Evaluation of microstructure evolution and mechanical properties of Al-10Zn-1.63Si/ particulates alloy composites.

This study demonstrates the feasibility of using shell particulates (IGSp) as alternative reinforcing materials in the development of aluminium-based composites. In this experimental study, the microstructure, phase composition, and mechanical behaviour of Al-10Zn-1.63Si/xIGSp (wt%, x = 1, 3, 5 and 7) composites were investigated. The Al-10Zn-1.63Si based composites were fabricated using the stir-casting technique. Different weight percentages (1, 3, 5 and 7) of IGSp were added to the Al-10Zn-1.63Si matrix. The chemical constituents of the IGSp were determined using X-ray fluorescence (XRF). The grain characteristics and phase(s) compositions were determined using Scanning Electron Microscopy (SEM) and X-ray diffractometer (XRD). The ultimate tensile strength, hardness, and impact strength of the developed composites were also determined. The SEM and XRD results revealed the presence of different phases: aluminium phosphate (AlPO), gahnite (ZnAlO), andalusite (AlSiO), Quartz (SiO) and aluminium silicate (AlO.SiO). Results show that addition of IGSp led to an increase in ultimate tensile strength, with the highest value (128 MPa) obtained at 3 wt% IGSp. The hardness of the composites increased with increasing concentrations of IGSp, reaching a maximum value of 285 HV after adding 7 wt% IGSp. The impact strength improved with the addition of IGSp, with the highest value (30 J) obtained at 1 wt% IGSp. The improvements in mechanical properties were attributed to the dispersion of three major phases: aluminium silicate (AlOSiO), AlPO and AlOSiO. These phases contributed to the enhanced strength and hardness of the composites. The study noted a sudden decrease in ultimate tensile strength with higher concentrations of IGSp due to the increase in the intensities of AlPO and precipitation of hard but brittle new phase; AlSi6O126.33. The study concludes that IGSp has the potential to serve as an alternative reinforcing material for aluminium-based composites.