Finite element analysis and validation of sic graphite hybrid aluminium metal matrix composite for resilient brake rotor component for light weight vehicle

Abstract

The automobile industry places a significant emphasis on research and development efforts directed towards the creation of materials that are both lightweight and robust for use in braking systems. Conventional rotor materials have been utilised for many years, but they do not come without their share of drawbacks. One of the prime examples of these materials is grey cast iron. It is cumbersome, prone to wear, and do not perform well especially in areas where the temperature is high. The research work is about why aluminum-based hybrid metal matrix composites (MMCs) are better than conventional alloys to solve these problems. The goal of this study was to determine whether a SiC/Graphite reinforced Aluminum alloy (LM6) could be effectively used as a brake rotor material in disc braking systems. In order to do this, the composite was manufactured by a method known as stir-casting, which entails combining molten metal with a reinforcing substance during the casting step. Then the material was analyzed by subjecting it to a number of different tests, including hardness, tensile, compression, and tribological tests. The microstructure and chemical composition of the composite were then analysed using XRD, and microstructural analysis was also performed. In comparison to the conventional alloys that are used in braking systems, the results of the testing revealed that the SiC/Graphite reinforced LM6 alloy had significantly enhanced mechanical and wear resistance capabilities. Graphite present in the composite led to a considerable improvement in the material resistance to wear when subjected to high temperatures; as a result, it is now appropriate for usage in challenging environments. XRD examination confirmed the existence of Fe-Mn inter-metallic, and microstructural analysis showed that SiC was distributed in a homogeneous way throughout the manufactured MMC. These findings were consistent with the anticipation that intermetallics should present.