosure will follow by reference to specific embodiments thereof, which are illustrated in the appended figures. It is to be appreciated that these figures depict only typical embodiments of the disclosure and are therefore not to be considered limiting in scope. The disclosure will be described and explained with additional specificity and detail with the appended figures.

BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The disclosure will be described and explained with additional specificity and detail with the accompanying figures in which:

[0010] FIG. 1 is a flow diagram representing steps of a process for synthesizing nano-reinforced aluminium metal matrix composite in accordance with an embodiment of the present disclosure;

[0011] FIG. 2 is a schematic representation of the steps of the process for synthesizing nano-reinforced aluminium metal matrix composite in accordance with an embodiment of the present disclosure;

[0012] FIG. 3 is a representation of optical micrographs of nano-reinforced aluminium metal matrix composite indicating the grain refinement and uniform distribution by nano-reinforcement in comparison with an alloy in accordance with an embodiment of the present disclosure;

[0013] FIG. 4 is a representation of Field Emission Scanning Electron Microscopy (FESEM) images of a nano-reinforced aluminium metal matrix composite in accordance with an embodiment of the present disclosure; and

[0014] FIG. 5 is a representation of the nano-reinforced aluminium metal matrix composite manufactured for automotive application via forging in accordance with an embodiment of the present disclosure.

[0015] Further, those skilled in the art will appreciate that elements in the figures are illustrated for simplicity and may not have necessarily been drawn to scale. Furthermore, in terms of the method steps, chemical compounds, and parameters used herein may have been represented in the figures by conventional symbols, and the figures may show only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the figures with details that will be readily apparent to those skilled in the art having the benefit of the description herein.

DETAILED DESCRIPTION
[0016] For the purpose of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiment illustrated in the figures and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Such alterations and further modifications in the illustrated system, and such further applications of the principles of the disclosure as would normally occur to those skilled in the art are to be construed as being within the scope of the present disclosure.

[0017] The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such a process or method. Similarly, one or more components, compounds, and ingredients preceded by "comprises... a" does not, without more constraints, preclude the existence of other components or compounds or ingredients or additional components. Appearances of the phrase "in an embodiment", "in another embodiment" and similar language throughout this specification may, but not necessarily do, all refer to the same embodiment.

[0018] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this disclosure belongs. The system, methods, and examples provided herein are only illustrative and not intended to be limiting.

[0019] In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings. The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.

[0020] Embodiments of the present invention relates to a process for synthesizing nano-reinforced aluminium metal matrix composite. The process replaces the high density material or alloy with high strength and lightweight nano-composites. The process provides nanocomposite with high mechanical strength i.e. UTS (Ultimate tensile strength), YS (Yield strength), E (Modulus of Elasticity), without making it brittle. The nano-reinforced aluminium metal matrix composite exhibits high endurance and durability with increased life cycle.

[0021] FIG. 1 is a flow diagram representing steps of the process for synthesizing nano-reinforced aluminium metal matrix composite in accordance with an embodiment of the present disclosure. The present invention mainly relates to the process for synthesizing nano-reinforced Aluminium 6082 metal matrix composite with modified composition. As used herein the term ‘Aluminium 6082 metal matrix’ refers to a medium strength alloy having exceptional corrosion resistivity and is widely used for structural applications. The density of Al 6082 alloy is reported as 2.70 g/cm3 and melting point is 555°C. Workability, machinability, weldability, brazability of Al 6082 alloy are found to be good.

[0022] The process for synthesizing nano-reinforced aluminium metal matrix composite begins with providing one of melting treatment and powdering treatment to one or more pure metals and one or more master alloys to obtain a melt at step 102. The one or more pure metals are selected from a group comprising aluminium (Al), magnesium (Mg), and Silicon (Si). The one or more master alloys comprises one or more aluminium alloy. The one or more aluminium alloy comprises at least one of silicon, copper, titanium, zirconium, iron, chromium and manganese in combination with aluminium.

[0023] In the melting treatment the one or more pure metals and the one or more master alloys are melted at 680 °C to 730 °C in a gas fired furnace to obtain the melt. In the powdering treatment the one or more pure metals and the one or more master alloys are powdered using ball mill for duration of 2 hours, wherein the powdered the one or more pure metals and the one or more master alloys being preheated at 200 to 300 °C to obtain the melt. The powdering the one or more pure metals and the one or more master alloys using ball mill is carried out in case of a hybrid nano-reinforcement. As used herein the term ‘hybrid nano-reinforcement’ refers to reinforcement of material using different nanometre-size particles i.e. lower and higher particle sizes. Hybrid nano-reinforced materials provides better bonding property with interlocking in the metal matrix.

[0024] As used herein the term ‘gas fired furnace’ refers to a furnace wherein a closed vessel of metal or ceramic is utilized in a batch process. The gas fired furnace allows accurate and efficient control of the workspace atmosphere and provide low atmosphere usage due to the closed nature of the system. As used herein the term ‘ball mill’ refers to a type of grinder, cylindrical device used in grinding (or mixing) materials like ores, chemicals, ceramic raw materials and paints. The ball mills rotate around a horizontal axis, partially filled with the material to be ground plus the grinding medium.

[0025] In an embodiment, the process for synthesizing nano-reinforced aluminium metal matrix composite also includes nano-reinforcing the melt at step 104. The nano-reinforcing the melt carried via a stirrer inlet. A nano-reinforcement being carried using at least one of hybrid carbide and carbonaceous powder comprising at least one of spherical shape and plate shape. The at least one of hybrid carbide and carbonaceous powder being preheated at 200°C before the nano-reinforcing the melt to ensure complete removal of moisture and achieve better bonding with the melt. The nano-reinforced melt being stirred at 500 to 600 rpm for duration of 10 to 15 minutes by creating a vortex by means of eddy current induction via super-magnets. As used herein the term ‘nano-reinforcement’ refers to reinforcement of materials using nanometre-size particles, platelets, or filaments.

[0026] In an embodiment, a nano-reinforced melt being ultra-sonicated for duration of 10 minutes at step 106. The nano-reinforced melt being ultra-sonicated using a probe. Ultrasonicating the nano-reinforced melt using a probe imparts the additional strength by de-agglomeration and uniform dispersion of the nano-reinforcement.

[0027] In an embodiment, a nano-reinforced billet being produced via top pouring technology from a ultrasonicated nano-reinforced melt at step 108. The top pouring technology includes pouring the nano-reinforced melt into a mould and immediately quenching the nano-reinforced billet to achieve the nano-reinforced billet comprising refined microstructure and excellent quality melt.

[0028] In an embodiment, the nano-reinforced billet is extruded into a rod shape using extrusion ratio >9 at step 110. The nano-reinforced billet being preheated at 480°C before extruding. As used herein the term ‘extrusion’ refers to a process used to create objects of a fixed cross-sectional profile. A material is pushed through a die of the desired cross-section. As used herein the term ‘extrusion ratio’ refers to a starting cross-sectional area divided by a cross-sectional area of the final extrusion. One of the main advantages of the extrusion process is that this ratio can be very large while still producing quality parts.

[0029] In an embodiment, an extruded rod being forged using a forging press to obtain a nano-reinforced aluminium metal matrix composite at step 112. The nano-reinforced aluminium metal matrix composite replaces the high density material or alloy with high strength and lightweight nano-composites. As used herein the term ‘forging press’ refers to a machine that applies gradual pressure on the forging dies.

[0030] In an embodiment, a T6 treatment is provided to the nano-reinforced aluminium metal matrix composite to increase hardness and mechanical properties at step 114. As used herein the term ‘T6 treatment’ refers to a two-phase process which is applied to aluminium, copper or silicon alloys to increase the strength of the alloy by as much as 30%.

[0031] FIG. 2 is a schematic representation of the steps of the process for synthesizing nano-reinforced aluminium metal matrix composite in accordance with an embodiment of the present disclosure. The process provides nanocomposite with high mechanical strength i.e. UTS (Ultimate tensile strength), YS (Yield strength), E (Modulus of Elasticity), without making it brittle.

[0032] FIG. 3 is a representation of optical micrographs of nano-reinforced aluminium metal matrix composite indicating the grain refinement and uniform distribution by nano-reinforcement in comparison with an alloy in accordance with an embodiment of the present disclosure. The microscopic images of the nano-reinforced aluminium metal matrix composite also represent grain deformation by the action of load applications.

[0033] FIG. 4 is a representation of Field Emission Scanning Electron Microscopy (FESEM) images of a nano-reinforced aluminium metal matrix composite in accordance with an embodiment of the present disclosure.

[0034] FIG. 5 is a representation of the nano-reinforced aluminium metal matrix composite manufactured for automotive application via forging in accordance with an embodiment of the present disclosure. The nano-reinforced aluminium metal matrix composite exhibits high endurance and durability with increased life cycle. The higher strength of nano-reinforced aluminium metal matrix composite is may be due to modified Aluminium 6082 metal matrix composition and selection of hybrid based nano-reinforcement materials or individual nanoparticle.
[0035] The present invention provides the process for synthesizing nano-reinforced aluminium metal matrix composite. The process replaces the high density material or alloy with high strength and lightweight nano-composites. The process provides nanocomposite with high mechanical strength i.e. UTS (Ultimate tensile strength), YS (Yield strength), E (Modulus of Elasticity), without making it brittle. The nano-reinforced aluminium metal matrix composite exhibits high endurance and durability with increased life cycle. The nano-reinforcing of aluminium metal matrix composite using submicron and nano size material helps in interlocking the grains and prevent the grain growth, thereby preventing non-uniformity. Use of the induced magnetic field and the ultra-sonication process also contributes to the uniformity in the aluminium metal matrix composite.

[0036] While specific language has been used to describe the disclosure, any limitations arising on account of the same are not intended. As would be apparent to a person skilled in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein.

[0037] The figures and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. Moreover, the actions of any flow diagram need not be implemented in the order shown; nor do all of the acts need to be necessarily performed. Also, those acts that are not dependant on other acts may be performed in parallel with the other acts. The scope of embodiments is by no means limited by these specific examples.