Synthesis, Microstructural Investigation, and Mechanical Behavior of AA5083/Boron Nitride Nanocomposite

The as-received aluminum alloy (AA5083) powders (44 mu m) and hexagonal boron nitride (BN) nanoparticles (65-75 nm) are used to fabricate AA5083-BN nanocomposites with varying BN content (0, 3, 6, 9, and 12 wt%). A powder metallurgy solid-state method is employed, involving ball milling for 20 h at 100 rpm with a ball-to-powder mass ratio of 10:1. The processed powders are then consolidated through forging-sintering at 550 degrees C for 30 min, followed by hot forging at 225 MPa. The microstructure is examined using X-ray diffraction, scanning electron microscopy, energy-dispersive X-ray, transmission electron microscopy, and electron backscatter diffraction to understand the effect of processing variables. The compaction behavior is investigated both experimentally and empirically, revealing a relative green density exceeding 88% at 500 MPa. The empirical models display coefficients of determination (R2 values) exceeding 99% for predicting the compaction behavior. Compression tests on bulk samples show that BN reinforcement significantly enhances ultimate compressive strength, with values reaching 473.256 +/- 5.54, 536.374 +/- 2.87, 567.694 +/- 4.22, and 601.911 +/- 6.54 MPa for TRB-3, TRB-6, TRB-9, and TRB-12, respectively. The developed composites achieve relative densities greater than 97%, indicating promising applications in the aerospace, automotive, and marine industries. This study investigates AA5083 boron nitride (BN) nanocomposites with varying BN content, produced via powder metallurgy. Emphasizing the impact of BN on microstructure and mechanical properties, the research highlights enhanced compressive strength and homogenous dispersion. Detailed analyses using X-ray diffraction, scanning electron microscopy, transmission electron microscopy, and electron backscatter diffraction offer insights into the materials' potential for aerospace, automotive, and marine applications.image (c) 2024 WILEY-VCH GmbH