Production and testing of Al-12%Si composites strengthened with ZrO₂ using an innovative disintegrated melt deposition manufacturing technique

Abstract This study aims to produce Al 12% Si-ZrO 2 composites using the Disintegrated Melt Deposition (DMD) technique and assess their microstructure and mechanical properties. The Al-12%Si alloy is recognized for its strength and corrosion resistance, making it valuable in industries such as shipbuilding and aviation. ZrO 2 , a ceramic known for its corrosion resistance and hardness, enhances the strength and hardness of the composites. It also reduces elongation percentage and promotes lubrication between silicon and aluminum in the matrix alloy. Specimens with varying ZrO 2 wt% (AS, AS0.5Z, AS1Z, AS1.5Z, AS2Z, AS2.5Z, AS3Z) were fabricated from DMD process. Results indicated that hardness increased from 59.7 HB (as cast) to 75.2 HB (2.5 wt% ZrO2), with a slight decrease at 3 wt% ZrO2. Elongation percentage decreased from 12.3% to 8.5%, ultimate tensile strength ranged from 239.2 MPa to 281.9 MPa, ultimate compression strength from 313.7 MPa to 375.6 MPa, and impact energy absorbed increased from 3.6 J to 5.3 J. These findings suggest potential applications of aluminum-12% Si-ZrO 2 composites in various applications by improving their properties.