Research Projects

Aluminium 7075 series, also known as aluminium-zinc alloy, is a popular material for various applications, including aircraft parts, transportation, automotive, industrial, military, and missile parts. Ferrochrome slag (Fe-Cr) is a potential reinforcement material with high strength and low density, but its use in aluminium matrix composites is limited. Recent research suggests the potential of nano graphene oxide (GO) reinforcements in aluminium matrix for better mechanical properties, such as less weight, more strength, high conductivity, and stable dispersion. Hybrid Al7075/Fe-Cr/GO nanocomposites possess good hardness and self-lubricating properties, but machining is difficult due to the distribution of hard reinforcing materials and matrix irregularities. A high wear-resistant cutting tool with optimized machining parameters, optimum wt% of reinforcements, and microstructural study are essential for better results. This study proposes the development of novel ferrochrome slag and graphene oxide reinforced Al 7075 hybrid nanocomposites through ultrasonic stir casting and squeeze casting. The fabrication of secondary processing and machinability studies are rarely found in literature, and the effects of machining parameters and wt% of reinforcements on machinability characteristics and surface integrity are investigated. Parameters are optimized, and machinability models are developed for responses. Tool life assessment, economic analysis, and sustainability assessment are also conducted for cleaner machining that will be favorable to machining industries.