Microstructural Evolution and Mechanical Performance of Al6061-WC Composites Fabricated via Powder Metallurgy

Aluminium Matrix Composites (AMCs) are gaining interest for high-performance structural applications because they provide a higher Strength-to-Weight Ratio than conventional materials and superior Wear Resistance. Nevertheless, limitations like Dispersion of Reinforcement Particles, Interfacial Bonding, and Property Trade-offs hindered the broad use of these materials. In this study, the Fabrication and Characterization of an Aluminium composite based on Al6061, with Tungsten Carbide (WC) Particle Reinforcement using Powder Metallurgy (PM) and Controlled Atmosphere Sintering, is investigated. The effect of added varying percentages (0, 3, 6, 9, and 12 wt%) of WC particles to Al6061 on the Microstructural Characteristics and Mechanical Properties of the Al6061-WC Composite was investigated to optimize the optimum level of pre-milled nano-WC particles. Scanning Electron Microscopy (SEM), Transmission Electron Microscopy (TEM), and X-ray Diffraction (XRD) were used to confirm that the improvement in Particle Distribution and Phase Stability of the Al6061-WC Composite is directly related to the percentage of WC. Additionally, Mechanical Testing demonstrated that the mean Ultimate Tensile Strength (UTS) (151 MPa - 326 MPa) significantly improves with WC addition; however, Ductility and Impact Strength decrease due to an increase in Brittle Behaviour. Therefore, results clearly show that there is a Direct Relationship Between Strength and Ductility depending on the Content of Reinforcing Material and Quality of Interface. Analysis of Variance (ANOVA) was performed to check the data for significance, which showed a marked improvement for all properties, with a p-value of < 0.0001. As such, this investigation has provided new knowledge regarding the optimization of Reinforcing Levels to achieve Enhanced Mechanical Performance in Al-Based Composites for Aerospace and Automotive Applications.