Aluminium alloy metal matrix composites (MMCs) have obtained wide spread acceptance in automotive and aerospace applications because of its high strength, low density and good structural rigidity. This work studies the mechanical and microstructural properties of hybrid metal matrix composite reinforced with Al₂O₃/SiC prepared by using powder metallurgy technique. Hardness and compressive strength of aluminum matrix composite increased with increase in wt% of SiC. The characterization results showed the improvement in mechanical properties with addition of hybrid reinforcement.

Automotive manufacturers rely on rigorous testing and simulations to construct their vehicles durable and safe in all aspects. One such vital factor is crash safety, otherwise known as crashworthiness. Crash tests are conventional forms of non-destructive methods to validate the vehicle for its crashworthiness and compatibility based on different operating conditions. The frontal impact test is the most primary form of crash test, which focuses on improving passenger's safety and comfort. According to NHTSA, a vehicle is rated based on these safety criteria, for which automobile manufacturers conduct a plethora of crash-related studies. Numerical simulation aids them in cutting down testing time and overall cost endured by providing a reliable amount of insights into the process. The current study is aimed at improving the crashworthiness of a crash box in a lightweight passenger car, such that it becomes more energy absorbent in terms of frontal impacts. All necessary parameters such as energy absorption, mean crush force, specific energy absorption, crush force efficiencies are evaluated based on analytical and finite element methods. There was a decent agreement between the analytical and simulation results, with an accuracy of 97%. The crashworthiness of the crash box was improved with the help of DOE-based response surface methodology (RSM). The RSM approach helped in improving the design of the crash box with enhanced EA & CFE by 30% and 8.8% respectively. The investigation of design variables on the energy absorption capacity of the thin-walled structure was also done. For the axial impact simulations, finite element solver Virtual Performance Solution − Pam Crash from the ESI group is used.

This research work focuses on the impact of graphite addition to the Al/SiC hybrid metal matrix composites manufactured by stir casting process. Three specimens were prepared with Al6061 alloy + 5 wt. % SiC and varying weight percent of graphite. Al6061 matrix material is suitable for machining and welding applications commonly used in construction of aircraft wings and fuselages. Machining of composite materials is often required to meet dimensional tolerances, surface roughness and to create holes. A layered SiC/Gr composite material is used in gas turbine combustor can. Machining of Al/SiC/Gr hybrid composite was done in Esteem ETM 356 lathe using tungsten carbide insert. Optimization of three machining parameters cutting speed, feed rate and depth of cut, was done using four levels. From ANOVA results feed rate (35.83%) is the important factor influencing surface roughness. Grey Relational analysis was done for simultaneous improvement of Material Removal Rate and surface roughness.

The current research focuses on investigation of crashworthiness of the high-strength steel (HSS) columns filled with aluminium honeycomb. In this study, five variants of honeycomb thickness; Thickness-1, Thickness-2, Thickness-3, Thickness-4, Thickness-5 and six variants of honeycomb cell size; CellSize-1, CellSize-2, CellSize-3, CellSize-4, CellSize-5 and CellSize-6 are considered. Numerical analysis is performed for sandwich honeycomb separated by steel plates in HSS crash box and by inducing V-Notch triggers in the honeycomb. It was perceived that energy absorption (EA), specific energy absorption (SEA) and crush force efficiency (CFE) of Thickness-5 increased by 77%, 19% and 60% respectively compared to Thickness-1 and for CellSize-1, increased by 51%, 24% and 38% respectively compared to CellSize-6. Similarly, the crash box filled with V-Notch triggered honeycomb is increased by 10%, 17% and 4% respectively compared to crash box filled with regular honeycomb and 17%, 55% and 7% respectively compared to crash box filled with sandwich honeycomb.