Processing and performance assessment of particulate TiB2 reinforced aluminum MMC developed via a novel hybrid ultrasonic casting system

The production of aluminum metal matrix composites (AMMCs) has been a great challenge for commercial sectors and the research fraternity. Over the past few decades, many modifications and hybrid techniques have been designed and developed by the researchers to address the manufacturing issues and reduce the production cost in developing AMMCs. In this regard, there is a need to address fundamental issues such as wettability and uniform distribution of particles across the matrix. Due to the poor mixing of particles, the materials' hardness, strength, and wear properties are affected. In the present research, aluminum-titanium diboride metal matrix composite (Al-TiB2 MMC) has been synthesized by developing a novel hybrid liquid processing technique. The performance efficacy of the novel hybrid experiment setup has been determined through the computational fluid dynamics (CFD) approach. Metallography has been done to demonstrate the uniformity of TiB2 phase in aluminum. Mechanical and wear behavior of the Al-TiB2 MMC have been subsequently assessed and compared with conventional processing technique. The results obtained in the current study are promising and demonstrate the potential benefits of the novel hybrid liquid processing system from an industrial standpoint.