Description:DESCRIPTION:

TECHNICAL FIELD
The clinical field related to the fabrication and mechanical characterization of nano-sized B4C (boron carbide) and graphite (Gr) reinforced Al6061 composites primarily falls under Materials Science and Engineering. This field encompasses the study of composite materials, their properties, and applications, particularly in engineering and industrial contexts.

1.Aerospace and Automotive Engineering: The enhanced mechanical properties of Al6061 composites make them suitable for lightweight structural components in aerospace and automotive applications where strength-to-weight ratios are critical.

2.Nuclear Applications: B4C is known for its neutron absorption capabilities, making these composites useful in nuclear reactor components and radiation shielding materials[2].

3.Wear-Resistant Applications: The incorporation of hard ceramic reinforcements like B4C and graphite improves wear resistance, making these composites ideal for components subjected to high wear conditions, such as engine parts and machinery[4].

4.Biomedical Engineering: While not directly mentioned in the search results, the principles of composite material enhancement can also extend to biomedical applications, where lightweight and strong materials are required for implants and prosthetics.

The study of nano-sized B4C and Gr reinforced Al6061 composites is significant in advancing materials technology, particularly in developing high-performance materials for various industrial applications. The research focuses on optimizing mechanical properties, enhancing wear resistance, and ensuring effective reinforcement distribution within the aluminum matrix, which is crucial for achieving desired performance in practical applications.

DEFINITION

- The reinforcement of B4C and Gr particles improves the mechanical properties of Al6061 composites
- Key properties evaluated include:
- Tensile strength
- Compressive strength
- Hardness
- Wear resistance[3][4]
- Characterization techniques like SEM, EDS and XRD are used to analyze the microstructure, distribution of reinforcements, and presence of particles in the Al6061 alloy[5]

The goal is to develop lightweight, high-strength, and wear-resistant aluminium composites for applications in aerospace, automotive, and other industries by optimizing the fabrication process and reinforcement content.

Some key findings from the research:

- Adding 3-12 wt% of B4C particles enhanced the hardness, ultimate tensile strength, yield strength and compression strength of Al6061 alloy by 23.9%, 15.4%, 14.9% and 34.7% respectively, with a slight decrease in elongation[5]
- Graphite and 5 wt% B4C particles were mixed with Al7075 using stir casting to investigate hardness and wear behavior[3]
- Ultrasonic assisted stir casting improved the mechanical properties of AA6061-B4C composites compared to conventional stir casting[4]

The research demonstrates the effectiveness of nano-sized B4C and Gr reinforcements in enhancing the mechanical characteristics of Al6061 composites, making them suitable for various engineering applications requiring high strength, hardness and wear resistance.

BACKGROUND AND PRIOR ART OF THE INVENTION:

US11932925B2
Provided herein are new aluminium alloys comprising Ca, Mg and/or Zn and new coated aluminium alloys comprising surface layers (e.g., coatings) comprising Ca, Mn, Zn, and/or Ni that can be used in aluminium alloy products, such as clad layers. Also provided are methods of making these aluminium alloys, coated aluminium alloys, and clad layers, as well as clad products. These alloys, coated alloys, clad layers, and products possess a combination of strength and other key attributes, such as corrosion resistance, formability, and applicability of paint line pretreatments. The materials can be used in a variety of applications, including automotive, transportation, and electronics applications.

CN112218962B
Aluminium alloy products and methods of making and processing such products are disclosed. Thus, aluminium alloy products exhibiting controlled surface characteristics including excellent bond durability, low contact resistance, and corrosion resistance are disclosed. The aluminium alloy products described herein include a migrating element, a subsurface portion having a concentration of the migrating element, and a bulk portion having a concentration of the migrating element. The aluminium alloy product includes an enrichment ratio of 4.0 or less, wherein the enrichment ratio is a ratio of the concentration of the migrating element in the subsurface portion to the concentration in the bulk portion. Additionally, the aluminium alloy product surface and/or subsurface may contain phosphorus (e.g., elemental phosphorus or phosphorus oxide). The phosphorus-containing surface provides reduced electronic stress on the electrode tip of the resistance spot welding device and provides an extended service life (e.g., welding cycle to
failure) of the electrode tip.

CA3077516C
The present disclosure generally provides aluminium alloy articles having improved bond durability at certain surfaces of the article. The disclosure also provides methods of making such materials, for example, via a selective etching process, as well as methods of using such articles in applications that involve bonding the article to other articles, such as other aluminium articles. The disclosure also provides articles of manufacture made from such articles, including bonded aluminium articles. The disclosure also provides aluminium alloy articles having an inert or neutralized surface. The inert or neutralized surfaces described herein are characterized by surfaces containing oxidized copper. Also described herein are methods including etching a surface of the aluminium alloy articles with an oxidant. The resulting aluminium alloy articles exhibit desirable bond durability properties and exceptional corrosion resistance. The disclosure also provides various end uses of such articles, such as in automotive, transportation, electronics, and industrial applications.

CN106435302B
The invention discloses a kind of corrosion-resistant and high-temperature resistant aluminium alloy extrusions and preparation method thereof, the aluminium alloy extrusions includes alloy matrix aluminium and ceramic coating, the raw material of the alloy matrix aluminium includes: Cu, Si, Fe, Cr, Mg, Mn, Zn, Ti, Li, Ni, Zr, Nb, Mo, Ca, remaining is Al;The raw material of the ceramic coating includes: 20-30 parts of TiC, 10-20 parts of Cr by weight2O3, 15-25 parts of BN, 12-20 parts of B2O3, 20-30 parts of Al2O3.Using Laser Cladding Treatment technology by ceramic powders cladding in aluminium alloy matrix surface, the aluminium alloy extrusions made has the mechanical properties such as good intensity, hardness, toughness, while also having the performances such as good corrosion-resistant and high temperature resistant, increases its service life.

CN104745903B
A kind of 480MPa grades of aluminium alloy oil pipe of the present invention with aluminium alloy by weight percentage, including Zn:5.50~6.90%, Mg:1.75~1.80%, Cu:0.05%, Mn:0.10~0.30%, Cr:0.10~0.30%, Ti:0.01~0.02%, Zr:0.15~0.18%, remaining is Al and inevitable impurity;In wherein inevitable impurity, 0.15%, the Fe contents that Si contents are not more than aluminium alloy gross weight are not more than the 0.15% of aluminium alloy gross weight .The manufacture method of aluminium alloy pipe, comprises the following steps:1) raw material of as above content smelt and obtained pipe is cast after external refining;2) three-level Homogenization Treatments;3) at high temperature through being extruded;4) carry out double stage guide processing and quench cooling;5) pre-tension deformation;6) processing of twin-stage artificial aging is carried out to obtain

JP2023123593A
To provide new aluminium alloy products and methods of making these alloys, where the aluminium alloy products are age-hardenable, display high strength and formability, and allow the use of recycled scraps, where the aluminium alloys can serve as a core in a clad aluminium alloy product, and where the alloy products can be used in a variety of applications, including automotive, transportation, and electronics applications. SOLUTION: An aluminium alloy comprises: 0.5 wt.% to 1.6 wt.% of Mg; 0.2 wt.% to 0.5 wt.% of Si; up to 1.0 wt.% of Fe; up to 0.5 wt.% of Cu; up to 0.5 wt.% of Mn; up to 0.3 wt.% of Cr; up to 0.3 wt.% of Ti; up to 0.5 wt.% of Zn; up to 0.25 wt.% of impurities; and Al.

CN116234652A
The present disclosure generally provides an aluminium alloy product having a functional gradient across at least one dimension of the aluminium alloy product. The present disclosure also provides articles made from such products, and methods of making such products, such as by casting and rolling. The present disclosure also provides various end uses for such products, such as in automotive, aerospace, marine, defense, transportation, electronics, and industrial applications.

US5593516A
An aluminium-based alloy composition having improved combinations of strength and fracture toughness consists essentially of 2.5-5.5 percent copper, 0.10-2.30 percent magnesium, with minor amounts of grain refining elements, dispersoid additions and impurities and the balance aluminium. The amounts of copper and magnesium are controlled such that the solid solubility limit for these elements in aluminium is not exceeded. The inventive alloy composition may also include 0.10-1.00 percent silver for improved mechanical properties. The alloys are useful as high strength, high fracture toughness components for aircraft and aerospace structural parts.

EP1441041A1
The alloy comprises aluminium metal with production contaminants which individually constitute not more than 0.05 wt% and in total not more than 0.15 wt%. Other metals included in the alloy are 4.6-5.2 wt% Zn; 2.6-3.0 wt% Mg; 0.1-0.2 wt% Cu; 0.05-0.2 wt% Zr; not more than 0.05 wt% Mn; not more than 0.05 wt% Cr; not more than 0.15 wt% Fe; not more than 0.15 wt% Si; not more than 0.10 wt% Ti. Preferred amounts of the metals are: 4.6 wt% Zn; 2.6-2.8 wt% Mg; 0.10-0.15 wt% Cu; 0.08-0.18 wt% Zr; not more than 0.03 wt% Mn; not more than 0.02 wt% Cr; not more than 0.12 wt% Fe; not more than 0.12 wt% Si; not more than 0.05 wt%Ti. Independent claims are included for: a) a process for manufacturing plates up to 300 mm thick in the claimed alloy in which: A) the alloy is extruded to form bars not less than 300 mm thick; B) the bars are heated at not more than 20 degrees C/hr from 170-410 degrees C to 470-490 degrees C; C) the bars are homogenized for 10-14 hrs at 470-490 degrees C; D) bars are hot rolled to form plates; E) the plates are cooled to 400-410 degrees C to not more than 100 degrees C; F) plates are cooled to room temperature; G) plates are hardened: b) a similar process in which hot rolling to form plates is omitted and the final hardened bars are used as plates.

CN108385003B
A kind of aerospace high-ductility corrosion aluminium alloy extrusions and preparation method thereof, the present invention relates to a kind of aerospace high-ductility corrosion aluminium alloy extrusions and preparation method thereof, the problem of being unable to satisfy aerospace requirement the purpose of the present invention is to solve existing aluminium alloy extrusions, aluminium alloy extrusions of the present invention includes that the melting raw material of Cu, Mg, Zn, Zr and Al are made, be by aluminium ingot, tough cathode, primary magnesium ingot, zinc ingot metal, aluminium zircaloy ingot be smelting, casting, homogenizing annealing, hot extrusion, quenching, stretching, timeliness are fabricated. The present invention is optimized by alloying component, ingot quality controls, the twin-stage quenching and three-step aging technology of multistage uniform processing technique, extrusion forming technology, strengthen-toughening mechanism, high-ductility corrosion aluminium alloy extrusions is produced, effectively cut down profile residual stress by increasing tension aligning amount, improves the subsequent machining accuracy of profile. Present invention application aluminium alloy extrusions preparation field.

CN114015913A
The invention belongs to the field of nonferrous metals, and relates to a high-strength soluble aluminium alloy and a preparation method thereof. The high-strength soluble aluminium alloy has the compressive yield strength of 110-300 MPa, the compressive strength of 500-900 MPa, the tensile strength of 140-400 MPa and the tensile rate of 1-15%, can be adjusted in the dissolution rates of clear water and mineralization solutions at different temperatures, and is applied to various tools with solubility requirements, such as temporary plugging tools, bridge plugs and the like.

CN105714223A
The invention relates to a homogenization heat treatment method of Al-Zn-Mg-Cu-Zr aluminium alloy. The homogenization heat treatment method of the Al-Zn-Mg-Cu-Zr aluminium alloy is characterized in that a three-level homogenization heat treatment process for controlling a heating process is used for homogenization heat treatment, and the homogenization heat treatment method comprises the following steps: (1) carrying out low-temperature pre-precipitation, and carrying out a first-level homogenization heat treatment process for promoting precipitation of Al3Zr as a dispersed phase; (2) insulating, and carrying out a second-level homogenization heat treatment process for increasing the overburnt temperature of a structure; and (3) carrying out a long-term uniform insulating process, and carrying out a third-level homogenization heat treatment process for eliminating high-melting-point Al2CuMg. By the heat treatment process, the problem of insufficient soaking in large cast ingots of 7xxx series aluminium alloy can be solved well, a coarse phase does not dissolve in a microscopic structure, an S phase is fully re-dissolved, and meanwhile, uniform precipitation of Al3Zr as the dispersed phase can be regulated and controlled. More importantly, the homogenization heat treatment method is suitable for industrial production of large cast ingots, and has good operability; meanwhile, homogenization heat treatment time can be shortened; and energy consumption of heat treatment is reduced.

CN113564466A
The invention relates to a high corrosion resistant aluminium-zinc-magnesium coated steel plate and a manufacturing method thereof, wherein the aluminium-zinc-magnesium coated steel plate comprises the following chemical components: 30 to 75 percent of Al, 1 to 13.0 percent of Si and 0.5 to 7 percent of Mg; additionally contains one or more of the following chemical components: 0.03 to 0.50 percent of Ti, 0.01 to 0.20 percent of Re, 0.05 to 3 percent of Li, 0.1 to 5.0 percent of Cu, 0.05 to 1.0 percent of Fe, 0.5 to 3.0 percent of Mn, 0.5 to 4.0 percent of Ni, 0.01 to 0.5 percent of V, 0.5 to 1.0 percent of Zr and 0.1 to 1.0 percent of Cr; the balance of Zn and inevitable impurities. According to the invention, by a method combining alloy element addition and hot dip coating process optimization, the toughness and the punch forming performance of the aluminium-zinc-magnesium coating are improved, the coating structure is refined, and the corrosion resistance of the coating is improved.

JP2011058047A
To provide a method for producing a thick plate of =50 mm by hot rolling for an Al-Zn-Mg-Cu-based heat treatment type alloy containing =1.0% Cu, wherein, by controlling production conditions, the reduction of coarse intermetallic compounds is achieved, thus the remarkable improvement of its ductility (toughness) is achieved while securing its high strength.

SOLUTION: Regarding an Al-Zn-Mg-Cu-based alloy containing 1.0 to 3.0% Cu, in a cooling stage after performing a homogenizing treatment at 450 to 520°C for =1 hr to an ingot, the average cooling rate at least to 400°C is regulated to =100°C/hr, thereafter, hot rolling is performed to a plate thickness of =50 mm at a temperature within the range of 300 to 440°C, and, subsequently, solution treatment, quenching and artificial aging treatment are performed so as to obtain a thick plate in which the total area ratio of intermetallic compounds having an equivalent circle diameter of >5 µm is controlled to =2%. Further, electric conductivity of the ingot when measured in a state of being cooled to room temperature after the homogenizing treatment is controlled to be =40 IACS%.

CN104073699A
The invention relates to metal smelting technology and particularly relates to a Al-Si-Cu-Mg cast aluminium alloy and a preparation method thereof. The cast aluminium alloy comprises 89.5-90.5wt% of aluminium (Al) and the balance of 6.5-7.5wt% of silicon (Si) and 0.02-0.04wt% of modificator strontium (Sr), wherein according to the alloy, the content of copper (Cu) is 1.5-2.5wt%, the content of magnesium (Mg) is 0.35-0.65wt% and 0.05-0.25wt% of zirconium (Zr) and 0.1-0. 5wt% of cadmium (Cd) are both added into the alloy. The preparation method comprises the steps of smelting, refining, carrying out modification treatment, adding 0.04wt% of Sr, standing for 40-60 minutes, carrying out low pressure casting by using an electromagnetic pump and carrying out T6 heat treatment on castings to obtain the corresponding castings. Since more accurate element content control values and reliable operation process parameters are provided by the scheme, the high-performance cast aluminium alloy, especially suitable for the automotive industry can be prepared based on the optimized configuration of trace elements in AlSi7Cu2Mg.

Detailed description
This study aims to analyse and compare the mechanical properties, microstructure, and corrosion behaviour of friction stir welds made from AA2219 and AA2519 alloys. The AA2519 alloy's superior mechanical and corrosion properties are largely due to the presence of semi-coherent precipitates (?') and undissolved precipitates such as Al3Ti, Al2CuMg, and Al2Zr.The base metal's microstructure is made up of a white matrix of a-solid phase and secondary particles that are surrounded by a crystalline structure. Due to an increase in the sub-grain boundary, the stir zone of AA2519 exhibited a finer microstructure compared to AA2219.AA2519 exhibits superior mechanical properties when compared to AA2219. Undissolved precipitates in the weld nugget zone and the TMAZ may be the reason behind the noticeable rise in micro-hardness observed in AA2519. The AA2519 alloy has a higher tensile strength than the AA2219 alloy because magnesium, zirconium, vanadium, and titanium form extra precipitates.
Compared to AA2219 welds, the pitting corrosion resistance and exfoliation corrosion of AA2519 alloy friction stir welds are relatively better. Because there are undissolved precipitates like Al2CuMg, Al3Zr, and Al3Ti present, they act as insulation paths and stop the galvanic coupling between the Al2Cu and the a-Al matrix.

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

BRIEF DESCRIPTION OF DRAWINGS
The objects and features of the present invention, which are believed to be novel, are set forth with particularity in the appended claims. The present invention, both as to its organization and manner of operation, together with further objects and advantages, may best be understood by reference to the following description, taken in connection with the accompanying drawings, in which:

several figures that illustrate key aspects of the study on aluminum matrix composites (AMCs) reinforced with boron carbide (B4C) and graphite (Gr). Here is a brief description of the drawings:

Figure 1: Stir casting setup
- This figure shows the graphite-based crucible used for fabricating the desired AMC castings with the selected materials.

Figure 2: Dimensions of the specimens developed for testing of mechanical properties
- The figure presents the dimensions of the specimens developed from various AMC samples for testing tensile strength, compressive strength, impact strength, and hardness according to ASTM standards.

Figure 3: Equipment used for testing of mechanical properties
- This figure shows the equipment used to study the influence of reinforcements on the mechanical properties of AMCs, including:
- Universal Testing Machine (Instron 8801, 60 kN capacity) for tensile and compressive strength testing
- Pendulum Impact Testing Machine (KT 300, 165 J capacity) for impact strength testing
- Vickers Hardness Tester (25-100 g capacity) for hardness testing

Figure 4: Tensile strength for the fabricated AMC
- The figure plots the tensile strength of the fabricated AMCs with varying reinforcement percentages (2%, 4%, 6%, 8%) compared to the base Al 6061 alloy.

Figure 5: Yield strength diagram for the fabricated AMC
- This figure shows the yield strength of the AMCs with different reinforcement levels.

Figure 6: Compressive strength of the fabricated AMC
- The figure plots the compressive strength of the AMCs with varying reinforcement percentages.

Figure 7: Hardness of the fabricated AMC
- This figure illustrates the hardness values of the AMCs with different reinforcement levels, measured using the Vickers hardness test.

These figures provide visual representations of the experimental setup, specimen dimensions, testing equipment, and the results obtained for tensile strength, compressive strength, and hardness of the AMCs. They support the analysis and discussion of the mechanical properties of the composites in relation to the reinforcement content.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
To promote an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings, and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates. It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the invention and are not intended to be restrictive thereof.
Reference throughout this specification to "an aspect", "another aspect," or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrase "in an embodiment", "in another embodiment" and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.
Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The system, methods, and examples provided herein are illustrative only and not intended to be limiting.

The compositions and the process steps of the current invention is explained below:

Materials and their proportions used for making
TABLE 1:Material composition

Constituent (%)
Material Cu Mg Mn Fe Si Zn Ni Cr Li Balance
Al 6061 4.41 1.36 0.54 0.23 0.07 0.04 0.02 0.022 0.001 Al
B4C 1.9 2.4 0.2 0.4 0.5 5.8 - - - B4C
Gr - 22.75 - 27.28 0.58 - - - - Gr
CaCO3 0.89 242.8 0.91 6.9 - 0.92 - 6.1 - CaCO3
S1 4.48 1.36 0.56 0.2 0.18 0.07 0.72 0.014 0.001 Al
S2 4.41 1.28 0.51 0.22 0.05 0.06 1.51 0.016 0.001 Al
S3 4.16 1.08 0.48 0.22 0.07 0.04 2.19 0.018 0.001 Al
S4 3.88 0.67 0.29 0.11 0.05 0.003 2.75 0.051 0.001 Al

Experimental Study
The experimental study concludes The results highlight the effectiveness of B4C and Gr as reinforcing materials in enhancing the mechanical properties of aluminum matrix composites. The study concludes that an optimal reinforcement level of around 6% provides significant improvements in tensile and compressive strength, while higher levels may lead to agglomeration and reduced performance.

This experimental study contributes valuable insights into the design and optimization of aluminum matrix composites for various engineering applications, emphasizing the importance of reinforcement selection and processing techniques in achieving desired mechanical properties.

SEM Analysis:
Scanning Electron Microscopy (SEM) was used to analyze the microstructure and distribution of reinforcement particles within the aluminium matrix composites. This technique provides detailed images of the composite material at a high magnification, allowing for the observation of the morphology and distribution of the NANO FILLERS (B4C and Gr).
SEM Images:
Here are the descriptions of the SEM images corresponding to the different samples:
Microstructure Visualization:
- SEM images provide a detailed view of the microstructural features of the AMCs, highlighting the distribution and morphology of the reinforcing particles (B4C and Gr) within the aluminum matrix.
- The images reveal how well the reinforcing materials are dispersed at the interstitial layers of the aluminum matrix, which is crucial for enhancing the mechanical properties of the composites.

2. Dispersion of Reinforcements:
- The SEM analysis indicates a fine dispersion of B4C and Gr particles, which contributes to the improved mechanical performance of the AMCs. A uniform distribution of these particles helps in achieving better load transfer and resistance to deformation under stress.

3. Particle Interaction:
- The images also show the interactions between the reinforcing particles and the aluminum matrix. Effective bonding at the interface is essential for maximizing the strength of the composite material.
- The presence of a well-defined interface between the matrix and the reinforcements can lead to the Orowan strengthening mechanism, which enhances the overall strength and hardness of the composites.

4. Grain Refinement:
- The SEM images may illustrate grain refinement in the aluminum matrix due to the addition of the reinforcing materials. Smaller grain sizes typically lead to higher strength due to the Hall-Petch effect, where grain boundaries impede the movement of dislocations.

5.Identification of Defects:
- SEM can also help identify any defects or agglomerations of the reinforcing particles, which can adversely affect the mechanical properties. The document notes that while the addition of B4C and Gr improves properties up to a certain point, excessive reinforcement can lead to particle agglomeration, resulting in decreased performance.

6.Comparative Analysis:
- By comparing SEM images of AMCs with different weight percentages of reinforcements, researchers can assess the optimal composition for achieving the desired mechanical properties.

The SEM images serve as a critical tool in understanding the microstructural characteristics of the AMCs. They provide insights into how the distribution and interaction of reinforcing materials influence the mechanical properties, thereby guiding the optimization of composite formulations for various applications. This analysis is vital for confirming the effectiveness of the fabrication process and the suitability of the materials used in enhancing the performance of aluminum matrix composites.
Mechanical Features
The mechanical features of aluminium matrix composites (AMCs) reinforced with boron carbide (B4C) and graphite (Gr) have been extensively investigated in the study. The following key mechanical properties were evaluated:

1. Tensile Strength
- The tensile strength of the AMCs increased significantly with the addition of reinforcing materials. The results are as follows:
- 2% Reinforcement: 85.2 MPa
- 4% Reinforcement: 94.8 MPa
- 6% Reinforcement: 211.8 MPa (highest)
- 8% Reinforcement: 186.2 MPa

The 6% AMC exhibited the highest enhancement, showing a 59% improvement over the 2% sample. However, a decline in tensile strength was noted at the 8% reinforcement level, attributed to particle agglomeration.

2. Compressive Strength
- The compressive strength results demonstrated a similar trend:
- 2% Reinforcement: 1478.9 MPa
- 4% Reinforcement: 1662.6 MPa
- 6% Reinforcement: 2959.05 MPa (highest)
- 8% Reinforcement: 2214.8 MPa

The 6% AMC again showed the greatest improvement, with a 50.02% increase compared to the 2% sample. The decline at 8% was also noted, but the strength remained higher than the base material.

3. Impact Strength
- The impact strength of the 6% AMC was measured at 0.66 Kg-m, indicating a notable enhancement due to the reinforcement. However, specific values for the lower percentages were not provided.

4. Hardness
- The hardness of the AMCs increased with the addition of reinforcing materials:
- 2% Reinforcement: 67.54 VHN
- 4% Reinforcement: 70.24 VHN
- 6% Reinforcement: 72.86 VHN
- 8% Reinforcement: 74.59 VHN (highest)

The 8% AMC exhibited the highest hardness, showing a 31.07% improvement over the base material.

Summary of Mechanical Features
- The study highlights that the optimal reinforcement level for achieving the best mechanical properties is around 6%. Beyond this point, the mechanical properties begin to decline due to agglomeration and stress concentration around the reinforcing particles.

- The improvements in tensile strength, compressive strength, and hardness can be attributed to the effective load distribution provided by the reinforcing materials, which enhances the overall structural integrity of the AMCs.

These findings suggest that the incorporation of B4C and Gr into aluminium matrix composites significantly enhances their mechanical performance, making them suitable for applications in industries requiring high strength-to-weight ratios.

Results:
The study concludes that the optimal reinforcement level for achieving the best mechanical properties in AMCs is around 6%. Beyond this point, the mechanical properties decline due to agglomeration and stress concentrations around the reinforcing particles.

- The findings suggest that incorporating B4C and Gr into aluminum matrix composites significantly enhances their mechanical performance, making them suitable for applications in aerospace, automotive, and other industries requiring high strength-to-weight ratios.

This section effectively correlates the experimental results with the underlying mechanisms influencing the mechanical behavior of the composites, providing valuable insights for future research and applications.
1.Study and Findings:
2.Materials and Methods:
3.The materials and methods utilized in the study of aluminium matrix composites (AMCs) reinforced with boron carbide (B4C) and graphite (Gr) are detailed below. This section outlines the selection of materials, fabrication processes, and testing methods used to evaluate the mechanical properties of the composites.

4.Materials

5. Base Material
6. Aluminium 6061 (Al 6061):
7. - Source: Here nba Instruments for epoxy, Chennai
8. - Density: 2.7 g/cc
9. - Chemical Composition:
10. - Copper (Cu): 4.41%
11. - Magnesium (Mg): 1.36%
12. - Manganese (Mn): 0.54%
13. - Iron (Fe): 0.23%
14. - Silicon (Si): 0.07%
15. - Zinc (Zn): 0.04%
16. - Nickel (Ni): 0.02%
17. - Chromium (Cr): 0.022%
18. - Lithium (Li): 0.001%
19. - Balance: Aluminium
20. Reinforcing Materials
21. - Boron Carbide (B4C):
22. - Density: 2.26 g/cc
23. - Chemical Composition:
24. - Boron (B): 1.9%
25. - Carbon (C): 2.4%
26. - Graphite (Gr):
27. - Density: 2.4 g/cc
28. - Chemical Composition:
29. - Carbon (C): 22.75%
30. - Calcium Carbonate (CaCO3):
31. - Density: 2.52 g/cc
32. - Chemical Composition:
33. - Calcium (Ca): 0.89%
34. - Carbon (C): 0.91%
35. - Oxygen (O): 6.9%
36. Sample Preparation
37. The reinforcing elements (B4C and Gr) were subjected to a ball milling process to achieve a particle size of approximately 89 nm. The materials were mixed in varying ratios for different samples during the fabrication process.
38.
39. Fabrication of AMCs
40.
41. Stir Casting Process
42. The AMCs were fabricated using the stir casting technique, which involved the following parameters:

43. | Parameter | Value |
44. |----------------------|-----------------|
45. | Pouring Temperature | 800°C |
46. | Stirring Time | 30 minutes |
47. | Stirrer Blade Angle | 30° |
48. | Stirrer Speed | 350 rpm |
49. 1.Setup: An electrical furnace with a heating capacity of 1000°C was used to melt the aluminium. The crucible was graphite-based and preheated to prevent contamination.
50. 2.Degasification: Hexa-chloro-ethane (C2Cl6) was added to the molten metal to remove impurities such as dust and moisture.

51. 3.Stirring: A zirconia-coated impeller was used for stirring the molten metal. The stirring continued at 350 rpm for 15 minutes, during which pre-heated reinforcing elements were gradually added to create a vortex.
52. 4.Cooling: The solid ingots were allowed to cool at room temperature for 45 minutes in an argon environment.
53. Testing of Mechanical Properties
54. The mechanical properties of the fabricated AMCs were evaluated according to the following ASTM standards:
55. - Tensile Strength: ASTM D638
56. - Compressive Strength: ASTM E9
57. - Impact Strength: ASTM D256
58. - Hardness: ASTM E384
59. Equipment Used
60. -Universal Testing Machine: Instron 8801 (60 kN capacity) for tensile and compressive strength testing.
61. -Pendulum Impact Testing Machine: KT 300 (165 J capacity) for impact strength testing.
62. -Vickers Hardness Tester: For hardness testing with a capacity of 25-100 g.
63. Specimen Dimensions
64. The dimensions of the specimens used for testing were standardized and are illustrated in the study.
65. Characterization Techniques
66. - X-ray Diffraction (XRD): Used for phase analysis and to study the microstructural characteristics of the AMCs.
67. - Scanning Electron Microscopy (SEM): Employed for detailed microstructural analysis of the composites.
68. This comprehensive methodology allows for a thorough investigation into the mechanical performance of aluminium matrix composites reinforced with B4C and Gr, providing insights into their potential applications in various industries.

, Claims:69. CLAIMS
We claims that
Key Claims
A metal matrix composite material consists of:
An aluminum matrix

Claim 1: Composition of Matter
A composite material comprising aluminum 6061 as a base matrix, reinforced with boron carbide (B4C) and graphite (Gr), wherein the weight percentage of the reinforcing materials ranges from 2% to 8% of the total composite material.

2. Claim 2: Method of Fabrication
A method for fabricating aluminum matrix composites, comprising the steps of:
- Mixing aluminum 6061 with boron carbide and graphite powders in specified weight ratios;
- Subjecting the mixture to a ball milling process to achieve a particle size of approximately 89 nm;
- Utilizing a stir casting technique to combine the mixed powders at a pouring temperature of approximately 800°C, followed by cooling in an argon environment.

3. Claim 3: Mechanical Properties
The aluminum matrix composite as claimed in Claim 1, exhibiting improved mechanical properties, including:
- An ultimate tensile strength of at least 211.8 MPa,
- A compressive strength of at least 2959.05 MPa,
- An impact strength of at least 0.66 Kg-m,
- A hardness of at least 74.59 Vickers Hardness Number (VHN).

4. Claim 4: Reinforcement Ratios
The composite material as claimed in Claim 1, wherein the ratio of boron carbide to graphite is optimized to enhance mechanical properties, specifically with a preferred ratio of 80:20.

5. Claim 5: Structural Integrity
The aluminum matrix composite as claimed in Claim 1, wherein the microstructure analysis reveals a fine dispersion of reinforcing elements within the aluminum matrix, contributing to enhanced structural integrity and mechanical performance.

6. Claim 6: Applications
The aluminum matrix composite as claimed in Claim 1, suitable for use in aerospace, automotive, and construction applications due to its lightweight and high-strength properties