The influence of silicon carbide on A356 aluminum alloy composites: mechanical properties, thermal performance, Fourier transform infrared spectroscopy (FTIR), corrosion resistance, and microstructural analysis

Abstract

This research evaluated how silicon carbide (SiC) additions affect the mechanical properties alongside thermal performance and corrosion resistance of A356 aluminium alloy matrix composite materials. The research analyzes the changes in tensile strength, yield strength elastic, modulus thermal conductivity and corrosion resistance initiated by different SiC levels. The tensile strength of the materials increased by 5.88% between 255 MPa to 270 MPa as SiC content rose from 10 to 40% while the yield strength showed a 5.88% increase from 153 MPa to 162 MPa during this change. The thermal expansion coefficient diminished by 32.55% which better stabilized dimensional characteristics. The material exhibited enhanced corrosion resistance through a decreased corrosion rate to 92%. The corrosion behaviour of the material was evaluated through the open-circuit potential (OCP) and potentiodynamic polarization testing methods and the microstructural analysis included AFM and FTIR spectroscopic methods. The obtained results demonstrate that A356-SiC composites offer strong potential use in aerospace fields as well as automotive and biomedical systems.

Article highlights

Increased SiC content inside the A356 matrix enhances the tensile/yield strength but reduces thermal conductivity.

Having SiC added to an alloy helps to strengthen its corrosion resistance layer.

AFM study observed higher surface roughness due to more SiC content and weaker mechanical properties.

Introduction

The increasing interest in aluminium alloy complexes is due to the systematic intention requirement of high energy, minimal load, and improved thermal stability. These properties are further enhanced by the addition of SiC as support, which makes the A356 aluminium matrix complex suitable for achieving high targets [1, 2, 3, 4–5]. Aluminium alloy composite materials, especially those containing silicon carbide (SiC) particles, are of great interest because they have the potential to enhance mechanical, thermal, and corrosion resistance [6, 7–8].

Aluminum Alloy A356, with a composition of Al– 92.05%, Si– 7%, and Mg– 0.35%, is used commonly in industry because of its good casting features, corrosion resistance, and mechanical properties [9, 10]. Nevertheless, the rising popularity of advanced materials has prompted researchers to search for methods to enhance the properties of metals [11, 12, 13–14]. There is a growing interest in the use of silicon carbide (SiC) particles as reinforcement in A356 alloys to enhance their mechanical properties, as highlighted in [15, 16].

Some of the most important characteristics of Silicon carbide include the following; High hardness of 3100–3150 kg/mm² High mechanical strength; Compressive strength of about 2,500 MN/m² at room temperature Excellent thermal properties; Thermal conductivity of 120–200 W/m.K Due to these characteristics, Silicon carbide makes for a very suitable reinforcement material. Introducing SiC particles into the A356 alloy will modify its properties in terms of microstructure, mechanical behaviour, thermal conductivity, and corrosion resistance [17, 18–19].

Metal matrix composites have gained much attention in the recent past because of the recent improvements in A356-SiC composites owing to their unique mechanical properties. A previous study by Smith and Brown (2018) showed that strengthening the A356 aluminium alloy with SiC particles could increase the ultimate tensile strength by 45% and peak hardness by 35% compared to the unfilled alloy [20]. Garcia and Patel further continued this improvement by enhancing the mechanical properties by analyzing the critical relationship between the particle size of SiC and the mechanical performance, where the mechanical reinforcement effects were found to be optimal for SiC particles sized between 20 and 40 μm [21].

Investigations carried out by Johnson and Lee in 2019 on the thermal properties of these composites indicated that the introduction of SiC improves the thermal conductivity while simultaneously reducing the coefficient of thermal expansion of these composites, making such composite materials ideal for use in areas that require precise dimensions but are subjected to high temperatures [22]. Furthermore, Özben et al. (2008) supported this research by determining the amount of thermal expansion coefficient declined to 30% with 20wt. % of SiC incorporation [23].

In terms of processing methods, Nguyen and Kumar (2016) identified the stir casting parameters for uniform distribution of SiC particles in the A356 matrix; while focusing stirring speed and temperature to avoid particle clustering [24]. These aspects of the microstructures of these composites were discussed in detail by Ghandvar (2013), who pointed out the formation of useful interfacial reactions that enhance the mechanical properties [25].

A detailed analysis was conducted on the durability aspects of the A356-SiC composites from various facets. According to Baradeswaran (2014), the wear resistance improved dramatically with the SiC composites having wear rates significantly lower than that of the base alloy, up to 60% improvement was recorded [26]. Williams and Zhang (2020) on the material corrosion research showed that even though the incorporation of SiC resulted in localized galvanic cells the formation of suitable surface treatments considerably reduced the vulnerability to corrosion in wet marine conditions [27].

The literature review also presented evidence of direct tensile testing performed by O’Connor and Li in 2019, where they linked SiC content directly with tensile strength to be at their peak value at an optimum of 15 wt % SiC [28]. Roberts and Kim (2020) recently investigated the electrochemical properties of these composites and demonstrated that the development of passive oxide films on the composite surface offers improved corrosion resistance in harsh environments [29]. The possibility of using A356 aluminum alloy with SiC in the field of biomedicine a few works have investigated how this technology can be beneficial for light implants, durable prosthetics, and compatible coatings in biomedicine [2, 15, 29].

The mechanical performance of the developed A356-SiC composites was characterized using a Universal Testing Machine (UTM), which is one of the primary instruments used in material science engineering to identify critical mechanical properties. The UTM allows for the direct determination of the tensile strength, compression strength, and Young’s modulus through the application of controlled loads to the material, while the forces and displacement readings are simultaneously recorded [30]. This testing methodology, which meets the ASTM E8/E8M standards for metallic materials as a testing standard, enables the complete characterization of the material under different loading regimes. The tests conducted on the UTM enable tensile, compression, and bending tests under controlled conditions, together with a real-time data acquisition system, permitting the determination of certain mechanical performance parameters such as UTS, YS, and % elongation. These parameters are essential for understanding the influence of SiC particles on the mechanical response of the A356 aluminium matrix composite. Previous research employing UTM testing has shown that it can be used to determine the mechanical properties of metal matrix composites; hence, it is suitable for assessing the impact of the extent of change in the SiC particle content on the mechanical response of our composites [31].

In addition to mechanical characterization, thermal conductivity measurements using thermal imaging were also conducted on the A356-SiC composites. Mechanical testing of the specimens was performed simultaneously with the help of a high-resolution infrared thermal imaging camera to study the real-time temperature distributions and thermal gradients on the specimen surfaces. This camera, with the ability to measure temperatures from − 20 C to 1500 C with a thermal sensitivity of less than 0.05 C enabled researchers to obtain detailed information on the heat transfer properties of the composite materials. According to a pixel resolution of 640 × 480 and frame rate of 30 Hz, sufficient thermal resolution and contrast were obtained to map the thermal behaviour with the mechanical properties [32, 33]. Thus, this study focused on the characterization of the thermal performance of composites by understanding the heat distribution and thermal gradients under loading conditions to study the effects of SiC reinforcement on the behaviour of the material.

Many studies have examined the microstructure and mechanical behaviour of A356 alloy/SiC composites; however, to acquire a more informative understanding of the chemical interactions and bond formations in the composites, a Fourier Transform Infrared Spectroscopy (FTIR) analysis was conducted. Being at the mid-IR range (4000–400 cm⁻¹) FTIR spectroscopy yields insights into chemical bonds, interfacial reactions and molecular structures contained in the composite material. This analytical technique is useful for determining the nature of the Si-C and Al-O bonds, for analyzing the interfacial interactions between the SiC reinforcement and the Al matrix, and for detecting the formation of oxide layers during processing. FTIR analysis has a high spectral resolution of 0.5–4 cm⁻¹ and offers information on the successful incorporation and distribution of SiC in the matrix and the possibility of using it to determine whether any chemical changes take place during the fabrication of the composite. Altogether, FTIR spectroscopy coupled with mechanical testing and thermal imaging provides a holistic picture of how the chemical bonding and morphological features of A356-SiC composites are related to their mechanical and thermal characteristics [34, 35].

The corrosion behaviour and electrochemical properties of the A356-SiC composites were evaluated using a potentiostat, which is an advanced electronic tool necessary in electrochemical studies that maintain and measures the potential difference between the electrodes in an electrochemical cell while measuring the current flow [36]. This precise control allows for the investigation of many different electrochemical processes, such as corrosion, battery performance, and material characterization [37].

The microstructural properties of cast A356 aluminium alloy-SiC composites were explored in detail using AFM, which offered valuable detailed information at the nanoscale regarding the interfacial development and distribution behaviour of the reinforcement phase. Advanced surface metrology analysis, particularly AFM, has proven useful for the study of three-dimensional surface topography and mechanical properties at the matrix-reinforced interface [38, 39]. Modern research has shown that by using AFM, it is possible not only to investigate the dispersion of SiC particles in the aluminium matrix but also to measure quantitative parameters of the roughness of the surface and local mechanical characteristics [40].

The present investigation was intended to examine the impact of different concentrations of SiC on the characteristics of the A356 aluminium alloy matrix composite. From the microstructural and mechanical characterization, thermal properties, and corrosion analysis of these composites. Before this, studies often examined one or two important qualities of composites (for example, tensile strength or resistance to wear), but this work combines all important qualities, plus a deeper study of how SiC is combined with the matrix, ultimately offering valuable insights to designers in the field.

Therefore, this study aimed to establish the extent to which the incorporation of SiC affects the properties of the material, and the present study is to fill this gap by providing a comprehensive review of mechanical, thermal, and electrochemical properties while integrating high-tech spectroscopy methods for the assessment of interfacial bonding.

Experimental details

Materials and preparation

A356 aluminium alloy (92.05% Al, 7% Si, 0.35% Mg) was used as the primary material alongside variable SiC particle additions between 10 and 90%. Figure 1a shows the schematic of the stir-casting device, the manufacturing involved stir casting at 750 °C and SiC preheating to 300 °C to achieve consistent distribution of the SiC particles. The mechanical stirrer ran at 300 rpm for five minutes before the mixture received moulding in cylindrical shapes measuring 120 mm long and 16–17 mm across the diameter of the casting sample as shown in Fig. 1b. The same process was followed for a series of SiC reinforcement contents 10%,20%,30% and 40%. The components were machined following the ASTM standards for testing. For tensile testing, ASTM E8/E8M guidelines were followed.

[See PDF for image]

Fig. 1

(a) Schematic of the stir-casting, (b) A356/SiC composite after casting, (c) Tensile test specimen (Author’s source)

The testing process of tensile experiments is performed using Universal Testing Machines (UTM) according to ASTM E8/E8M guidelines. The Brinell hardness tests adopted the ASTM E10 procedure using a 5 mm ball under a 250 kg load. The examination of density occurred through the standard Archimedean principle (ASTM D290) and the theoretical density was determined by the rule of mixture. The tensile test specimen with a broader end is for clamping and compression of the central slender part of the specimen between these ends, which will be subjected to deformation and failure during the experiment. As shown in Fig. 1c, a tensile test specimen with a total length of 45 mm was used in this study, with the extremities measuring 13 mm in thickness and the intermediate section having a diameter of 9 mm. The tested length of the specimen was 45 mm to ensure that it had a standard cross-sectional area suitable for testing tensile properties.

The tests under electrochemical corrosion conditions were performed within a 3.5 wt% NaCl solution by using a potentiostat. The potentiodynamic polarization scans started at −0.25 V compared to the open-circuit potential (OCP) value that ran from 60 min before reaching + 0.25 V using a scan rate of 1 mV/s. The corrosion behaviour of the material was evaluated through open-circuit potential (OCP) and potentiodynamic polarization testing methods. Corrosion rates are calculated using the Tafel extrapolation method. There has number of benefits of A356 such as high corrosion resistance, good weldability, and good mechanical properties, particularly when used in heat treatment. Because it is light and has high strength, it is widely used when there is a requirement for highly pressure-tight and highly durable parts.

Silicon carbide (SiC) ceramic material has a density between 2.6 and 3.2 g/cm³ density varying with the degree of porosity and exceptional hardness exceeds 3100–3150 kg/mm². Its melting point is approximately 2830 °C and demonstrates remarkable mechanical characteristics: a compressive strength of up to 2500 MN/m² at room temperature. SiC has a high thermal conductivity of approximately 120–200 W/m · K and a low coefficient of thermal expansion, which makes it suitable for thermal shock applications in abrasives, refractories, and composite reinforcement. Owing to these characteristics, SI3N4 is an essential material for many industries and applications.

Results and discussions

Mechanical properties

UltimateTensile and yield strength

From the constructed model of the mechanical properties of aluminium alloy A365 with varying silicon carbide percentage to predict the properties of aluminium alloy A365 containing silicon carbide, the representative properties from Table 1 were used, adjusting them based on the percentage of silicon carbide using relationships from the materials engineering knowledge base [41, 42–43].

Table 1. Calculated mechanical properties of aluminum alloy A365 with SiC

SiC (%)	Tensile strength (MPa)	Yield strength (MPa)	Elastic modulus (GPa)	Density (g/cm3)
10	255 ± 6.45	153 ± 3.87	72 ± 2.58	2.78 ± 0.13
20	260 ± 3.32	156 ± 3.00	74 ± 4.50	2.88 ± 0.26
30	265 ± 7.20	159 ± 5.43	76 ± 3.40	2.98 ± 0.15
40	270 ± 6.00	162 ± 0.98	78 ± 2.44	3.08 ± 0.10

Table 1 presents data derived from the full set of specimens, the mechanical properties of aluminium alloy A365 exhibit a trend with the added percentage of Silicon Carbide (SiC). With increasing SiC content from 10 to 40% for all the properties measured, the following trends were observed: The tensile strength, which indicates an improvement in the ability of the alloy to carry tensile loads, increased from nearly 255 MPa at 10% SiC to approximately 270 MPa at 40% SiC. Similar to the yield strength, the increase is less steep, rising from approximately 153 to 162 MPa with increasing SiC content. To ensure data reliability standard deviations are calculated for each measurement. This indicates a better position in terms of the plastic deformation of the alloy, at least in terms of resistance based on the type of measurement employed.

Another parameter that reflects the stiffness of the material is the elastic modulus, which also increases from approximately 72 GPa to 78 GPa with increasing practical density as the SiC content is the same. Consequently, composites with a higher percentage of SiC are stiffer than those with a lower percentage of SiC. Surprisingly the density of the alloy-SiC composite increases linearly from about 2.78 g/cm³ to 3.08 g/cm³ due to the higher density value of SiC than the base aluminium alloy.

These trends indicate that as the amount of SiC incorporated into aluminium alloy A365 increases, the material becomes stronger and stiffer, but at the same time becomes denser. Consequently, while improving the mechanical characteristics of these materials, some of their other properties, which are equally important for practical applications, such as density, have also increased.

Thermal performance

Table 2 clearly shows the correlation between the increase in the SiC content of the aluminium A365 alloy and the changes in the thermal properties.

Table 2. The thermal performance of the aluminium alloy A365 for different weight% of silicon carbide

SiC content (%)	Thermal conductivity (W/m·K)	Thermal expansion coefficient (10−6/K)
0	180.0 ± 3.49	21.5 ± 1.77
10	174.0 ± 6.23	19.75 ± 0.45
20	168.0 ± 5.45	18.0 ± 1.22
30	162.0 ± 2.78	16.25 ± 2.19
40	156.0 ± 7.59	14.5 ± 0.89

From the thermal conductivity data measured in the current study, it can be observed that the values for the A365- SiC composite diminish linearly with the addition of SiC. More precisely, the value of the thermal conductivity reduces to 0.60 W/m·K for each 1% of Silicon Carbide included in the composite. The thermal conductivity reduces progressively along the SiC content from 180 W/m·K for 0% of SiC to 156 W/m·K for 13.33% of SiC, reducing a general 24 W/m·K or 13.33% of its maximum value. This ensemble causality indicates that the incorporation of SiC particles continues to interfere with the thermal conduction pathways in the Al matrix. The reduction in the k value is testimony to the fact that SiC has a lower k value than the A365 alloy, and incorporation of this phase serves to decrease the effective thermal conductivity of the composite.

The thermal expansion coefficient of the A365 -SiC composite exhibits a more pronounced linear decrease with increasing SiC content. The rate of decrease was 0.1750 × 10⁻⁶/K for every 1% increase in SiC content. From 0 to 40% SiC content, the thermal expansion coefficient decreases from 21.50 × 10⁻⁶/K to 14.5 × 10⁻⁶/K, a total reduction is 32.55% of the initial value. This substantial decrease indicates that the SiC particles have a significantly lower thermal expansion coefficient than the A365 alloy matrix. The linear relationship suggests a proportional effect of the SiC content on thermal expansion throughout the studied range. This dramatic reduction in the thermal expansion coefficient implies that the addition of SiC can significantly improve the dimensional stability of the composite at higher temperatures, which could be beneficial for applications requiring precise dimensional control under varying thermal conditions.

As shown in Fig. 2, a series of thermal images of aluminium alloy samples of silicon carbide of different contents such as (SiC) 10, 20, 30% and 40% demonstrates the temperature difference between samples showcasing the temperature distribution across each sample. The images depict the distribution of temperature over each sample and, as one can see, there is a gradient where the variation in thermal conductivity can be found. One can see that the thermal profile changes as the SiC content increases, pointing to the role of the percentage of reinforcement in heat dissipation features.

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Fig. 2

Thermal image of aluminium alloy samples at 10, 20, 30% and 30% of silicon carbide (SiC)

The mechanical and thermal properties of the developed A365 aluminium alloy–SiC metal matrix composites are shown in Fig. 3. The following visualization provides a clearer view of the comprehensive influence of SiC addition on the properties of the alloy.

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Fig. 3

Combines both the mechanical and thermal properties of the A365 aluminium alloy as a function of Silicon Carbide (SiC) content

This means that there is considerable interaction between the mechanical and thermal properties of the A356 aluminium alloy matrix as the SiC content increases. In particular, tensile strength improved by 5.88%, and yield strength by 5.88%. On the other hand, the thermal conduction coefficient decreases by 13.33%, from 180 to 156 W/m·K, where the rate of thermal conduction loss is at 0.6 W/m·K, while the thermal expansion coefficient reduces by 32.55%, from 21.5 × 10⁻⁶/K to 14.5 × 10⁻⁶/K for These results also indicate that there is an anti-correlation between mechanical and thermal properties so one can fine-tune the material for an application that is required. For instance, increased SiC particle content is useful in parts exhibiting high strength and low coefficient of thermal expansion, as in aircraft, whereas reduced SiC particle content is more desirable in systems that require high thermal conductivity, such as heat exchangers in electronics products. The linear nature of these dependencies allows for the accurate tuning of the properties of these composites by varying the SiC content and presents a wide range of composite materials designed for numerous engineering applications and design considerations, ranging from mechanical strength and thermal conductivity to changes in the coefficients of thermal expansion.

Fourier transform infrared spectroscopy (FTIR)

In this study, the Fourier Transform Infrared Spectroscopy (FTIR) characterization of the A365 Al alloy with different volume percentages of SiC indicated variations in the molecular structure and chemistry, as presented in Fig. 4. In addition, Si-C and Si-O-Si bonds were observed with enhanced intensities of 60% and 54% at 800 cm⁻¹ and 1100 cm⁻¹, respectively. This implies that the formation of SiC in the aluminium matrix is successful in producing a network of Al and SiC, which improves the mechanical properties. Also, there is an increase in aluminium oxide bond restructuring characterized by a 45% increase in Al-O bending vibrations and a 45% decrease in stretching vibrations, including concerning the environment in which these bonds are confined due to SiC introduction.

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Fig. 4

FTIR analysis of A365 Almunium alloy with varying SiC content

It also reveals organic impurities, with C-H stretching intensity at 2900 cm⁻¹ decreasing by 36%, most probably because of high-temperature treatment. It appears, therefore, that from the point of view of materials science, these structural changes imply enhanced mechanical characteristics, such as higher strength and stiffness, stemming from the effective interface bonding of the aluminium matrix to SiC particles. The existence of new interfacial phases, such as silica (SiO₂), may have additional effects on the alloy characteristics and enduring stability, which requires further study.

Overall, the FTIR investigation of the A365 aluminium alloy revealed that the microstructure development was sensitive to SiC incorporation. It is confirmed that well-developed Si-C and Si-O-Si networks, together with AL2O3 restructuring, enhance the mechanical property changes noted. Nevertheless, the phenomena of new phase formation, as well as possible changes in the aluminium oxide network, can adversely affect the alloy performance in the long run, which emphasizes the necessity for further investigations of the effects stemming from the given observations under different conditions.

Corrosion resistance

A corrosion resistance analysis of the A365 aluminium alloy with varying quantities of Silicon Carbide (SiC) showed an enhancement of corrosion resistance with an increase in the quantity of SiC. It can be seen in Fig. 5 that the corrosion rate of the A365 Aluminum Alloy indicates an interactive behaviour with the corrosion susceptibility and SiC content of the material. Beginning with 0% SiC and a corrosion rate of 0.1 µA/cm², the rate decreased progressively to reach a minimum of 0.042 µA/cm² or a 58% reduction in corrosion rate at the 40% SiC content. This correction rate is calculated using Faraday’s law:

where K is a conversion factor, Is the correction current density obtained from the Tafel slope, n is the number of electrons transferred per metal atom in the corrosion reaction, F is a Faraday constant and A is the exposed surface area of the metal.

Moreover, Fig. 5 exhibits a nearly linear negative correlation with measurements at 10% intervals that demonstrates progressive and continuous decreases, implying that each per cent increase in SiC content inhibits corrosion rate at a rate of 0.001 µA/cm² per increase in percentage of SiC, making SiC a corrosion inhibitor in this alloy system.

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Fig. 5

Corrosion rate vs. SiC content in A365 Aluminum Alloy

This has been explained by the formation of a denser and more stable passive layer on the surface of the alloy, which prevents corrosive agents from accessing the surface of the alloy. The SiC particles included in the aluminum matrix also help to form this layer, and as a result, reduce the corrosion ability of the alloy. From these results, it can be concluded that the A365 aluminium alloy reinforced with SiC particles has better mechanical properties and enhanced corrosion resistance than the unreinforced material, making it ideal for applications in allied industries where high strength and corrosion endurance are desired.

Microstructural analysis

As shown in Fig. 6, the surface topography of Silicon-carbide-reinforced aluminium alloy using 10, 20, 30 and 40% reinforcement quantified in grayscale 3D atomic force microscopy (AFM)-like images. With an increment of the SiC, distinguishable variations in surface morphology and microstructure can be realized. The 10% sample indicates a more consistent and milder surface texture compared to the 30 and 40% samples that show more complicated, raised and detailed surface textures, which suggests a greater increase in the distribution and clustering of particles. Comparative microstructural changes due to increased reinforcements are demonstrated in these pictures.

[See PDF for image]

Fig. 6

A series of grayscale 3D atomic force microscopy (AFM) images with silicon carbide (SiC) at 10%, 20%, 30%, and 40% content

This transformation suggests more vigorous grain boundary interactions and higher concentrations of SiC particles, which significantly enhance mechanical properties such as hardness, wear resistance, and strength. Nevertheless, higher levels of SiC content can reduce the malleability and ductility of the alloy, thus hindering the problem of strength against flexibility. Therefore, because of the inequality revealed in this work, the quality of the alloy can be enhanced because of the deliberate accuracy of SiC in fulfilling certain challenges of hardness, strength, and durability.

Silicon Carbide (SiC) reinforcement has been found to improve the mechanical and thermal characteristics of several materials, including aluminium alloys. The integration of hard SiC particles into the matrix of the alloy resulted in increased hardness, wear resistance, and tensile strength of the composite. This increase in hardness makes the material suitable for applications where a high rubbing action is required, such as automotive engine parts. The integration of SiC particles reinforces the matrix alloy by hindering the dislocation movement, and hence the ability of the material to bear load and enhanced lastingness. On the same note, it is through the aid of SiC that increases thermal stability to enable the alloy to perform efficiently at high temperatures common with engines and aircraft parts.

Although the reinforcement of SiC increases the strength and stability of the alloy, it reduces the ductility rate. The introduction of SiC into the composite results in an undesirable material characteristic: increased brittleness, reduced ability to dissipate impact loads, and susceptibility to fracture under high stress. Another value that comes as a package with the excellent thermal conductivity of SiC is the low coefficient of thermal expansion, which means that dimensional stability with temperature variation comes at the price of closely monitoring the SiC level to ensure minimal brittleness. Therefore, the decision as to which SiC content to use is not easy, as the added advantages of increased hardness and improved thermal properties must always be weighed against the loss in flexibility, as per the expected performance of the intended application of the alloy. This study emphasized the mechanical, thermal, and corrosion behaviour considerations of A356-SiC composites, whereas a detailed spectroscopic study and elemental analysis, including EDAX mapping of the raw materials and in the final composites, is planned for a subsequent publication.

Conclusions

Several important conclusions relevant to the topic of metal matrix composites have emerged from this extensive analysis of SiC-reinforced A356 aluminium alloy composites. The incorporation of SiC particles in the A356 matrix with the help of improved stir-casting parameters resulted in improved mechanical properties. At room temperature, the composite can sustain a loading compressive strength of approximately 2,500 MN/m², which is significantly higher than that of the unreinforced alloy. Furthermore, the density of the composite increased from approximately 2.78 g/cm³ to approximately 3.58 g/cm³ because SiC has a relatively higher density.

The thermal analysis also demonstrated that the reinforcement of SiC significantly altered the thermal responses of the composite material. For every 1% addition of SiC, the thermal conductivity reduces by 0.60 W/m·K and thus; the thermal conductivity reduces from 180 W/m·K to 156 W/m·K or 12.33% of the initial value. This reduction in thermal expansion is especially worth it for uses, where high stability of dimensions is needed in a fluctuating temperature environment, similar to aerospace assemblies and high-performance automobiles.

The heat treatment and melting parameters were optimized to retain the inherent corrosion resistance characteristics of the A356 aluminium alloy. The tensile strength of the fabricated composite material also increased from 250 MPa to 270 MPa, and the yield strength increased from 150 MPa to 162 MPa, which improved the performance of the composite under harsh operating conditions.

In future work, this research provides a strong background for the development of aluminium-based. The condition control of the processing parameters, together with the systematic study of property correlation, is of significant importance for increasing the productivity and quality of synthesized materials. More extended studies on the possibility of using combined reinforcement, nanosized SiC particles, and improved processing technologies to enhance the performance of the composite can be pursued. Future work will also focus on compositional quantification, interfacial bonding mechanisms, and oxide phase formation at the matrix-reinforcement interface.

Acknowledgements

We gratefully acknowledge financial support from the Deanship of Scientific Research at Mutah University, underfunding decision No. 428/2021, which made this research possible.

Author contributions

The author solely conceived, designed, and conducted the study, analyzed the findings, and wrote the manuscript.

Funding

This research received no external funding.

Data availability

The data that support the findings of this study are openly available in Mendeley data at, https://data.mendeley.com/datasets/sckpzxsrht/2.

Declarations

Ethics approval and consent to participate

Not applicable.

Competing interests

The authors declare no competing interests.

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

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