Development of Zirconia Reinforced AA7075/AA7050 Aluminum Chip-Based Composite Processed Using Hot Press Forging Method.

The solid-state recycling technique has gained significant attention for its ability to reduce metal losses, energy consumption, and solid waste. This study introduced solid-state recycling method to develop zirconia-reinforced AA7075/AA7050 aluminum chip-based matrix composite via a hot press forging process (HPF). The chips were cold-compacted at 35 tons and then hot-forged through a dog bone-shaped die. Full factorial and response surface methodology (RSM) designs were applied using Minitab 18 software. The Face Centred Composite (CCF) of RSM was adopted to rank each factor's effect and analyze interactions between input factors and output responses, followed by process optimization. The selected factors of temperature (Tp) and volume fraction of zirconia (ZrO₂) nanoparticles (Vf) were set at 450, 500, and 550 °C with 5, 10, and 15 wt %, respectively. The analyzed responses were ultimate tensile strength (UTS) and microhardness (MH). SEM micrograph revealed a slightly uniform distribution of ZrO₂ particles in the matrix. The developed composite gained the maximum strength of 262.52 MPa, a microhardness of 135.5 HV and a density of 2.828 g/cm³ at 550 °C and 10 wt % setting. RSM optimization results suggested 550 °C and 10.15 wt % as optimal conditions for maximum UTS and MH. The preheating temperature exhibited a more significant influence than the ZrO₂ volume fraction on the composite's mechanical properties; however, both had a slight effect on grain size. The future prospects of this work are briefly addressed at the end. In conclusion, the HPF process was found to be an efficient recycling method for mitigating environmental impacts by conserving energy and materials. [ABSTRACT FROM AUTHOR]