Mechanical Properties and Porosity Evaluation of the Casted Composite (Al1050/B4C/FA) after Multi-Cycles of SPD

Abstract

Aluminum composite products have become a significant component in advanced engineering applications, due to their lightweight nature and excellent mechanical properties.  In this article, pure aluminum grade 1050 with a content 93%, boron carbide of 2%, and fly ash of 5% were mixed using the stir casting process to fabricate Al1050/B₄C/FA composite rods. Severe plastic deformation (SPD) using equal channel angular pressing (ECAP) was adopted to enhance the mechanical properties and to assess the porosity state. The two-channel angles 120° and 135° with multi-cycles of ECAP (1,2,3,4,5, and 6) under room temperature were used to determine the mechanical properties and porosity state of the Al1050/B₄C/FA composite. The results revealed that the number of ECAP cycles (passes) can improve both the yield tensile stress, ultimate tensile stress, and hardness due to strain hardening and microstructural changes. The sixth cycle of ECAP and a channel die angle of 120° have the greatest impact on enhancing the mechanical properties compared to the others. Additionally, the porosity magnitudes recorded discrepancies with multiple ECAP cycles and channel die angles. The increase in ECAP passes showed a slight rise in porosity; moreover, the die angle of 120° gave a greater effect than 135°.