Interface Engineering and Microstructural Enhancement of Aluminum LM25 Composites Reinforced with MoS 2 and SiC Nanoparticles

Interface Engineering and Microstructural Enhancement of Aluminum LM25 Composites Reinforced with MoS 2 and SiC Nanoparticles Sudarsan Dileepan Saveetha School of Engineering Saveetha Institute of Medical and Technical Sciences Chennai Tamil Nadu 602105 India https://orcid.org/0000-0003-2011-6361 Bovas Herbert Bejaxhin Alphonse Saveetha School of Engineering Saveetha Institute of Medical and Technical Sciences Chennai Tamil Nadu 602105 India https://orcid.org/0000-0001-6188-3626 Sivanantham Nallusamy Division of Physics, School of Sciences, SRM Institute of Science & Technology (SRMIST) Tiruchirappalli Campus Tiruchirappalli Tamil Nadu 621105 India https://orcid.org/0000-0003-4375-0541 Manimegalai Raja Department of Physics K. Ramakrishnan College of Engineering Samayapuram Trichy 621112 India https://orcid.org/0000-0003-0909-4181 Gopalakrishnan Thangavel Department of Mechanical Engineering Vels Institute of Science Technology & Advanced Studies Pallavaram Chennai 117 India https://orcid.org/0000-0003-0560-2935 Vasanthi Venkidusamy Department of Physics School of Engineering and Technology Dhanalakshmi Srinivasan University Samayapuram Tiruchirappalli 621112 India https://orcid.org/0000-0002-4001-8147 Thangavelu Kavinkumar Centre for Energy and Environment Department of Physics Karpagam Academy of Higher Education Coimbatore 641021 India https://orcid.org/0000-0002-5575-2192 Perumal Asaithambi Faculty of Civil and Environmental Engineering Jimma Institute of Technology Jimma University Jimma 378 Ethiopia https://orcid.org/0000-0003-2910-0833 Gabriela Sandoval‐Hevia Departamento de Química, Facultad de Ciencias Naturales, Matemáticas y del Medio Ambiente, Universidad Tecnológica Metropolitana Las Palmeras 3360, Ñuñoa, Región Metropolitana Santiago 7800003 Chile https://orcid.org/0009-0003-8195-8973 Ramalinga Viswanathan Mangalaraja Faculty of Engineering and Sciences Universidad Adolfo Ibáñez Diagonal las Torres 2640 Peñalolén Santiago 7941169 Chile Vicerrectoría de Investigación e Innovación Universidad Arturo Prat Avenida Arturo Prat 2120 Iquique 1110939 Chile https://orcid.org/0000-0003-1016-9830 Arun Thirumurugan Sede Vallenar Universidad de Atacama Costanera #105 Vallenar 1612178 Chile https://orcid.org/0000-0001-7261-988X

This study addresses challenges in metal matrix composite fabrication by optimizing an ultrasonic‐assisted stir casting process for aluminum LM25 composites reinforced with 5 wt% MoS2 and varying SiC nanoparticles (5–15 wt%). While previous research explored individual benefits of these reinforcements, their synergistic effects in hybrid composites remain underexplored. Our experimental investigation establishes correlations between processing parameters, microstructure, and mechanical properties. SEM‐EDX mapping confirms uniform reinforcement dispersion with well‐defined interfacial reaction zones (120–180 nm). Porosity decreases from 3.2% in the unreinforced alloy to 1.1% in the 15 wt% SiC composite. The LM25–5% MoS2–15% SiC composite demonstrates significant mechanical improvements: 34.23% higher ultimate tensile strength (312.64 MPa), 40.93% increased yield strength (220.56 MPa), and 40.57% greater hardness (118.24 BHN). These enhancements result from multiple strengthening mechanisms including Orowan strengthening, Hall‐Petch effect (grain size reduction from 42 to 12 μm), and improved load transfer efficiency. Fractography reveals a transition from dimple‐dominated ductile fracture in the base alloy to mixed‐mode fracture with transgranular cleavage in reinforced composites.
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