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Forging Innovation: Advanced Aluminium Matrix Composites for Additive Manufacturing
The development of advanced composite materials is critical to meeting the evolving needs of modern manufacturing and performance-driven industries. Forging processes offer a unique approach to fabricating aluminum matrix composites (AMCs). This project aims to establish a forging methodology for producing aluminum-based composites reinforced with carbide powders, ensuring the structural integrity and processability of the resulting rods and wires for additive manufacturing applications. Using a forging machine known as a round swage, composite-filled tubes will be compacted into solid rods and wires. These forged materials will be further analysed for their suitability in Ultrasonic Plasma Atomization (UPA) and other advanced manufacturing techniques such as Direct Energy Deposition (DED).
Keywords: Round Swage, Composite Development, Aluminum Forging, Material Properties, Carbide Integration, Experimental Design, Rod and Wire Production
This project explores the fabrication of aluminum matrix composites using powder-filled metal tubes that undergo forging via a round swage technique. By integrating carbide particles into an aluminum matrix, the goal is to produce composites ready to be used for UPA and DED. The round swage will be used to consolidate and refine the composite-filled tubes into rods and wires of controlled dimensions. These forged composites will later be assessed for their microstructural integrity, mechanical properties, and potential applicability in additive manufacturing. The project also involves an evaluation of how forging parameters influence carbides distribution and densification within the matrix.
This project explores the fabrication of aluminum matrix composites using powder-filled metal tubes that undergo forging via a round swage technique. By integrating carbide particles into an aluminum matrix, the goal is to produce composites ready to be used for UPA and DED. The round swage will be used to consolidate and refine the composite-filled tubes into rods and wires of controlled dimensions. These forged composites will later be assessed for their microstructural integrity, mechanical properties, and potential applicability in additive manufacturing. The project also involves an evaluation of how forging parameters influence carbides distribution and densification within the matrix.
The overarching goal of this project is to establish a robust forging process for aluminum matrix composites that can be used in additive manufacturing technologies. The specific objectives include:
• Gain proficiency in wire and rod production techniques on a small scale.
• Developing proficiency in composite forging techniques on a small scale.
• Conducting a literature review on aluminum matrix composite processing and forging techniques.
• Investigating the effects of forging parameters on composite microstructure and mechanical properties.
• Producing aluminum matrix composite rods and wires reinforced with carbide powders.
• Analyzing the forged composites for density, hardness, and phase distribution.
• Evaluating the feasibility of utilizing the produced composite rods and wires for additive manufacturing applications.
The overarching goal of this project is to establish a robust forging process for aluminum matrix composites that can be used in additive manufacturing technologies. The specific objectives include: • Gain proficiency in wire and rod production techniques on a small scale. • Developing proficiency in composite forging techniques on a small scale. • Conducting a literature review on aluminum matrix composite processing and forging techniques. • Investigating the effects of forging parameters on composite microstructure and mechanical properties. • Producing aluminum matrix composite rods and wires reinforced with carbide powders. • Analyzing the forged composites for density, hardness, and phase distribution. • Evaluating the feasibility of utilizing the produced composite rods and wires for additive manufacturing applications.
Student Project Description_composite_by_forging.pdf
