Al-Cu-Mg Alloy Powder Reinforced with Graphene Nanoplatelets: Morphology, Flowability and Discrete Element Simulation
Abstract
:1. Introduction
2. Materials and Methods
2.1. Powder Specification and Characterisation
2.2. Powder Preparation
2.3. Flow Characterisation
2.4. Compaction Characterisation
3. Results
3.1. Particle Size Distribution (PSD) of the Composites
3.2. Microstructural Characterisation
3.3. Microhardness Analysis of the Powders
3.4. Calibration of the DEM Surface Energy, Particle Type, Volume and Morphology
3.5. Flowability Analysis
3.6. Effect of Gr Concentration on Flowability
4. Discussion
5. Conclusions
- Short milling times (below 4 h) provided insufficient impact energy inside the milling bowls to separate the agglomerated Gr particles. However, long milling times (over 4 h) notably changed the powder morphology from nearly rounded to flat. Furthermore, GNPs were better separated and adhered to the Al powder surface at longer milling times.
- For 16 h of milling, there was a slight increase in microhardness (3%), as well as a reduction in average crystallite size (24%) in the milled powder (see Figure 20). This inverse correlation suggests that grain refinement gives additional strength to the milled powder due to the improved internal crystallite strain.
- Common DEM particles (Type 1) in the literature and near-shape SEM particles (Type 2) were tested and it was found that Type 2 particles are more representative and provide accurate results than Type 1. Additionally, more variety in morphology results in sensitive results; however, the running time of the simulation and preparation of more particles is extensive. It was concluded that experimental work for flowability tests of irregular and non-uniform particle morphologies is faster and more reliable than simulation.
- The contrast of the experimental work and simulation results regarding the flowability test show excellent correlation at long milling times (Figure 16). However, simulation results at short milling times show differentiation from the experimental results. The reason behind this is that separated Gr particles at long milling times become less effective on the angle of repose. These findings lead us to conclude that the flowability of the composite more depends on powder morphology than the existence of Gr at longer millings.
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
References
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Parameters | Values |
---|---|
Milling speed (rpm) | 100 |
Total milling time (h) | 0.5/1/2/4/8/12/16 |
Milling/pause time (min) | 10/10 |
Ball-to-powder weight ratio | 10:1 |
Parameters | Value | Ref. |
---|---|---|
Poisson’s ratio | 0.33 | [38] |
Solid density | 2768 kg/m3 | [39] |
Young’s modulus | 73.08 GPa | [39] |
Coefficient of restitution | 0.8 | [39] |
Coefficient of static friction | 0.15 | [40] |
Coefficient of rolling friction | 0.05 | [41] |
Particle surface energy | 1.4 mJ/m2 | (Determined) |
Flow Characteristics | Hillside Angle | Carr’s Index | Hausner Ratio (HR) |
---|---|---|---|
Excellent-flow | <30° | <10% | 1–1.11 |
Free-flow | 30–38° | 11–15% | 1.12–1.18 |
Fair-flow | 38–45° | 16–20% | 1.19–1.25 |
Poor-flow | 45–55° | 21–25% | 1.26–1.34 |
Very poor-flow | >55° | >26% | >1.35 |
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Pekok, M.A.; Setchi, R.; Ryan, M.; Gu, H.; Han, Q.; Gu, D. Al-Cu-Mg Alloy Powder Reinforced with Graphene Nanoplatelets: Morphology, Flowability and Discrete Element Simulation. J. Manuf. Mater. Process. 2022, 6, 148. https://doi.org/10.3390/jmmp6060148
Pekok MA, Setchi R, Ryan M, Gu H, Han Q, Gu D. Al-Cu-Mg Alloy Powder Reinforced with Graphene Nanoplatelets: Morphology, Flowability and Discrete Element Simulation. Journal of Manufacturing and Materials Processing. 2022; 6(6):148. https://doi.org/10.3390/jmmp6060148
Chicago/Turabian StylePekok, Mulla Ahmet, Rossitza Setchi, Michael Ryan, Heng Gu, Quanquan Han, and Dongdong Gu. 2022. "Al-Cu-Mg Alloy Powder Reinforced with Graphene Nanoplatelets: Morphology, Flowability and Discrete Element Simulation" Journal of Manufacturing and Materials Processing 6, no. 6: 148. https://doi.org/10.3390/jmmp6060148