Utilization of rice husk ash waste and scrap aluminum as composite materials fabricated by evaporative casting
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Dec 27, 2024
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Abstract
To achieve environmental sustainability, the integration of waste materials into new production processes is essential. This study investigates the development of aluminum matrix composites (AMCs) reinforced with rice husk ash (RHA) using the evaporative casting method. This study focuses on the effects of aluminum scrap-RHA composition, casting temperature, and styrofoam pattern thickness on key physical and mechanical properties such as fluidity length, surface roughness, hardness, and porosity. The composite material from aluminum scrap electrical cables and rice husk ash was heated in a furnace at a temperature of 900 °C for 2 hours with a sieve size of 200 mesh. The pattern material is styrofoam from electronic equipment packaging. The molding sand used is local silica sand with a sieve size of 60 mesh. The melting furnace uses a crucible furnace type with used oil as fuel. The independent variables were Al-RHA composition (100:0, 95:5, 90:10) %, pouring temperature (650 °C, 700 °C, and 750 °C), and Styrofoam pattern thickness (1, 2, 3, 4, 5, 6, and 10) mm. The results showed that the pouring temperature and the composition ratio of Al-RHA affected the fluidity length, surface roughness, hardness, and porosity, showcasing the potential of using waste materials in cost-efficient and environmentally sustainable composites for various industries.
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References
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[28] A. Seshappa, K. Prudhvi Raj, B. Subbaratnam, U. Pranavi, N. srihithagunapriya, and S. Chhabra, “Investigations of Al-Manufacturing while 7075/RHA/Al2O3 Composite by Squeeze Casting Approach",” MATEC Web of Conferences, vol. 392, p. 1027, 2024, doi: 10.1051/matecconf/202439201027.
[29] A. H. Mohamed Ariff, O. Jun Lin, D.-W. Jung, S. Mohd Tahir, and M. H. Sulaiman, “Rice Husk Ash as Pore Former and Reinforcement on the Porosity, Microstructure, and Tensile Strength of Aluminum MMC Fabricated via the Powder Metallurgy Method,” Crystals, vol. 12, no. 8, p. 1100, 2022, doi: 10.3390/cryst12081100.
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[31] A. Cañadilla, A. Romero, and G. P. Rodríguez, “Sustainable Production of Powder Metallurgy Aluminum Foams Sintered by Concentrated Solar Energy,” Metals, vol. 11, no. 10, p. 1544, 2021, doi: 10.3390/met11101544.
[32] W. Qudong et al., “Study on the fluidity of AZ91+xRE magnesium alloy,” Materials Science and Engineering: A, vol. 271, no. 1–2, pp. 109–115, 1999, doi: 10.1016/s0921-5093(99)00185-9.
[33] S. Kumar, P. Kumar, and H. S. Shan, “Effect of evaporative pattern casting process parameters on the surface roughness of Al–7% Si alloy castings,” Journal of Materials Processing Technology, vol. 182, no. 1–3, pp. 615–623, 2007, doi: 10.1016/j.jmatprotec.2006.09.005.
[34] M. Divandari, V. Jamali, and S. G. Shabestari, “Effect of strips size and coating thickness on fluidity of A356 aluminium alloy in lost foam casting process,” International Journal of Cast Metals Research, vol. 23, no. 1, pp. 23–29, 2010, doi: 10.1179/174313309x449291.
[35] A. Y. Awad, M. N. Ibrahim, and M. K. Hussein, “Effects of Rice Husk Ash–Magnesium Oxide Addition on Wear Behavior of Aluminum Alloy Matrix Hybrid Composites,” Tikrit Journal of Engineering Sciences, vol. 25, no. 4, pp. 16–23, 2018, doi: 10.25130/tjes.25.4.04.
[36] R. Siswanto, Ma’ruf, A. M. Mukti, and R. Subagyo, “The effect of pure temperature and pressure on alloy hardness of Al-6.7% Cu using squeeze casting method,” IOP Conference Series: Materials Science and Engineering, vol. 1034, no. 1, p. 12173, 2021, doi: 10.1088/1757-899x/1034/1/012173.
[37] C. H. Fan, Z. H. Chen, W. Q. He, J. H. Chen, and D. Chen, “Effects of the casting temperature on microstructure and mechanical properties of the squeeze-cast Al–Zn–Mg–Cu alloy,” Journal of Alloys and Compounds, vol. 504, no. 2, pp. L42–L45, 2010, doi: 10.1016/j.jallcom.2010.06.012.
[38] J. W. Wang, J. X. Zhou, S. Q. Tang, F. M. Chu, and Y. S. Yang, “Effects of Casting Temperature on as Cast Microstructure and Tensile Properties of AS31-Sr Alloy,” Advanced Materials Research, vol. 915–916, pp. 583–587, 2014, doi: 10.4028/www.scientific.net/amr.915-916.583.
[39] F. Gillani, M. Z. Khan, and O. R. Shah, “Sensitivity Analysis of Reinforced Aluminum Based Metal Matrix Composites,” Materials (Basel, Switzerland), vol. 15, no. 12, p. 4225, Jun. 2022, doi: 10.3390/ma15124225.
[2] S. M. B. Respati, H. Purwanto, I. Fakhrudin, and P. Prayitno, “Tensile Strength and Density Evaluation of Composites from Waste Cotton Fabrics and High-Density Polyethylene (HDPE): Contributions to the Composite Industry and a Cleaner Environment,” Mechanical Engineering for Society and Industry, vol. 1, no. 1, pp. 41–47, 2021, doi: 10.31603/mesi.5252.
[3] R. Reinaldo and D. Setyanto, “The Potential of Ramie Fiber as Reinforcement in Calcium Carbonate-Filled Polyester Resin Matrix Composites for Roofing Applications,” Journal of Mechanical Engineering Science and Technology (JMEST), vol. 8, no. 2, p. 363, Oct. 2024, doi: 10.17977/um016v8i22024p363.
[4] M. R. F. Putra, H. Isworo, M. N. Yasin, and R. Subagyo, “Friction Modeling of Composite Brake Pads with Ulin Wood Powder (Eusideroxylon zwageri),” Journal of Mechanical Engineering Science and Technology (JMEST), vol. 8, no. 2, p. 520, Nov. 2024, doi: 10.17977/um016v8i22024p520.
[5] A. B. D. Nandiyanto, D. N. Al Husaeni, R. Ragadhita, M. Fiandini, D. F. Al Husaeni, and M. Aziz, “Resin matrix composition on the performance of brake pads made from durian seeds: From computational bibliometric literature analysis to experiment,” Automotive Experiences, vol. 5, no. 3, pp. 328–342, 2022, doi: 10.31603/ae.6852.
[6] M. Afiefudin, R. D. Widodo, and R. Rusiyanto, “Fabrication and Characterization of Asbestos Free Brake Pads Composite using Elaeocarpus Ganitrus as Reinforcement,” Automotive Experiences, vol. 6, no. 2, pp. 359–371, Aug. 2023, doi: 10.31603/ae.9367.
[7] A. Kholil, R. Riyadi, S. T. Dwiyati, E. A. Syaefuddin, R. H. Pratama, and Y. D. R. Putra, “Natural Fiber Composites from Coconut Fiber, Wood Powder, and Shellfish Shell of Centrifugal Clutch Materials,” Automotive Experiences, vol. 5, no. 2, pp. 111–120, 2022, doi: 10.31603/ae.6040.
[8] N. L. Indrayani, R. Sadiana, F. D. Ekawati, Y. Handoyo, H. Maulana, and D. N. Dayana, “Experimental study of variations in fiber types and volume fractions of unsaturated polymer resin (UPR) composites on the mechanical and physical properties of the material,” BIS Energy and Engineering, vol. 1, pp. V124019–V124019, 2024, doi: 10.31603/biseeng.59.
[9] A. B. D. Nandiyanto et al., “The effects of rice husk particles size as a reinforcement component on resin-based brake pad performance: from literature review on the use of agricultural waste as a reinforcement material, chemical polymerization reaction of epoxy resin, to experiments,” Automotive Experiences, vol. 4, no. 2, pp. 68–82, 2021, doi: 10.31603/ae.4815.
[10] A. B. D. Nandiyanto, D. F. Al Husaeni, R. Ragadhita, and T. Kurniawan, “Resin-based Brake Pad from Rice Husk Particles: From Literature Review of Brake Pad from Agricultural Waste to the Techno-Economic Analysis,” Automotive Experiences, vol. 4, no. 3, pp. 131–149, 2021, doi: 10.31603/ae.5217.
[11] M. Khafidh et al., “A Study on Characteristics of Brake Pad Composite Materials by Varying the Composition of Epoxy, Rice Husk, Al2O3, and Fe2O3,” Automotive Experiences, vol. 6, no. 2, pp. 303–319, 2023, doi: 10.31603/ae.9121.
[12] M. Geissdoerfer, P. Savaget, N. M. P. Bocken, and E. J. Hultink, “The Circular Economy – A new sustainability paradigm?,” Journal of Cleaner Production, vol. 143, pp. 757–768, 2017, doi: 10.1016/j.jclepro.2016.12.048.
[13] G. Arora and S. Sharma, “A review on monolithic and hybrid metal–matrix composites reinforced with industrial-agro wastes,” Journal of the Brazilian Society of Mechanical Sciences and Engineering, vol. 39, no. 11, pp. 4819–4835, 2017, doi: 10.1007/s40430-017-0910-x.
[14] P. Ghisellini, C. Cialani, and S. Ulgiati, “A review on circular economy: the expected transition to a balanced interplay of environmental and economic systems,” Journal of Cleaner production, vol. 114, pp. 11–32, 2016.
[15] I. D. Robertson et al., “Rapid energy-efficient manufacturing of polymers and composites via frontal polymerization,” Nature, vol. 557, no. 7704, pp. 223–227, 2018, doi: 10.1038/s41586-018-0054-x.
[16] J. Joustra, B. Flipsen, and R. Balkenende, “Circular Design of Composite Products: A Framework Based on Insights from Literature and Industry,” Sustainability, vol. 13, no. 13, p. 7223, 2021, doi: 10.3390/su13137223.
[17] M. Ding, J. Song, and L. Honghui, “Effect of Pouring Temperature on Typical Structure of Thin-Walled ZL105A Alloy Casting,” Materials and Manufacturing Processes, vol. 29, no. 7, pp. 853–863, 2014, doi: 10.1080/10426914.2014.880472.
[18] O. O. Joseph, J. O. Dirisu, J. Atiba, S. Ante, and J. A. Ajayi, “Mechanical, and corrosive properties of AA7075 aluminium reinforced with rice husk ash particulates,” Materials Research Express, vol. 10, no. 11, p. 116520, 2023, doi: 10.1088/2053-1591/ad0dd3.
[19] R. Siswanto, R. Subagyo, M. Tamjidillah, M. Mahmud, and M. S. I. Setiawan, “Identifying the influence of pouring temperature, Al-RHA composition, and pattern thickness on the properties of Al-RHA composites produced by evaporative casting,” Eastern-European Journal of Enterprise Technologies, vol. 5, no. 12 (131), pp. 39–49, 2024, doi: 10.15587/1729-4061.2024.310274.
[20] S. D. Saravanan and M. S. Kumar, “Effect of Mechanical Properties on Rice Husk Ash Reinforced Aluminum Alloy (AlSi10Mg) Matrix Composites,” Procedia Engineering, vol. 64, pp. 1505–1513, 2013, doi: 10.1016/j.proeng.2013.09.232.
[21] Suyitno and Sutiyoko, “Effect of Pouring Temperature and Casting Thickness on Fluidity, Porosity and Surface Roughness in Lost Foam Casting of Gray Cast Iron,” Procedia Engineering, vol. 50, pp. 88–94, 2012, doi: 10.1016/j.proeng.2012.10.011.
[22] T. Sarıyer and Ç. Kaya, “Agricultural wastes in climate change mitigation,” JOURNAL OF GLOBAL CLIMATE CHANGE, vol. 1, no. 1, pp. 15–20, 2022, doi: 10.56768/jytp.1.1.03.
[23] M. S. Ahmed, M. S. Anwar, M. S. Islam, and M. Arifuzzaman, “Experimental study on the effects of three alloying elements on the mechanical, corrosion and microstructural properties of aluminum alloys,” Results in Materials, vol. 20, p. 100485, 2023, doi: 10.1016/j.rinma.2023.100485.
[24] E. O. Oyedeji, M. Dauda, S. A. Yaro, M. Abdulwahab, and A. Nathaniel Oyedeji, “Analysis of Al–Mg–Si alloy reinforced with optimal palm kernel shell ash particle and its impact on dynamic properties for sounding rocket application,” Functional Composites and Structures, vol. 5, no. 4, p. 45001, 2023, doi: 10.1088/2631-6331/acd48f.
[25] R. Yadav, A. Islam, and V. Kumar Dwivedi, “Wear and microstructure analysis of aluminium based composite using eggshell and rice husk ash as reinforcement,” World Journal of Engineering, vol. 21, no. 1, pp. 186–193, 2022, doi: 10.1108/wje-05-2022-0186.
[26] Z. Seikh, M. Sekh, G. Kibria, R. Haque, and S. Haidar, “Density, Hardness, and Wear Responses of Rice Husk Ash Reinforced Aluminium Composites,” Materials Science Forum, vol. 1074, pp. 67–78, 2022, doi: 10.4028/p-78710r.
[27] T. Hasan, M. A. Wadud, M. H. Niaz, M. K. Uddin, and M. S. Islam, “Fabrication and Characterization of Rice Husk Ash Reinforced Aluminium Matrix Composite,” Malaysian Journal on Composites Science and Manufacturing, vol. 14, no. 1, pp. 34–43, 2024, doi: 10.37934/mjcsm.14.1.3443.
[28] A. Seshappa, K. Prudhvi Raj, B. Subbaratnam, U. Pranavi, N. srihithagunapriya, and S. Chhabra, “Investigations of Al-Manufacturing while 7075/RHA/Al2O3 Composite by Squeeze Casting Approach",” MATEC Web of Conferences, vol. 392, p. 1027, 2024, doi: 10.1051/matecconf/202439201027.
[29] A. H. Mohamed Ariff, O. Jun Lin, D.-W. Jung, S. Mohd Tahir, and M. H. Sulaiman, “Rice Husk Ash as Pore Former and Reinforcement on the Porosity, Microstructure, and Tensile Strength of Aluminum MMC Fabricated via the Powder Metallurgy Method,” Crystals, vol. 12, no. 8, p. 1100, 2022, doi: 10.3390/cryst12081100.
[30] S. Essa Salih, B. Hashim, and H. Mahmood Al-tamimi, “The Mechanical and Thermal Properties of Polymer Hybrid Composite Reinforced by Rice Husk Ash at Different Conditions,” Engineering and Technology Journal, vol. 32, no. 9, pp. 2119–2133, 2014, doi: 10.30684/etj.32.9a2.
[31] A. Cañadilla, A. Romero, and G. P. Rodríguez, “Sustainable Production of Powder Metallurgy Aluminum Foams Sintered by Concentrated Solar Energy,” Metals, vol. 11, no. 10, p. 1544, 2021, doi: 10.3390/met11101544.
[32] W. Qudong et al., “Study on the fluidity of AZ91+xRE magnesium alloy,” Materials Science and Engineering: A, vol. 271, no. 1–2, pp. 109–115, 1999, doi: 10.1016/s0921-5093(99)00185-9.
[33] S. Kumar, P. Kumar, and H. S. Shan, “Effect of evaporative pattern casting process parameters on the surface roughness of Al–7% Si alloy castings,” Journal of Materials Processing Technology, vol. 182, no. 1–3, pp. 615–623, 2007, doi: 10.1016/j.jmatprotec.2006.09.005.
[34] M. Divandari, V. Jamali, and S. G. Shabestari, “Effect of strips size and coating thickness on fluidity of A356 aluminium alloy in lost foam casting process,” International Journal of Cast Metals Research, vol. 23, no. 1, pp. 23–29, 2010, doi: 10.1179/174313309x449291.
[35] A. Y. Awad, M. N. Ibrahim, and M. K. Hussein, “Effects of Rice Husk Ash–Magnesium Oxide Addition on Wear Behavior of Aluminum Alloy Matrix Hybrid Composites,” Tikrit Journal of Engineering Sciences, vol. 25, no. 4, pp. 16–23, 2018, doi: 10.25130/tjes.25.4.04.
[36] R. Siswanto, Ma’ruf, A. M. Mukti, and R. Subagyo, “The effect of pure temperature and pressure on alloy hardness of Al-6.7% Cu using squeeze casting method,” IOP Conference Series: Materials Science and Engineering, vol. 1034, no. 1, p. 12173, 2021, doi: 10.1088/1757-899x/1034/1/012173.
[37] C. H. Fan, Z. H. Chen, W. Q. He, J. H. Chen, and D. Chen, “Effects of the casting temperature on microstructure and mechanical properties of the squeeze-cast Al–Zn–Mg–Cu alloy,” Journal of Alloys and Compounds, vol. 504, no. 2, pp. L42–L45, 2010, doi: 10.1016/j.jallcom.2010.06.012.
[38] J. W. Wang, J. X. Zhou, S. Q. Tang, F. M. Chu, and Y. S. Yang, “Effects of Casting Temperature on as Cast Microstructure and Tensile Properties of AS31-Sr Alloy,” Advanced Materials Research, vol. 915–916, pp. 583–587, 2014, doi: 10.4028/www.scientific.net/amr.915-916.583.
[39] F. Gillani, M. Z. Khan, and O. R. Shah, “Sensitivity Analysis of Reinforced Aluminum Based Metal Matrix Composites,” Materials (Basel, Switzerland), vol. 15, no. 12, p. 4225, Jun. 2022, doi: 10.3390/ma15124225.