Research progress on ceramic nanomaterials reinforced aluminum matrix nanocomposites

Abstract

Aluminum as a matrix phase in the metal matrix nanocomposites has several advantages, such as lightweight, ductile, corrosion resistance, and alloying ability with other elements. However, major disadvantages of aluminum as matrix phase for the nanocomposite are poor mechanical properties, low hardness, and poor wear resistance. Ceramic nanomaterials as continuous fibre, short fibre, particle or whisker can be reinforced in the aluminum in order to produced nanocomposites. An attempt has been made in this review paper to assess and ascertain recent research progress on ceramic nanoparticles reinforced aluminum matrix nanocomposites. The paper presents a review and overview of manufacturing, microstructure, properties and prospective applications of different ceramic nanomaterials incorporated aluminum/alloy matrix based nanocomposites.

Keywords

Aluminum matrix ceramic fibre interfacial interaction metal matrix microstructure nanocomposites reinforcement

Introduction

Recently, there is an extensive research thrust for the fabrication of high performance materials for advanced engineering fields [1 -4]. Advanced composite materials are a class of materials with high strength and modulus, lightweight, good ductility and other desired functional properties [5 -8]. In general, composite materials are defined by a materials with at least two phases. Matrix material is continuous in nature and major constituent of the composite. Minor constituent of the composite is the reinforcement phase which is generally in discontinuous form. Composite materials are broadly categorised as ceramic, polymer and metal matrix composites [9 -12]. Reinforcement phases in the composite materials can be of various types such as fibre, flakes, particulate or whiskers [13 -16]. Depending on size of the reinforcing phase, composite materials can be categorised as conventional composite materials with macro- or micro-sized reinforcing materials and nanocomposite with nano sized reinforcing materials. Enhancement of desired properties for the metal matrix phase can be tailored through the selection, size and concentration of reinforcing materials which are core composite design aspects [17]. Metal matrix composites or nanocomposite contains metal as matrix domain and reinforcing domain is generally carbon based, ceramic based micro or nano sized materials [18 -24]. Metal matrix composites combined tough property of metal with hard reinforcement in order to produce extra ordinary material properties. Pure metals exhibits both favourable quality and unfavourable quality for a specific application. Unfavourable quality of pure metals can be improved by reinforcing an appropriate material.

Metal matrix nanocomposite (MMNC) materials can be defined by a material with metal as matrix phase and reinforcing material has at least one dimension ≤ 100 nm [25]. Either a pure metal or its alloy can be the matrix phase to fabricate nanocomposites. Different types of metals or their alloys are used to manufacture metal matrix nanocomposites, such as aluminium, copper, magnesium, nickel, and steel [26 -31]. In comparison with conventional composite materials, manufacturing of metal matrix nanocomposite faces several challenges such as inhomogeneous distribution and/or dispersion of nanomaterial in the matrix phase, and controlling the interfacial adhesion between dissimilar matrix and nano reinforcing phases [18,32]. Improvement of mechanical properties for the nanocomposite relied on the distribution and dispersion of nano reinforcing materials in the matrix phase. Apart from these, wettability of nanoparticles in the matrix domain and subsequent enhancement of interfacial attachment between matrix and nanomaterials plays a key role for the strengthening mechanism. In addition to the selection of matrix and reinforcement phase, improvement of properties for MMNC depends on processing routes and processing parameters that can enhance dispersion, distribution of nano reinforcing materials and subsequently could enhance the interfacial adhesion between constituent phases [33].

Aluminium/alloys are widely applied in automobile, aerospace, defense, mineral processing industries for various high performance parts due to their lightweight, ductility, and excellent thermal conductivity. However, aluminium has poor strength and stiffness that can be enhanced by incorporating a suitable materials in the metal matrix [34,35]. Aluminium matrix composites possesses improved mechanical and physical properties, superior wear and corrosion resistance, and high temperature creep resistance [36,37]. Jiang et al. [35] presented aluminium alloy matrix composite reinforced with micro sized SiC fabricated by using squeeze casting method. Improvement for the mechanical property of metal matrix composite material is due to grain refinement. Grain size continuously reduced with increasing ceramic micro particle in the aluminium matrix. Different types of ceramic nanoparticles can be reinforced into the aluminium/alloy matrix. Some of the common ceramic nanoparticles reinforced into the aluminium domain to fabricate MMNC are alumina, silicon carbide, magnesium oxide, titanium boride, and boron nitride [38 -43]. Superior properties for these ceramic nanoparticles such as excellent hardness, wear resistance and high compressive strength makes them ideal candidate to be reinforced into the aluminium matrix.

Ceramics are attractive materials as reinforcing phase for various metal matrix due to their several excellent qualities such as high strength and elastic modulus, corrosion resistance, and temperature resistance properties [44 -47]. Ceramic reinforcing materials are available in various forms such as continuous fibre, short fibre, whisker or particles. Chemically, ceramic nanoparticles can be of various types namely oxides, carbide, borides, or nitrides. Some of key requirements for the ceramic nanoparticles to be incorporated into the aluminium matrix are: (i) low density in order to achieve lightweight composite material, (ii) temperature resistant property, (iii) chemical compatibility between aluminium matrix and ceramic nanoparticle in order to prevent dissolving nanoparticle in the melted metal and to ensure good adhesion in the metal matrix [17]. Ceramic reinforced aluminium matrix composites exhibited improved specific strength and modulus, and demonstrated excellent wear and corrosion resistant characteristics, and all these are desired material characteristics in mechanical structures due to their light weight design [43]. Degree of strengthening of metal matrix depends on type, shape, size, concentration, dispersion, distribution of nano ceramic particles in the aluminum domain [48]. Properties of ceramic nanomaterial incorporated aluminium matrix nanocomposites can be manipulated and controlled by the appropriate selection of nanomaterials, controlling interface between reinforcement and matrix, and fabrication method. There are several review papers on aluminium or its alloy matrix composite materials have been published in the recent year [19,49 -56]. However, these review papers are mainly focused on various micro or nanoparticles other than ceramic nanoparticles. Therefore, objective of this review paper is to provide the recent research progress on various ceramic nanomaterial reinforced aluminium matrix nanocomposites, their fabrication methods, microstructure, properties and prospective applications are included. The aim of this paper is to correlate the structure–property relationship of ceramic nanomaterials and aluminium matrix.

Brief overview of aluminum matrix nanocomposites

Aluminium/alloys are widely considered as matrix materials to fabricate conventional composites and nanocomposites, due to their inherent qualities, namely light weight, good ductility, and conductivity [37]. Poor qualities such as strength, stiffness, and corrosion resistance of pure metal can be enhanced by reinforcing an appropriate micro or nano material in the matrix phase [36,43,57 -59]. Recently, there is a huge research interests on various nanomaterials reinforced aluminium/alloy matrix nanocomposites. Aluminum has been reinforced with different types of ceramic or carbon based nanomaterials [7,40,60 -63]. Wang et al. [43] described microstructure, tribological and mechanical properties of aluminium matrix nanocomposite which was reinforced with graphene. Nanocomposites are manufactured by high-energy ball milling assisted powder metallurgy process. The process ensured homogeneous dispersion and distribution of nano particles in the aluminium matrix. Fabricated nanocomposite exhibited good corrosion and wear resistance. Strengthening mechanism of nanocomposite materials was thermal mismatch strengthening. Structure and properties of graphene incorporated aluminium or alloy nanocomposites are reported by Brodova et al. [64]. Materials were synthesised in situ under a layer of molten salt. Reinforcing graphene nanomaterial decreases grain structure of the matrix phase. Experimental results revealed sharp increase of hardness for the nanocomposites because of the grain refinement. Homogeneous dispersion, distribution of nano particles and improvement of interfacial interaction are key aspects for the enhancement of mechanical properties of nanocomposite materials. Nanomaterials can be coated by metal in order to improve interfacial interaction and reduce the byproduct formation at the interface. Guo et al. [65] compared coated by copper and uncoated carbon nanofibre containing aluminium matrix nanocomposites which was manufactured by spark plasma sintering. Copper coating can protect microstructure of carbon nanofibre and inhibit formation of Al₄C₃. Copper coating improves interfacial interaction, and promotes nucleation and growth of P-oriented grains, hence improved the mechanical properties. Yarahmadi et al. [66] have compared microstructure and mechanical properties of carbon nanotube diameter and concentration in the aluminium matrix nanocomposites. Nanocomposites were manufactured by powder metallurgy method using double pressing double sintering process. Experimental results revealed that carbon nanotube concentration and diameter of the carbon nanotube had significant influence on clustering, interfacial interaction and mechanical properties of nanocomposite materials. Smaller diameter carbon nanotube has higher tendency to form agglomeration and aluminium carbide formation at the interface of nanotube and aluminium matrix. Maximum hardness and compressive strength of nanocomposite materials were observed with 8 wt% of carbon nanotube with 40 nm diameter, which was the highest diameter selected for the fabrication process. Multiwalled carbon nanotube reinforced aluminium matrix nanocomposites were described by Carneiro et al. [67]. Nanocomposites were manufactured by powder metallurgy route via ultra-sonication and ball milling as dispersion/mixture techniques. Uniform dispersion and distribution without damaging the carbon nanotube is desired in powder metallurgy route. Carbon nanotube (CNT) functionalisation has been influenced dispersion of nanoparticles in the matrix. Agglomeration of carbon nanotube has been occurred in the pore and grain boundaries (Figure 1). Enhancement of mechanical property of manufactured nanocomposite is due to the load transfer between matrix and CNT, and vice versa. Introducing phases/interfaces or more grain boundaries are useful and effective method to strengthen metal matrix. Maleki et al. [68] reported nickel ferrite nanoparticle reinforced aluminium matrix nanocomposite manufactured by using powder metallurgy technique. Aluminium matrix has been reinforced with 1, 2.5, 5 and 10 wt% of nanomaterial. Relative density of the nanocomposite materials has been decreased with increasing nanomaterial concentration. Whereas, yield stress and ultimate tensile strength have been increased with increasing concentration of nanoparticles up to 5 wt%, however, they decreased at 10 wt% of nano reinforcement. Decline of mechanical properties is due to the clustering of nanoparticles in the metal matrix as shown in Figure 2. Agglomerated nanoparticles has poor interaction with aluminium matrix. Zhang et al. [69] reported significant enhancemnet of mechanical properties for CNT reinforced aluminium matrix nanocomposite which was produced by friction stir processing (FSP). Microstructural study has been revealed little interfacial reaction product, no visible gaps between carbon nanotube and metal interfaces due to the clean and tight bond formation in the interfaces of constituent components. Others proposed strengthening mechanism of carbon nanotube incorporated aluminium matrix nanocomposites are grain refinement, dispersion, load transfer through interface, and thermal mismatch between aluminium matrix and carbon nanotube [27,70]. For industrial applications, tribological property of metal is very important. However, aluminium has poor tribological properties. Reinforcement of graphene in aluminium matrix has been significantly improved the tribological property of aluminium. Graphene nanoparticles act as lubricant on the interface and improved the lubrication effect [71].

Fabrication of ceramic nanoparticle reinforced aluminum matrix nanocomposites

The major challenges for the manufacturing of ceramic nanoparticle reinforced aluminium/alloy nanocomposites are agglomeration and inhomogeneous dispersion of nanoparticles, and poor wettability of nanomaterials in the matrix materials. To improve the dispersion and/or distribution of nanomaterials, and afterwards improvement of interfacial interaction, various processing routes namely solid-state, semi liquid-state and liquid-state can be adopted to fabricate ceramic nanomaterials reinforced aluminium matrix nanocomposites. Classification of fabrication techniques for the ceramic nanoparticles reinforced aluminium matrix nanocomposites are schematically depicted in Figure 3. Processing routes of ceramic nanoparticles reinforced aluminium matrix nanocomposites (AMNE) are updating rapidly due to the ease of fabrication and final quality of desired composites [72]. Some of the methods for the manufacturing of ceramic nanomaterial incorporated nanocomposites are discussed.

Powder metallurgy is a solid state process which can be applied to fabricate ceramic nanomaterials reinforced aluminium/alloy matrix nanocomposites. Three major steps of powder metallurgy method are mixing of powder to achieve homogeneous mixture, compaction of powder mixture to obtain the required shape, and sintering to stabilise the structure. Sintering process will help for bonding ceramic nanoparticles with aluminium matrix. Mu et al. [73] reported aluminium matrix nanocomposites reinforced with SiC nanomaterial and produced by powder metallurgy method. The process has been schematically shown in Figure 4. Powder mixture has been milled by high energy ball milling. Afterwards, powder has been consolidated by spark plasma sintering process at 500°C for 10 min under 50 MPa pressure. Afterwards, samples were hot extruded at extrusion ration of 16:1 under the flow of argon gas [73]. Microstructure and properties of metal matrix nanocomposites were influenced by process parameters in powder metallurgy method [74]. Salur et al. [75] reported influence of milling time on microstructure of Y₂O₃ nanoparticle reinforced aluminium matrix composite. Milling time has two ways influence on microstructure of nanocomposites. With increasing milling time particles clusters are breakdown due to the shear force (Figure 5). On the other hand, nanoparticles are evenly distributed in the matrix.

Stir casting is a simple and economical liquid state method for producing of metal matrix composites or nanocomposites. In this method, ceramic nano materials are incorporate into the molten aluminium/alloy matrix materials. Afterwards, molten nanocomposite materials are casted by traditional casting method. Major challenges for this method for the fabrication of ceramic nanomaterial and aluminium nanocomposites are: (i) agglomeration of nanoparticles, (ii) limited wettability of sloid nanoparticles in the molten metal and (iii) incorporation of higher porosity in the resultant nanocomposites due to the entrapment of air introduced during rotating stirrer [17]. Covering the melt with an inert gas will reduce the arial oxidation of melt during processing [76]. Poor adhesion of reinforcement material in the matrix phase can be improved by coating of reinforcement. In addition to the enhanced wettability, coating of reinforcement can improve stability of reinforcement in the composite, interfacial interaction between the constituent phases and reduces the porosity in the end product. Further, coating of nanoparticle can reduce byproduct formation at the interface during fabrication at high temperature [77]. Yi-Long et al. [78] presented TiC nanomaterial reinforced aluminium 2219 nanocomposite manufactured by high intensity ultrasonic casting process. TiC nanoparticles distribution in the aluminium melt has been significantly influenced by the ultrasonic energy. Ultrasonic power promote the dispersion of nanoparticles. Number of nanoparticles at the centre was lower than that at the edge due to the ultrasonic streaming. As a result, agglomeration was observed at the edge. Average grain structure in the edge was bigger than that of at the centre. Kumar et al. [79] reported a novel method of stir casting coupled with cryo FSP in order to enhance the mechanical properties of nanocomposite samples. As casted specimens were machined and sliced into rectangular pieces to carry out the FSP. The specimens were clamped with cooling fixture (Figure 6). FSP on specimens were performed with 1025 rpm and 65 mm/min traverse speed [79].

Friction stir processing can be used to incorporate nanoparticle within a metal matrix in order to produce surface nanocomposite. FSP is a green way of producing surface nanocomposites layer on the substrate. This is an ideal method for the manufacturing of ceramic nanoparticles incorporated aluminium matrix nanocomposites. FSP is an intense plastic deformation technique to produce heat and form surface nanocomposite by combining ceramic nanomaterial and substrate matrix material [40]. Friction stir processing for reinforcing alumina nanoparticles in the aluminium alloy matrix has been depicted schematically in Figure 7 [80]. Nano ceramic particles are reinforced into the aluminium matrix in a plastic state. Several parameters influences the quality of nanocomposite materials, namely tool rotational speed, axial force, traverse speed, size of the groove, and tool geometry. This is an efficient method to produce high-quality ceramic nanoparticle reinforced nanocomposites in the solid state with optimum energy spent, and improved interfacial bonding between nano reinforcing material and aluminium matrix [72].

Ceramic nanoparticle reinforced aluminium matrix nanocomposite can also be manufactured by accumulative roll bonding (ARB) technique. Before ARB process, surface of aluminium sheet has been prepared. ABR passes can influence the distribution and dispersion of nanomaterials, and grain structure. Najjar and Elmahdy [81] reported homogeneous dispersion of TiO₂ nanoparticles in the aluminium matrix after five ARB passes. Five ARB passes ensured homogeneous distribution of nanoparticles, and ultrafine and elongated grains of the matrix material [81]. Major problems for the manufacturing of aluminium matrix nanocomposites by using casting methods are inhomogeneous distribution of nanomaterial in the matrix, creation of porosity and weak bonding between matrix and reinforcements. Applying ARB after stir casting can improve microstructure of nanocomposite and ensured homogeneous distribution of nano reinforcing material in the matrix [82].

Wang et al. [58] reported a novel wire arc additive manufacturing (WAAM) technique assisted with ultrasonic for the manufacturing of ceramic nanomaterial reinforced aluminium (AA 7075) matrix nanocomposites as shown in Figure 8. The process is basically a gas tungsten arc welding method. The filler metal has been fed in front of arc and ultrasonically assisted (UA) probe which is travelled behind arc. UA probe has been attached at the end of the UA horn, which was mounted on the welding torch to give synchronous travel. For each layer, travel time was 1 min with a travel speed of 1.5 mm/s. Throughout the process, an average height deposition rate of 0.9 mm/pass has been maintained. The synergistic effect of ultrasound and ceramic nanoparticle modified the solidification process and improved the microstructure of nanocomposite material. Ultrasound assisted method significantly reduced the porosity of the nanocomposite sample. Further, ultrasonic assisted sample exhibited consistent grain structure throughout the deposited layers. Ultrasonic assisted WAAM showed reduced porosity, refined solidification structure and uniform dispersion of nanomaterial in the matrix, which subsequently improved the mechanical properties of the nanocomposite materials [58]. Key advantages and disadvantages of different processing routes for the manufacturing of ceramic nanomaterials incorporated aluminium matrix nanocomposites are reported in this paper are tabulated in Table 1.

Table 1

Key advantages and disadvantages of different fabrication process for the ceramic nano materials reinforced aluminium matrix nanocomposite.

Nanocomposite manufacturing methods	Advantages	Disadvantages
Powder metallurgy	Simplest technique for the fabrication of ceramic nano reinforcing material reinforced aluminium matrix nanocomposites as compared with other techniques	Homogeneous dispersion and distribution of tiny ceramic nano particles in the aluminium matrix is challenging.
Stir casting	Simplicity, flexibility and applicability for bulk ceramic nano material reinforced aluminium matrix nanocomposites; Good matrix and nano reinforcement interface	Agglomeration of ceramic nanoparticles Limited wettability of ceramic nanoparticles in the aluminium matrix; Stirring introduces high porosity in the nanocomposites.
Friction stir processing (FSP)	Green technique to fabricate ceramic nanomaterial reinforced surface composite Uniform dispersion of ceramic nanoparticles in the aluminium matrix	Tool wear with ceramic nano reinforcing materials; Nanocomposite with high concentration of nano reinforcing material is not possible. Other limitation of FSP are depth of penetration of particles and scale up for mass production.
Accumulative Roll Bonding (ARB)	The process produces homogeneous dispersion and distribution of nano material in the matrix; The process is independent of physical and chemical properties of nano reinforcing materials. Good interfacial attachment between nano reinforcing material and metal matrix.	Porosities are incorporated in the fabricated nanocomposite materials
Ultrasound assisted wire arc additive manufacturing technique	Ultrasound assisted technique significantly reduces porosity and maintained uniform grain structure throughout the deposited layers of the nanocomposites; Homogeneous dispersion of ceramic nano particles in the metal matrix.	Slow process Higher capital investment

Properties of ceramic nanoparticle reinforced aluminum matrix nanocomposites

Reinforcement of various ceramic nanoparticles in the aluminium matrix significantly has been improved mechanical properties (Table 2). Jamali et al. [83] reported ZrO₂ reinforced aluminium AA7075-T6 fabricated by using friction stir processing. Two major parameters which have influenced the wear and mechanical properties of nanocomposites were grain and agglomeration size. Maximum micro hardness of nanocomposite has been increased by 44%, whereas, wear rate of nanocomposite has been decreased by 67% as compared with the base metal. Minimum grain and agglomeration size exhibited reduced wear rate. Boron carbide nanomaterial reinforced aluminium AA6063 matrix nanocomposite processed by friction stir method has been reported by Pratap et al. [84]. Reinforcement of boron carbide nanoparticle, significantly changed the tensile property, hardness, ductility and wear resistance properties of nanocomposite materials due to the grain refinement. Hardness of nanocomposite has been improved more than two folds with insignificant reduction of ductility and the improvement of wear property. Microstructure study revealed that significant improvement of nanocomposite properties is due to the refinement of grain structure. Zoalfakar et al. [85] reported tungsten carbide nanomaterial reinforced nanocomposites fabricated by FSP. Dispersion of nanoparticle in the aluminium matrix depended on FSP parameters. Significant plastic deformation and thermal energy generation during FSP breaks coarse matrix and cluster of reinforcement particles, reduced pore and generate ultrafine grain size via dynamic recrystallisation. Traverse speed was the dominating factor for the ultimate tensile strength, while, for the grain structure, number of passes was the most influential factor [85]. Increasing number of passes enhanced homogeneous dispersion and enhanced grain refinement of nanocomposite samples [86]. Aluminium matrix nanocomposites manufactured by powder metallurgy method possesses lack of ductility due to the processing parameters such as oxygen content, porosity, and undesirable microstructure properties due to the contamination imparted during powder preparation and sintering. Huang et al. [87] reported 5 wt% SiC reinforced Al-Mg-Sc-Zr nanocomposite produced by powder metallurgy. In order to achieve uniform, dense and refined microstructure, nanocomposite was subjected to FSP. FSP passes remarkably has been reduced microdefects and homogenised the microstructure. The yield strength has been increased from 92 MPa for as powder metallurgy processed sample to the 161 MPa after four passes of friction stir processed sample with a significant improvement of fracture strain from 0.11 to 0.29.

Table 2

Mechanical properties of ceramic nanoparticles incorporated aluminium matrix nanocomposites.

	Reinforcing nanomaterial			Enhancement of mechanical properties
Matrix type	Type and size	Conc.	Fabrication method	Compression	Tensile	Hardness	Ref
AA2024	SiC (50 nm)	5 vol%	Powder metallurgy	30.3% (YS)	26% (UTS)	–	[88]
Al	SiC (∼50 nm)	5 wt%	Powder metallurgy	40% (YS)	–	50%	[89]
Al	SiC (∼50 nm) &	5 wt%	Powder metallurgy	∼120% (YS)	—	86%	[89]
	ZrO₂ (15 nm)	9 wt%
Al7075	SiC (30–80 nm)	5 wt%	Stir casting	–	–	47.8%	[79]
Al7075	SiC (30–80 nm)	3 wt%	Stir casting & Cryo FSP	–	26.3% (UTS)	76.3% (HAZ)	[79]
AA2024	SiO₂ (∼10 nm) &	0.5 vol%	Stir casting & 5 passes ARB	–	110% (UTS)	160%	[82]
	TiO₂ (∼50 nm)	1 vol%
AA6005A	TiC (20 nm)	3 vol%	Powder metallurgy		29% (UTS)	43%	[90]
AA6061-T6	Al₂O₃ (15 nm)	0.4 vol%	Friction stir processing	–	∼−50%	∼127%	[80]
Al	SiC (60 nm)	8 wt%	Powder metallurgy	200%	–	264%	[74]
Al	Al₂O₃ (39.6 nm)	4 wt%	Powder metallurgy			24.8%	[38]
A6005	TiB2 (30–50 nm)	5 wt%	MA & extrusion	–	–	22%	[39]
AA7150	SiC (40–60 nm)	1 wt%	Ultrasonic assisted double stir casting	–	26%	11%	[91]
AA2219	TiC (20–100 nm)	0.9 wt%	Forged & heat treated	–	24.2% (UTS)	–	[92]
AA7150	hBN (70 nm)	1.5 wt%	Ultrasonic assisted stir casting	–	–	21.7%	[93]
AA7150	hBN (70 nm)	1 wt%	Ultrasonic assisted stir casting	–	–	17.4%	[93]
Al5083	SiC (35–40 nm)	3 wt%	Powder metallurgy	60% (YS)	–	134%	[94]
Al7075	Al₂O₃ (20–30 nm) & SiC (50 nm)	4 wt%	Liquid state process	–	∼70% (UTS)	∼40%	[95]
Al7075	Y₂O₃ (35 nm)	0.5 wt%	Powder metallurgy 1.5 hr milling time	–	101% (YS)	55.8%	[75]
Al7075	TiC (20–40 nm)	5 wt%	Powder metallurgy 1 h milling time	–	35.3% (UTS)	70%	[96]

YS: yield strength; UTS: ultimate tensile strength; MA: mechanical alloying; HAZ: heat affected zone.

Recently, there is a significant research thrust on ceramic nanoparticle reinforced hybrid nanocomposites with more than one nano reinforcements [97]. Reinforcement of more than one nanomaterials can eliminate negative aspect of one nano reinforcing material. Moustafa et al. [98] presented aluminium (AA 6061) matrix-based nanocomposites reinforced with hybrid nanomaterials such as graphene nano platelet, alumina and silicon carbide. Nanocomposites were fabricated by FSP. SiC and graphene hybrid nanomaterials reinforced nanocomposite exhibited excellent wear property due to reduced grain size. Thirty six-fold reduction of grain size has been observed in the process zone. Improvement of wear property for the hybrid nanocomposite materials was due to the self-lubricant property of graphene combined with hard SiC which eliminates negative effect of graphene nano platelet on the hardness. In another study, Moustafa [99] reported aluminium matrix hybrid nanocomposite reinforced with both ceramic nanomaterials namely alumina and boron nitride nanoparticle. Nanocomposites were fabricated by using FSP which ensured uniform dispersion and distribution of nanomaterials on the nanocomposite surface. Both nanoparticles separately increases hardness (45–55%) of the composite materials as compared with monolithic metal. However, enhancement of hardness with hybrid nano reinforcing materials was better. Vij et al. [100] described hybrid aluminium matrix nanocomposites incorporated with alumina and zirconia nanoparticles, and nanocomposites were manufactured by using stir casting. Matrix of the aluminium has been reinforced with 6.6% alumina nanoparticle and 3.3% zirconia nanoparticles. Experimental results revealed that stir casting process has been ensured homogeneous distribution and dispersion of nanoparticles in the matrix materials. As compared with base metal, tensile strength of hybrid nanocomposite has been improved to 54.32%, whereas, hardness has been improved to 114.28%. Manohar et al. [101] have compared microstructure and properties of hybrid nanocomposite which was manufactured by using powder metallurgy process, and sintered by conventional sintering process and spark plasma sintering process. B₄C and ZrC hybrid nanomaterials are reinforced into the aluminium AA 7075 matrix. As compared with conventional sintering process, spark plasma sintering process revealed clean interface and homogeneous dispersion of nanomaterials in the matrix phase. Due to the improved microstructure of spark plasma sintered samples, mechanical properties namely compression and tensile strength of the spark plasma sintered specimens were significantly better than that of the conventional sintered samples. Moustafa et al. [102] have reported hybrid ceramic nanoparticle reinforced aluminium AA 7075 reinforced nanocomposites which were fabricated by using FSP. Hexagonal boron nitride (BN) nanoparticle has been selected as primary reinforcing material, and niobium carbide (NbC), silicon carbide (SiC), and tantalum carbide (TaC) nanomaterials as secondary reinforcing materials in the matrix phase. Experimental findings revealed that secondary nano reinforcing materials has been enhanced chemical stability, improved resistance to deformation at elevated temperature and controlled grain growth. Microstructure study has been revealed that hybridisation ensured homogeneous dispersion of nanomaterials in the stir zone and significant reduction of grain size. Grain size has been reduced to 400% for the BN and TaC hybrid nanocomposite as compared with base alloy material. Reinforcement of boron nitride nanoparticles in the aluminium matrix significantly improved the wear resistance property (14–24 times). As compared with base alloy materials, compressive strength and micro hardness of the hybrid nanocomposite has been improved 26.5 and 40%, respectively [102]. Better load carrying properties of the nanocomposite materials was due to the decrease in grain structure, uniform dispersion and distribution of nanomaterials, and formation of dislocation because of the thermal mismatch between aluminium and ceramic nanoparticles [74]. Mechanical and wear properties of alumina and graphene oxide incorporated aluminium matrix hybrid nanocomposites has been described by Mohammed et al. [103]. Nanocomposites were manufactured by powder metallurgy route and sintered by using spark plasma sintering method. Nanocomposites with 10 vol% of alumina and 0.25 vol% of graphene oxide exhibits 48.4% improvement of hardness and 55.6% of specific wear rate. Enhancement of mechanical property for hybrid nanocomposite was due to the reinforcement of hard ceramic materials and homogeneous dispersion of both reinforcing particles in the aluminium matrix.

In the accumulative roll bonding (ARB) process, microstructure and properties of nanocomposites are depended on ABR passes. Najjar and Elmahdy [81] have reported uniform dispersion and distribution of TiO₂ nanoparticles, and ultrafine and elongated grains of the aluminium matrix. Vickers micro hardness properties of the nanocomposite has been increased with increasing number of ARB passes. After five ARB passes, Vickers micro hardness of 3% TiO₂ reinforced aluminium matrix nanocomposites has been increased to 155% as compared with ARB-processed monolithic aluminium. Further, tensile properties of nanocomposite was more than three times better than that of the aluminium matrix. Remarkably improvement of mechanical parameters of the nanocomposites was due to the good bonding among the component materials [81]. ARB process on the stir casted 0.5 vol% SiO₂ and 1 vol% TiO₂ reinforced aluminium alloy matrix nanocomposite has been significantly improved the microstructure and reduced agglomeration of nanoparticles in the matrix phase [82]. ARB passes finely grinded matrix phase, coarse particles were fragmented and distributed in the matrix. Further, ARB passes has been enhanced dispersion and distribution of nano particles in the matrix material. Reihanian et al. [104] also reported that ARB passes significantly improved dispersion of nanomaterials in the matrix. After one and three ARB passes, particles are exists at the interface of layer, however, with increasing ARB passes particles are separated at the interface. As a result, five ARB passes after stir casting has been improved hardness, yield stress and ultimate tensile strength of the nanocomposite samples by 160%, 300% and 110%, respectively [82].

Boron carbide nanoparticle reinforced aluminium (AA 7150) matrix nanocomposite has been presented by Madhukar et al. [105]. Materials were fabricated by using stir casting method using a sequence of vortex process and double casting method with ultra-sonication. Mechanical properties of as casted nanocomposite was improved significantly as compared with base AA 7150 due to the microstructure refinement, nanoparticle distribution in the aluminium matrix and good interfacial adhesion between nanoparticle and aluminium matrix. Yang et al. [106] reported TiC ceramic nanoparticles reinforced aluminium 2219 nanocomposite fabricated by using ultrasonic casting. Hardness property of the nanocomposite materials has been improved with an increased wear resistance of 30–90% as compared with base alloy material. Wear mechanism of TiC reinforced aluminium matrix nanocomposite was the combination of oxidative and adhesive wear. Wear of the composite reinforced with hard TiC particles being mainly abrasive in nature. Sharma and Mishra [107] reported nano chromium carbide (Cr₃C₂) reinforced aluminium AA 7075 nanocomposites prepared by stir casting method. Stir casting method has been ensured homogenous dispersion of nanomaterial in the molten aluminium matrix. Nanocomposites were aged at T6 and Retrogression and Reaging (RRA). Combined influence of reinforcement and ageing has been significantly enhanced the hardness and strength, however, ductility of the composite material has been deteriorated. T6 treated specimen showed better hardness and strength, whereas, RRA treated specimen displayed better ductility. Microstructure and properties of silicon nitride nanoparticle reinforced aluminium (AA 7068) matrix nanocomposite produced via ultrasonic assisted stir casting attached with bottom pouring set up has been described by kumar et. al. [108]. Grain refinement has been improved with the reinforcement concentration in the aluminium domain, however, clustering of nanoparticles was observed with higher nanoparticle concentration. Tensile strength, compressive strength and hardness value of 1.5 wt% nano particle reinforced nanocomposite has been improved to 50.07%, 27.41% and 72.71%, respectively as compared with base alloy material. Properties of the nanocomposite has been reduced with 2 wt% of nano reinforcement in the alloy matrix due to the significant agglomeration of nanoparticles. Impact strength and ductility of nanocomposite have been continuously decreased as compared with pure metal [108]. Kumar et al reported cryo friction stir processing of stir casted aluminium nanocomposite specimens for the enhancemnet of mechanical properties due to the microstructural changes in the specimen. Cryo FSP refine the grain structure (Figure 9) of nanocomposite specimens. Nanocomposite reinforced with 3 wt% of SiC nanoparticle showed better grain structure. Specimen with 3 wt% of SiC nanoparticle showed better hardness value as compared with base metal and other nanocomposite specimens [79]. Reinforcement of uniformly distributed hard and non-deformable ceramic nanoparticles has been increased hardness. Existence of nanoparticles in the aluminium matrix hinders the dislocation, hence, increased hardness property [109]. Silicon carbide nanoparticles are generally distributed at the grain boundary as shown in Figure 10a and 7b. Few nanoparticles can also be found inside the grain. Nanoparticles are homogeneously distributed in the aluminium matrix, however, agglomeration in some places can be observed (Figure 10c) due to tiny particle size, larger surface energy and surface area of particles. Energy dispersive spectroscopy (EDS) showed elemental composition of aluminium alloy and reinforcement nanoparticle [110]. Sintering process has marked influence on the mechanical properties of ceramic nanoparticle reinforced aluminium matrix nanocomposites. Ghasali et al. [111] reported TiO₂ nanoparticle (particle size 100 nm) incorporated aluminium matrix nanocomposites produced by powder metallurgy route. Specimens were sintered by using three sintering modes namely conventional, microwave and spark plasma sintering process. Microwave sintered specimen showed maximum Vickers hardness and bending strength due to the formation of Al₃Ti particles and homogeneous dispersion of Al₃Ti particles in the aluminium matrix. Whereas, spark plasma and conventional sintering process showed non-uniform distribution and agglomeration of Al₃Ti particles, and porosity on the sample, as a result of poor mechanical properties. In another study Ghasali et al. [112] reported vanadium reinforced aluminium matrix nanocomposite fabricated at low temperature (200°C) spark plasma sintering. Mechanical property of fabricated nanocomposite depends on the applied pressure. Composite fabricated at higher applied pressure exhibited better mechanical property. Microstructure investigation has been revealed layer by layer composite structure formation.

Applications of ceramic nanoparticle reinforced aluminum or its alloy matrix nanocomposites

There is a significant demand for high specific strength, lightweight composite material with improved corrosion resistance, high temperature performance and energy saving materials for aerospace, agriculture, automobile, construction and manufacturing industries [72]. Ceramic nanomaterials reinforced aluminium matrix nanocomposite possesses superior mechanical and surface properties with light weight feature. These advanced nanocomposite materials has the capability to replace conventional steel for automobile parts [108]. Combination of aluminium or its alloy and ceramic nanoparticle can provide a wide range of application in automobile, aerospace, defense, construction, agriculture, medical and other fields. Prospective various applications of ceramic nanomaterial reinforced aluminium matrix nanocomposites are depicted in schematically in Figure 11 [113]. Light weight with improved mechanical and other functional properties (such as corrosion resistance, wear resistance, improved strength at elevated temperature) of ceramic nano material reinforced nanocomposite based on aluminium matrix can be used in aerospace, automobile, biomedical, and defense. Ceramic nanoparticle reinforced lightweight aluminium matrix nanocomposites with high strength and specific stiffness can find application in high-speed machinery, high-speed rotating shaft, robots, brake parts and automotive engine [48]. Further, ceramic nanoparticles reinforced aluminium matrix nanocomposites exhibits good wear resistance property, hence could be considered as prospective for wear resistant lining. Friction stir processing method can fabricate ceramic nanoparticle reinforced aluminium matrix surface nanocomposite with light weight and improved surface properties. These nanocomposite could find applications in aerospace, marine, defense and transportation industries [85,114]. Due to the piston slap as a result of repeated sliding stroke, cylinder liners of aircraft and automotive engines encountered extensive wear. Ceramic nanoparticle reinforced aluminium matrix nanocomposite with improved wear properties can find applications as liners [115].

Conclusions: Challenges and future prospects

Weak mechanical properties of pure aluminium can be remarkably enhanced by reinforcing ceramic nanoparticles. Aluminium/alloy matrix-based ceramic nanoparticle reinforced composite materials are lightweight materials with improved properties. Different types of ceramic nanoparticles can be reinforced into the aluminium or its alloy matrix such as silicon carbide, alumina, titanium dioxide, zirconia, titanium carbide, and silicon dioxide. This review paper provides recent research progress in various ceramic nanoparticle reinforced aluminium matrix nanocomposites, microstructure, properties and applications. Selection of the manufacturing routes and processing parameters of the ceramic nanoparticles reinforced aluminium matrix nanocomposites are critical for developing MMNC with improved properties. Various routes namely liquid state, semi liquid state and solid state manufacturing methods of ceramic nanoparticles reinforced aluminium/alloy matrix nanocomposites are summarised in this review paper. Advantages and disadvantages of different fabrication process for the manufacturing of ceramic nanomaterials reinforced aluminium matrix nanocomposites are discussed. Based on the literature review, accumulative roll bonding could be considered as a good method for the bulk fabrication of ceramic nano particle reinforced aluminium matrix nanocomposites. Key challenges for the ceramic nanoparticle reinforced aluminium matrix nanocomposites are (a) homogeneous dispersion of tiny nano reinforcement particles in the metal matrix; (b) improvement of ceramic nanoparticle and aluminium interface; (c) reactivity of nano-reinforcement with aluminium matrix, especially for the liquid state processing of nanocomposites and (d) selection of ceramic nano-reinforcements, processing technique and processing parameters. Aluminium matrix nanocomposites reinforced with ceramic nanomaterial can be used in various engineering applications due to their better strength-to-weight ratio, improved wear and friction resistance, stiffness, and higher thermal conductivity. However, more researches are essential to understand the correlation between microstructure and properties of ceramic nanomaterials incorporated aluminium matrix nanocomposites. Therefore, authors of this paper recommended further research in the following areas: (i) selection of appropriate ceramic reinforcement and processing method for the nanocomposite fabrication depending on the end application of products; (ii) wettability of ceramic nano materials in the aluminium matrix; (iii) interface of dissimilar ceramic nano particles and aluminium matrix; (iv) micro structure of ceramic nano particle reinforced nanocomposites and their correlation with nanocomposite properties; (v) distribution and dispersion of nanomaterials in the metal matrix; (vi) optimising concentration of ceramic nanomaterials in the aluminium matrix; and (vii) tailoring process parameters for the selected nanocomposite fabrication method.

Footnotes

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Influence of secondary phase particles Al2O3/SiC on the microstructure and tribological characteristics of AA7075-based surface hybrid composites tailored using friction stir processing. Proc Inst Mech Eng C J Mech Eng Sci. 2021;235(1):161–178.