Mechanical, morphological, and fracture-deformation behavior of MWCNTs-reinforced (Al–Cu–Mg–T351) alloy cast nanocomposites fabricated by optimized mechanical milling and powder metallurgy techniques

Abstract

Abstract The carbon nanotube (CNT) is becoming more popular due to their low-density, high-strength etc. Among CNTs, multi-walled carbon nanotubes (MWCNTs) are gaining more importance due to their enhanced thermal and electrical conductivity. The present research is exploring the applicability of MWCNTs reinforced with AA2024-T351 alloys for electromechanical applications. This study is currently undertaken for using MWCNTs as a reinforcing particulate for the purpose to enhance the characteristics including low density, high strength, and hardness together with excellent thermal and electrical conductivity of the aluminum alloy matrices. Therefore, this article provides a state-of-the-art experimental approach to fabricate and furthermore, to evaluate the mechanical characteristics, microstructural analysis, and fatigue behavior of Al–Cu–Mg–T351/MWCNT composites under both the mechanical and thermal loading by utilizing powder technology processing route. The uniform dispersion of CNTs has been exposed using ball milling process. Results revealed that the MWCNTs provide extraordinary synergistic strength, enhances fatigue resistance, creep resistance, ductility, and other mechanical characteristics of the aluminum-based composites. The mechanical loading of the composite exhibited increased properties as compared to thermal-loaded aluminum-MWCNT composites. Findings conclude that the maximum hardness of 35Hv obtained for sintered AA2024-T351 and 45Hv for 0.5% MWCNT heat-treated samples indicate that the addition of MWCNT enhances the hardness which may be because CNT is evenly dispersed at the interfacial space. Maximum UTS of 105.21 MPa was obtained with 0.5% MWCNT for sintered composites. Microstructural analysis of the Al–Cu–Mg–T351/MWCNTs composite exhibits reasonably uniform distribution, void formation, and good interfacial bonding. X-ray Diffraction method patterns of fabricated composite shows that the CNT is present at 2β = 23.6 and 44.6°, whereas high peaks of aluminum are present at uniform dispersed positions. Transmission electron magnifying instrument study further substantiates the above research. Fracture micrographs of the Al–Cu–Mg–T351/MWCNTs composite portray the resistant nature of the nanotubes due to the presence of CNTs, Al–Cu, and aluminum carbide elements in the alloy and the reactions that happened during heat treatment. This significant improvement was attributed to the shear interactions among the constituents and high load carrying capacity of the CNT, uniform dispersion, and interface bond strength among the matrix and constituents. The findings in the study will undoubtedly be beneficial for the development of high-strength, MWCNTs/Al–Cu–Mg–T351, matrix composites in future for multifunctional applications on broader spectrum.