Thixoforming is a type of semi-solid processing which is based on forming metals in the semi-solid state rather than fully liquid or solid state. There have been no reports of the thixoforming of nanocomposites in the literature. The incorporation of ceramic nanoparticles into liquid metals is a challenging task for the fabrication of metal matrix nanocomposites due to their large surface-to-volume ratio and poor wettability. Previous research work by a number of workers has highlighted the challenges with the incorporation of nanoparticles into liquid aluminum alloy. In the present study, SiC and TiB₂ nanoparticles with an average diameter between 20 and 30 nm were firstly incorporated into green compacts by a powder forming route, and then the compacts were melted and treated ultrasonically. The microstructural studies reveal that the engulfment and relatively effective distribution of the nanoparticles into the melt were achieved. The hardness was considerably improved with only 0.8 wt pct addition of the nanoparticles. The nanocomposites were successfully thixoformed at a solid fraction between 0.65 and 0.70. The microstructures, hardness, and tensile mechanical properties of the thixoformed nanocomposites were investigated and compared with those of the as-received A356 and thixoformed A356 alloys. The tensile properties of the thixoformed nanocomposites were significantly enhanced compared to thixoformed A356 alloy without reinforcement, indicating the strengthening effects of the nanoparticles.

In this study, graphene nanoplatelets (GNPs) with a thickness of 50-100 nm have been utilized to improve the mechanical and tribological properties of A360 alloy due to their extraordinary mechanical properties and solid lubricant nature. For the investigation of tribological properties, ball-on disc tests were carried out at various temperatures including room temperature (RT), 150 °C, and 300 °C. According to the hardness and ball-on-disc test results, the nanocomposite samples reinforced with GNPs exhibited improved hardness and wear resistance. The improvement in the wear behavior of nanocomposites was referred to the temporarily formed solid lubricant film of harder GNPs during the wear, and hence coefficient of friction (COF) and volume loss were considerably reduced. Abrasive-adhesive, oxidative, and mild-to-severe were found to be main wear mechanisms at RT, 150 °C, and 300 °C, respectively. Overall, the results show that the nanocomposites fabricated by casting method combined with mechanical stirring and ultrasonication have promising wear performance, especially at elevated temperatures. This may suggest that these developed materials could be potential candidates to be used in the engineering applications requiring high temperature wear performance.

In this work, A357/0.5 wt.% SiC nanocomposites were fabricated with a combination of ultrasonic processing and a nanoparticle feeding mechanism that involves the introduction of a closed end aluminium tube filled with the ball-milled SiC nanoparticles (20–30 nm) and aluminium powders (<75 µm) into the melt for complete deagglomeration and uniform dispersion of nanoparticles through the matrix. The microstructural and mechanical properties of the fabricated nanocomposites were investigated. The microstructural studies conducted with optical and advanced electron microscopes indicate that relatively effective deagglomeration and uniform dispersion of SiC nanoparticles into the molten alloy were achieved. The hardness and tensile properties of the nanocomposites were notably improved compared to those of the ultrasonically processed A357 alloy without reinforcement, showing the strengthening potency of nanoparticles and the good bonding obtained at the particle-reinforcement interface.

Magnesium (Mg) and graphene in alloy formulations are of paramount importance for lightweight engineering applications. In the present study, ZE10 Mg-alloy-based nanocomposites reinforced with graphene nanoplatelets (GNPs) having a thickness of 10–20 nm were fabricated via ultrasound-assisted stir casting. The effect of GNP contents (0.25, 0.5, and 1.0 wt.%) on the microstructure, Vickers hardness, and tensile properties of nanocomposites was investigated. Further, tribological studies were performed under a ball-on-disc sliding wear configuration against a bearing ball counterbody, at room and elevated temperatures of 100 °C and 200 °C, to comprehend temperature-induced wear mechanisms and friction evolution. It was revealed that the GNP addition resulted in grain coarsening and increased porosity rate of the Mg alloy. While the composites exhibited improved hardness by 20–35% at room temperature and 100 °C, a minor change was observed in their hardness and tensile yield strength values at 200 °C with respect to the GNP-free alloy. A notable improvement in lowering and stabilizing friction (coefficient of friction at 200 °C~0.25) and wear values was seen for the self-lubricating GNP-added composites at all sliding temperatures. The worn surface morphology indicated a simultaneous occurrence of abrasive and adhesive wear mode in all samples at room temperature and 100 °C, while delamination and smearing along with debris compaction (tribolayer protection) were the dominant mechanisms of wear at 200 °C. Inclusively, the results advocate steady frictional conditions, improved wear resistance, and favorable wear-protective mechanisms for the Mg alloy–GNP nanocomposites at room and elevated temperatures.

Metal matrix nanocomposites (MMNCs) could be strong candidates for use in the automotive and aerospace industry, where the mechanical performance is a crucial factor. This study aims to determine the feasibility of Al/SiC nanocomposite fabrication by the ultrasonic technique for the production of thixoforming feedstock material. Aluminium (A356) matrix composites were fabricated with the addition of 0.2 wt.% SiC nanoparticles using an ultrasonic method. Two different particle feeding mechanisms; the Al foil double capsulate method and the crucible placement approach, were employed. Better results were obtained for the double capsulate method. Also, Ti and Nb probe tips were tried to provide ultrasonic vibration in the melt. It has been shown that Nb is a promising ultrasonic probe tip material to produce MMNCs above 650 °C as it is thermodynamically stable in comparison with Ti.