Multi-response optimization of aluminum matrix nanocomposites synthesis via powder metallurgy

Aluminum metal matrix nanocomposites (AMMNCs) exhibit superior mechanical properties compared with conventional micro-composites. However, achieving these enhanced properties depends not only on the incorporation of nanoparticles but also on their uniform dispersion within the matrix, which is strongly influenced by the selection of appropriate fabrication techniques. In this study, AA6082/Al 2 O 3 nanocomposites were fabricated using conventional and a novel high-energy mixer/mill-assisted powder metallurgy route based on an L9 Taguchi orthogonal array design. The developed nanocomposites were characterized using X-ray diffraction (XRD) and scanning electron microscopy (SEM). A Taguchi-based Grey Relational Analysis (GRA) approach was employed for multi-objective optimization of the hardness and compressive strength of the fabricated nanocomposites. The results confirmed that the incorporation of Al 2 O 3 nanoparticles significantly improved the mechanical performance of the AA6082 matrix. Statistical analysis revealed that reinforcement weight fraction and compaction pressure were the most influential processing factors affecting the mechanical properties by enhancing composite densification and structural integrity. The optimum processing condition was identified as A3B3C2D1 using the Taguchi-GRA optimization method. Furthermore, the novel high-energy mixer/mill consistently achieved superior mechanical performance compared with the conventional processing route. Overall, the integration of a novel high-energy mixer/mill with optimized powder metallurgy parameters provides an effective approach for developing high-performance AA6082/Al 2 O 3 aluminum nanocomposites with enhanced mechanical properties.