Interaction Effect on Silica Sand Reinforced AA5042 Composite Tensile Strength Properties

Abstract

This investigation explores the interaction effects of silica sand reinforcement on the tensile strength properties. The interaction effects of production parameters on the tensile strength properties of silica sand-reinforced AA5042 aluminum matrix composites are also presented in this study. The composites were processed using stir casting method with different weight percentages of silica sand particles. Systematic investigations of the influence of particle size (30-90 ?m), weight percentage (5-15%), and preheat temperature (200-300°C) on tensile strength were undertaken using response surface methodology. Tensile tests were conducted according to ASTM E8 standards, and microstructural characterizations were examined using scanning electron microscopy (SEM). Microstructure analysis confirmed even silica particle distribution and the prevailing strengthening mechanisms as load transfer and crack deflection. Effects analysis revealed particle size to be a negative (-3.00 coefficient) while weight percentage was a positive influence (3.75 coefficient) on tensile strength. The findings are critical in establishing optimum composite design and process parameters for enhanced mechanical properties.

Introduction

Metal Matrix Composites (MMCs) offer superior strength, stiffness, and wear resistance compared to traditional alloys. AA5042, an Al-Mg alloy, is a promising matrix material due to its excellent strength-to-weight ratio and corrosion resistance. Reinforcing such alloys with ceramic particles like silica sand (SiO?)—a hard, chemically stable, and low-cost material—can enhance properties like tensile strength and thermal stability.

2. Research Focus:
This study investigates the interaction effects of key production parameters—particle size, reinforcement weight percentage, and preheat temperature—on the tensile strength of silica sand-reinforced AA5042 composites. It uses Response Surface Methodology (RSM) to model and optimize these interactions for enhanced composite performance.

Materials and Methods:

• Materials Used:

  • Matrix: AA5042 aluminum alloy (95.69% Al, 3.85% Mg, trace elements).

  • Reinforcement: Silica sand particles (30–90 μm), added at 5%, 10%, and 15% weight fractions.

• Fabrication Method:

  • Stir casting at 750°C with stirring at 200–300 rpm for 4 minutes.

  • Poured into preheated molds for specimen creation.

• Characterization:

  • Chemical Analysis: Confirmed AA5042 composition via Positive Material Identification (PMI).

  • Microstructure: SEM showed dendritic structures and uniform particle distribution; some particles showed good bonding, others showed debonding.

  • Tensile Testing: Conducted using a 50 kN universal testing machine.

Key Findings:

1. Microstructural Observations:

• Silica particles are generally well distributed and well bonded.

• Signs of wear and stress concentration suggest interaction under mechanical loading.

2. Tensile Strength & Parameter Interactions:

• Reinforcement Content vs. Preheat Temperature:

  • Higher preheat temperatures enhance the positive effect of reinforcement percentage.

  • Optimum strength (~100 MPa) observed at 11–13% reinforcement and 250–270°C preheat.

• Particle Size vs. Preheat Temperature:

  • At high preheat temperatures, larger particle sizes significantly reduce tensile strength.

  • Best tensile strength achieved with smaller particles and lower preheat temperatures.

• 3D Response Surface Analysis:

  • Showed that tensile strength decreases with increasing particle size and preheat temperature.

  • Optimal conditions lie in the lower range of both parameters.

Mathematical Modeling & Regression Analysis:

• Key Coefficients:

  • Particle Size (A): Strong negative effect (−3.00).

  • Weight % (B): Strong positive effect (+3.75).

  • Preheat Temp (C): Moderate positive effect (+1.25).

• Interactions:

  • Significant interaction between B and C (−0.50).

  • Quadratic terms indicate non-linear relationships, e.g., diminishing returns at high reinforcement percentages.

• Model Validity:

  • Low multicollinearity (VIFs near 1.0).

  • Good agreement between predicted and actual tensile strengths.

Conclusion

The findings of this study have verified significant interaction effects of particle size, weight percent, and preheat temperature on the tensile strength behavior of silica sand reinforced AA5042 aluminum matrix composites fabricated using the stir casting process. The experimental and modeling results validate that particle size is adverse to tensile strength, but weight percent and preheat temperature are positive within optimum ranges. The influence of % reinforcement and preheat temperature on one another was largely strong: tensile strength increased with the reinforcement content up to 11–13%, especially when accompanied by preheat temperatures between 250–270°C. [16]. This is caused by improved wettability, interfacial bonding, and uniform distribution of particles, as indicated by SEM examination. Conversely, larger particles had poorer bonding and stress concentrations, especially at higher preheat temperatures, with a dramatic drop in tensile strength—yet displaying an essential interaction between these two factors. The built mathematical model accurately replicated these relationships, where it was both statistically significant and low in multicollinearity, with a focus on optimizing the linear and quadratic effects. Response surface and contour plots visually confirmed that optimal tensile performance is realized at smaller particle sizes (30–45 µm), reinforcement levels of 11–13%, and preheat temperatures near 260°C. Lastly, this study presents important data regarding the multi-factor optimization of process parameters of silica sand-reinforced AA5042 composites that can be used to fabricate materials with enhanced mechanical characteristics for structural and load-bearing applications.

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Copyright

Copyright © 2025 Emifoniye Elvis, Ezechukwu Vincent Chukwuemeka, Ogwor Oghoghoreva Edison. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.