j m a t e r r e s t e c h n o l .

2 0 1 9;8(3):3347–3356

Available online at www.sciencedirect.com

www.jmrt.com.br

Review Article

Characterization of Al-7075 metal matrix

composites: a review

Mohammed Imran ∗ , A.R. Anwar Khan

Department of Mechanical Engineering, Ghousia College of Engineering, Affiliated VTU, Ramanagaram, Karnataka, 562159, India

a r t i c l e i n f o a b s t r a c t

Article history:
Received 11 October 2016
Accepted 24 October 2017
Available online 28 May 2019
Keywords:
Al-7075 matrix composites
Reinforcements
Mechanical and tribological
properties
Aluminum-7075 series alloys commonly used in transportation applications are aerospace,
aviation, marine and automobile due to their good mechanical properties and low density
and high strength-to-density ratio [1]. The present review focuses on mechanical properties,
tribological properties and corrosion behavior of Al-7075 metal matrix composites (AMMCs)
by the addition of desirable reinforcements. The objective is to review the literature on
fabrication of the aluminum metal matrix composite materials by combining alloys and
reinforcements. The reinforcements may be particulate SiC, Al2 O3 , Gr, TiO2 , bagasse ash, etc.
These particulate reinforcements are incorporated in the stir casting method. The results
revealed that, there is significant improvement in mechanical properties. Superior wear and
corrosion resistance, low coefficient of thermal expansion as compared to conventional base
alloys.
© 2019 The Authors. Published by Elsevier B.V. This is an open access article under the
CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).

Mohammed Imran, research scholar, A.R Anwar Khan, Principal and Profes-
Department of Mechanical Engineering, sor, Ghousia College of Engineering, 41
Ghousia College of Engineering. journal papers has been published in
national and international journals, 20
conferences attended, 4 Ph.D guided and
3 Awarded.

∗
Corresponding author.
E-mails: mechmdimran@gmail.com, mechmdimran@ghousiaedu.rog (M. Imran), dranwarkhan@Ghousiaedu.Org (A.A. Khan).
https://doi.org/10.1016/j.jmrt.2017.10.012
2238-7854/© 2019 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
3348 j m a t e r r e s t e c h n o l . 2 0 1 9;8(3):3347–3356

aluminum and acts as self-lubricating property. SiC parti-

1. Introduction cles show higher hardness of aluminum. Organic agricultural
wastes utilized for reinforcement are fly ash, bagasse ash
In the past 7 decades (1943), aluminum 7075 series alloy
and coconut ash helps to improve the tensile strength, yield
materials used for the construction of desirable components
strength, etc. These studies were clearly discussed as follows.
of automobile, aerospace and marine applications are inline
skating-frames, shafts for lacrosse sticks, hang glider air-
2.1. Stir casting method
frames, rifles for the American military, camping knife and
fork sets, fuselage, turbine casing, missile tail cone, bicycle
Earlier in 5500 years ago, metals cast in carved or impressed
components, automobile engine casing, etc. [1]. These materi-
shape of cavities are used as molds prepared by clay and soft
als posses high strength/weight ratio [2,3], also desirable light
minerals. The different naturally available metals like gold,
weight and strength. In other fields, global needs are high
copper and silver were melted and solidified in these cavi-
performance rate, low cost and better quality materials have
ties. Casting of weapons, tools, etc. was developed by using
been made by researchers which transfer from monolithic to
metallurgy technique. The complex design of production was
composite materials [4].
done by preparing sand and clay mixtures molds. In 17th
Al-7xxx series alloy also called aluminum–zinc alloy due to
century, iron dies or steel dies have been introduced for the
maximum zinc quantity ranging between 5.1 and 6.1 percent
casting of alloy materials. An intensive effort was made by the
and chemical composition shown in Table 1 [2]. These series
researchers in first decade of the 20th century by introducing
were developed first secretly by Japanese company, Sumitomo
permanent iron and steel molds for the casting of aluminum.
Metal, in the year 1943 eventually for production of airframe
In 1820s first pressure die casting technique was used for large
in the Imperial Japanese Navy.
volumes of castings and second technique was introduced
Al-7075 has wide verities of applications due to this it
as injection molding technique. Initially injection molding
need further reinforcement. The aluminum alloy is used as
technique was used for metal casting under pressure into
matrix material (continues phase) and build with several prop-
metallic dies with mechanical action by hand crank mecha-
erties by adding desirable single and multiple reinforcement
nism. Presently, hydraulic and pneumatic systems were used
particulates (discrete constituent non-metallic ceramics) like
to get mechanical action. There are several other techniques
SiC, Al2 O3 , Gr, TiO2 , B4 C, AlN, fly ash, etc. as composites,
developed, later on stir casting technique was introduced for
which shows higher strength than the base alloy material.
the aluminum casting which is also known as liquid metallur-
This advancement in alloy material was required for fast
gical technique [6]. Stir casting technique is extensively low
growing technologies in different fields of applications. The
cost and economical process, easy procedure and gives uni-
recent interests in research are the MMCs ability in altering
form mixing of different composition of metal constituents,
physical properties (thermal expansion, density), mechani-
minimum moisture level, good adhesion and negligible ele-
cal properties (tensile and compressive behavior), tribological
mental reactions among the particles and the base material is
properties, etc. by changing constituent or filler material phase
shown in Fig. 1 [7,8].
[5].
In case of AMMCs material system, combining or mixing
process for more than two macro, micro, or nano constituents
interface and separating them shows different forms of chem-
ical composition. Also constituent materials are essentially
insoluble in phase material [5]. AMMCs proved useful in dif-
ferent engineering areas as well as structural and functional
applications because of changing or variation in mechanical
behavior depending upon the percentage variation of rein-
forcement and composition of matrix material.

2. Literature review

This review presents mechanical and tribological properties

of AMMCs containing single or multiple reinforcements. Fab-
rication was done by using stir casting method. Addition of
Al2 O3 (alumina) as reinforcement to aluminum alloy gives
an improvement in its mechanical and tribological proper-
Fig. 1 – Stir casting furnace [8].
ties. Graphite reinforcement improves the machinability of

Table 1 – Chemical composition of Al-7075 T6 [2].

Composition Zn Si Fe Ti Cu Mn Mg Cr other Balance

Percentage 5.1–6.1 0.40 0.50 0.20 1.2–2.0 0.30 2.1–2.9 0.18–0.28 0.65 Al
 j m a t e r r e s t e c h n o l . 2 0 1 9;8(3):3347–3356 3349

Fig. 2 – Optical microscope images of composite: (a) Al + 5% SiC/Gr [9], (b) Al + 10% of SiC/Gr [9], (c) Al + 15% of SiC/Gr [9], (d)
Al + 5% SiC [11], (e) Al + 10% SiC [11], (f) Al + 20% SiC [11], (g) Al (7075) + 5% SiC + 3% B4C [13], (h) Al (7075) + 10% SiC + 3% B4C
[13], (i) Al (7075) + 15% SiC + 3% B4C [13], (j) LM25 + 5% Al2 O3 + 3% fly ash [14], (k) LM25 + 10% Al2 O3 + 3% fly ash [14] and (l)
LM25 + 15% Al2 O3 + 3% fly ash [14].

The stir casting technique was used for the production
of AMMCs, which is most simplest and economical process
for particulate reinforced metal matrix composites. Optimum
properties of the hybrid composites were obtained by proper
distribution of particulate reinforcement in the base mate-
rial. The stirrer is used to obtain a high-quality distribution of
the reinforcement material in the base material. Aluminum
alloy was melted in the furnace at a temperature range of
600–800 ◦ C. A stirrer is introduced in the molten metal and
rotated at 200–600 rpm by electric motor for about 10–20 min
so that a vortex is created. Preheated particle reinforcement
subsequently introduced at the region of the vortex to obtain
uniform distribution of particle materials in base matrix [7,8].
2.2. Microstructure
Review on optical microscope structure shows that according
to the Krishna et al., reinforcement has uniformly dis-
tributed in aluminum matrix material [9,10] (Fig. 2(a)–(c)). The
microstructural interface characteristics depend on reinforce-
ments and matrix, microstructural investigation shows that
the distribution of SiC particles in Al matrix is clustering
3350 j m a t e r r e s t e c h n o l . 2 0 1 9;8(3):3347–3356
and non-homogeneous in nature [11] (Fig. 2(d)–(f)). The non-
homogeneous distribution of reinforcement takes place due to
contact time variation among molten Al matrix and SiC dur-
ing casting of composites that is poor wetting behavior and
high surface tension of silicon carbide (SiC) particles in the
liquid (molten) Al [12]. Also Al microstructures show porosi-
ties, during casting when reinforcement was added to molten
metal [11,13,14] (Fig. 2(f)–(l)). Hence, when increasing wt% of
particles reinforcement increased trapped air results in higher
porosity [15].
2.3. Scanning electron microscopy (SEM)
Morphology of Al matrix composite surfaces was seen by scan-
ning electron microscopy (SEM). The composite surface of
fractured samples results shows no segregation of reinforced
particles since mixture was uniform [9,16] (Fig. 3(a) and (b)).
The worn out surfaces of the composites were observed
intense flow and narrow grooves of material by using pin on
disk setup. The worn surfaces will depend on sliding direc-
tion, degree of wear and adhesion between the pin specimen
surface and the counter body. The adhesive wear mechanism
helps to indicate the topographies of the worn surface of the
composites due to ploughing and cutting effects by plastic
deformation. Abrasion and delaminating wear mechanisms
in composites indicate morphology of the worn surfaces. The
results show that the worn surfaces were quite similar to that
of the unreinforced base material alloys [17] (Fig. 3(c) and (d)).
Fig. 3 – SEM images: (a) fractured surface Al + SiC [9], (b) tensile fractured surface Al + Gr MMC [16], (c) worn surface
morphology of AA7075 [17] and (d) worn surface morphology of AA7075 + 6 wt% of Al2 O3 composites [17].
Worn surfaces of the MMCs were usually much rougher than
that of the unreinforced base material alloys [7].
2.4. Mechanical behavior
2.4.1. Hardness
The literature shows hardness tests were carried out as per
the E-10 ASTM Standard. The most commonly used brinell
hardness tester of standard 2.5 mm diameter of ball indenter
and a load of 10–35 kg is applied for a time of 20–30 s. Brinell
hardness number (BHN) readings were taken at different loca-
tions of specimens, relative effects of particle segregation were
observed [18].
Review on hardness is tabulated in Table 2. Al2 O3 , SiC, B4 C
and fly ash (FA) show increasing as weight percentage of rein-
forcement is increased in aluminum base material [14,19].
Further addition of graphite (Gr) particles reinforcement to
aluminum matrix material decreases hardness [16].
2.4.2. Tensile strength
The tensile tests were conducted at room temperature by
using universal testing machine (UTM) as per the E-8M ASTM
Standard. The E-8M standard dimensions of tensile specimens
of gauge length (G) five times more than diameter (D) are
shown in Fig. 4 [18].
Review on tensile behavior is tabulated in Table 2. Al2 O3 ,
SiC, B4 C, Gr and fly ash (FA) increase in weight percentage
of reinforcement in aluminum base material, tensile strength
increases gradually [9,20]. It was observed that, addition of
fly ash shows percentage elongation randomly decreases, on
 j m a t e r r e s t e c h n o l . 2 0 1 9;8(3):3347–3356 3351

Table 2 – Mechanical properties of aluminum matrix composites (AMCs).

Sl. No. Composition Tensile/yielding Elongation UTS (MPa) Hardness Compression Refs.
(MPa) (%) (BHN) (MPa)

Al + 5%SiC 132.34 – – – –
Al + 10%SiC 143.46 – – – –
Al + 15%SiC 150.95 – – – –
1. [5]
Al + 5%SiC + 5%Gr 144.73 – – – –
Al + 10%SiC + 10%Gr 173.39 – – – –
Al + 15%SiC + 15%Gr 192.45 – – – –
Al + 0% SiC 28.45 – – – –
Al + 5% SiC 59.36 – – – –
2. [11]
Al + 10% SiC 50.17 – – – –
Al + 20% SiC 77.56 – – – –
Al-7075 67
Al-7075 + 3%B4 C – – – 77 –
3. Al-7075 + 3%B4C + 5%SiC – – – 82 – [13]
Al-7075 + 3%B4C + 10%SiC – – – 85 –
Al-7075 + 3%B4C + 15%SiC – – – 88
Al(LM25) + 0 Al2 O3 + 3%FA – 7.1 136 57.2 –
Al(LM25) + 5 Al2 O3 + 3%FA – 5.3 162 61.0 –
4. [14]
Al(LM25) + 10 Al2 O3 + 3%FA – 4.0 187 61.8 –
Al(LM25) + 15 Al2 O3 + 3%FA – 2.4 168 62.0 –
Al6061 – 5.90 153.90 51.4 743.03
Al6061-1%Graphite – 7.31 173.80 44.58 847.90
5. Al6061-2%Graphite – 8.47 181.20 40.64 946.10 [16]
Al6061-3%Graphite – 8.60 182.10 39.98 1028.72
Al6061-4%Graphite 9.40 191.65 37.38 1067.21
Al-7075 – 210 115 265
Al-7075 + 2%Al2 O3 – 219 117 270
6. Al-7075 + 4%Al2 O3 – 226 121 275 [19]
Al-7075 + 6%Al2 O3 – 229 124 283
Al-7075 + 8%Al2 O3 236 134 294
As-cast
Al + 0% SiC 80.75 – 112.93 – –
Al + 3% SiC 88.02 – 114.70 – –
Al + 6% SiC 93.43 – 121.40 – –
Al + 9% SiC 111.0 – 150.74 – –
Al + 12% SiC 120.24 158.50 –
7. [20]
Age-hardened
Al + 0% SiC 86.95 – 116.70 – –
Al + 3% SiC 90.54 – 119.20 – –
Al + 6% SiC 118.40 – 135.36 – –
Al + 9% SiC 116.00 – 154.54 – –
Al + 12% SiC 118.4 154.90 –

Fig. 4 – E-8M standard dimensions of tensile specimens [18].

3352 j m a t e r r e s t e c h n o l . 2 0 1 9;8(3):3347–3356

Table 3 – Chemical composition of fly ash [14].

Composition Al2 O3 SiC2 Fe2 O3 TiO2 Loss of ignition

In wt% 28.44 59.96 8.85 2.75 1.43

Table 4 – ASTM E-9 standard dimensions for compression specimen [18].

Specimens Diameter Length Approx L/D ratio

in. mm in. mm

Short 1.12 ± 0.01 30.0 ± 0.2 1.00 ± 0.05 25.0 ± 1.00 0.8
0.50 ± 0.01 13.0 ± 0.2 1.00 ± 0.05 25.0 ± 1.00 2.0
Medium 0.50 ± 0.01 13.0 ± 0.2 1.50 ± 0.05 38.0 ± 1.00 3.0
0.80 ± 0.01 20.0 ± 0.2 2.38 ± 0.12 60.0 ± 3.00 3.0
1.00 ± 0.01 25.0 ± 0.2 3.00 ± 0.12 75.0 ± 3.00 3.0
1.12 ± 0.01 30.0 ± 0.2 3.38 ± 0.12 85.0 ± 3.00 3.0
Long 0.80 ± 0.01 20.0 ± 0.2 6.38 ± 0.12 160.0 ± 3.00 8.0
1.25 ± 0.01 32.0 ± 0.2 12.50 min 320 min 10.0

the other hand when graphite is added percentage elonga-
tion gradually increased [16]. In the case of ultimate tensile
strength (UTS), gradual increase with addition of reinforce-
ments is seen [14,19,20], except a fly ash. Effects of fly ash
reinforcement show random changes in UTS (Table 3) with
different wt% of reinforcements [14].
2.4.3. Compressive strength
The compression tests were conducted by using universal
testing machine (UTM) as per the E-9 ASTM Standard. The E-
9 standard dimensions of compression specimens of gauge
length to diameter (D) ratio are different for the length selec-
tion like short, medium and long length shown in Table 4[8].
Review on compression test shows the gradual increase
in compressive loads until the specimen failed and corre-
sponding strain was measured. The effect of Al2 O3 particle
reinforced in Al shows increase in compressive strength com-
pared to graphite reinforced composites (Fig. 5) [16,19].
2.5. Tribological behavior
2.5.1. Wear behavior
The tribological investigation is the discipline of interacting
surfaces under relative motion. Tribological behavior revealed
that direct relation with the load gives wear rate (WR) and
coefficient of friction (COF), while inverse relation with the
sliding speed (SS) and sliding distance (SD) [10]. The WR and
COF of AMMCs decreases compared to base alloy when wt%
of graphite reinforcement was increased as shown in Fig. 6(a)
and (b). Graphite reinforcement acts as self-solid lubricating
element which reduces the wear rate. The hybrid reinforced
composites are harder than the unreinforced aluminum alloy
and this shows the base alloy is softer material, surface of base
material undergoes greater plastic deformation which causes
the high wear rate [8,17].
The WR for base alloy was higher than AA7075/Al2 O3 com-
posite. The results revealed that at 6 wt% of Al2 O3 reinforced
composite, less wear rate at different loads and 1200 m sliding

Fig. 5 – Compression strength comparison between Gr reinforced AMMCs [19] and Al2 O3 reinforced AMMCs [16].
 j m a t e r r e s t e c h n o l . 2 0 1 9;8(3):3347–3356
Fig. 6 – (a) Wear rate vs. experimental sets and (b) COF vs. experimental set [8].
distance, compared to base matrix material the wear resis-
tance of the composite was increased (Fig. 7(a) and (b)) [17].
As the load is increased, WR is increased and WR decreases
with increasing in wt% of reinforcement and the sliding speed
(Fig. 7(c)) [17,21,22].
The COF of Al-7075 alloy compared with composites under
different loading conditions found that friction increases with
load increased [21]. The increasing COF depends upon adher-
ing of the worn out surface and rupture of mating surface gives
the value of COF with time [23–25]. The results revealed that
graphite reinforced composite shows very less friction on sur-
face of the composites compared to base alloy [8]. The boron
carbide (B4 C) powder reinforced composites show lower COF
compared to base Al-7075 alloy [21]. The silicon carbide (SiC)
reinforced composites show higher hardness and lesser COF
compared to base alloy [26]. To reduce the effect of higher
friction coefficient, TiO2 is added as solid lubricating element
in aluminum composites [9]. With the addition of fine rein-
forced powder particles, the COF decreases significantly. The
limited or small contact area plastic deformation may lead
to the lack in friction coefficient. Therefore composites sur-
face has lesser friction while they are harder and very less
plastic deformation. Addition of solid lubricating reinforce-
ment further decreases the COF and significantly increases the
3353
WR of base alloy [21,27,28]. Compared to all types of ceramics
reinforcements, graphite materials have superior tribological
properties.
2.6. Corrosion behavior
Al-7075 matrix composites have poor properties like low
formability and corrosion resistance and restricted their wider
usage. However investigator/researcher has to concentrate on
performance of produced AMMCs on corrosion resistance. The
addition of reinforcements in base alloy may affect the protec-
tive oxide layers of metal surface which shows less corrosion
resistance, because of discontinuity in the layer initiation of
corroded surface of the aluminum matrix composite mate-
rial [1]. The parameters that affect corrosion resistance of
the AMMC’s are base material composition, reinforcement,
porosity, micro-cracks, residual stresses and formation of
inter metallic brittle phases, etc. [2]. The common corro-
sion tests were conducted using electrochemical analyzer and
Tafel Polarization Technique (TPT). The electrochemical anal-
ysis was done by using electrochemical analyzer (CHI604E
series) with CH instrument beta software. The experimental
setup for electrochemical analyzer cell use three combina-
tion of normal electrodes like saturated calomel electrode
3354 j m a t e r r e s t e c h n o l . 2 0 1 9;8(3):3347–3356

Fig. 7 – Wear rate under different load conditions: (a) AA7075 + Al2 O3 [17], (b) AA7075 reinforced with B4 C and MoS4 [21] and
(c) Al + 5% Al2 O3 + MoS2 [22].

(SCE), counter electrode as platinum and working electrode
made up of preferred alloy with their composites along with
glass cell. The Tafel polarization method of corrosion mea-
surement was conducted with different environment by using
standard solutions such as seawater (NaCl) and industrial
(NaCl + (NH4 )2 SO4 ) environment. All the corrosion experi-
ments were conducted at room temperature [29].
In this review it was observed that corrosion increases
with increase in wt% of reinforcement compared to base
alloy. The corrosion analysis results revealed that pitting cor-
rosion was seen in sea water (NaCl) environment and inter
granular corrosion was seen in industrial (NaCl + (NH4 )2 SO4 )
environment [29]. The major advantage of B4 C fine particle
reinforcement is added to Al-alloy material, increases the cor-
rosion resistance with increase in wt% of B4 C particle. The
pitting corrosion resistance was improved but there may be
increased chances of segregation at the grain boundaries due
to finer particle size of reinforcement [30]. The higher corro-
sion rate shows when the standard solution level is high, this
indicates the selection of level of standard solution impor-
tant for experimental conduction [31]. Peak-aged treatments
were carried for 7xxx series, Al-alloys give higher strength
and good hardness but it experience poor corrosion resis-
tance because of precipitate free zones (PFZs) at the grain
boundaries. Many researcher/investigators use RRA technique
(Retrogression and Reaging) specially developed heat treat-
ment for improving the corrosion resistance of Al-7075 alloys
[32,33].
3. Conclusion
In last several decades, many researches/investigators were
concentrating how to reduce the cost of producing reinforced
composite materials with higher strength. The huge amount
of fly ash waste material available in nature with possible use
of mixing with base material of composites, the improvement
made to increase outcome compared to existing material with
rapid experimentation. The above cited review for Al-7075
metal matrix composite gives the following conclusions:
• Aluminum metal matrix composites are fabricated by using
powder and liquid metallurgy routes. In this review covers
the liquid metallurgy route by vortex method that is stir
casting method. This casting method was used success-
fully to manufacture AMMCs with desired effect of different
ceramic reinforcement particles on mechanical and tribo-
logical properties of aluminum alloys [6–8].
• Appreciable improvements in mechanical properties were
observed by addition of various wt% of ceramics parti-
cles reinforcing in aluminum alloys. Addition of silicon
 j m a t e r r e s t e c h n o l . 2 0 1 9;8(3):3347–3356
carbide, alumina, barium chloride, etc. reinforced particles
in aluminum increases the tensile strength, hardness, yield
strength, compressive strength, flexural strength, whereas
ductility is decreased [9,11,13,14,19,20]. Addition of graphite
as reinforcement in aluminum alloy improves the tensile
strength, ductility and elastic modulus whereas hardness is
decreased. Also tribological behavior of such AMMCs shows
decreased coefficient of friction with increase in wt% of Gr
particles [4,16].
• The extensive review found that the addition of industrial
waste organic reinforcement materials fly ash, rice husk
ash and coconut shell ash which significantly improves the
physical and mechanical properties of AMMCs. Whereas,
limited amount of improvement in tribological properties of
the aluminum metal matrix composite was observed [14].
This shows the gap in research work for further investiga-
tion.
• The wear resistance review reveals that the wear rate
improves significantly with incorporation of carbide parti-
cles reinforcement in AA7075 matrix alloy. The coefficient
of friction (COF) variation may be initiation of wear mecha-
nism for AA7075 alloy due to predominant under adhesion,
later it converts to abrasion. The wear mechanism is pre-
dominantly adhesive in nature, have lower COF due to steel
disk hard surface scratching on Al-7075 softer pin surface.
This shows the amount of adhesive wear and abrasive wear
in Al-7075 alloy decreased because of a relatively lower
COF and higher hardness. Wear process gives relatively
smooth worn out surface due to surface fracture associated
with initially adhesive mechanism then converts to abrasive
mechanism [21].
• The purpose of development of aluminum material as
of composites with the help of different reinforcements
leads to huge amount of application in different sectors
like automobile, defence, military and general engineering
applications.
4. Future scope
The review of literature is done to carry out my research in fab-
rication and characterization of Al-7075 metal matrix hybrid
composite.
Conflicts of interest
The authors declare no conflicts of interest.
Acknowledgements
I acknowledge to ghousia college of engineering, journal of
materials research & technology editor, reviewer and produc-
tion team, sciencedirect.com and my heartfelt thanks to ABM-
Brazilian Metallurgical, Materials and Mining Association for
their financial support for publication.
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