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<p>A hybrid self-healing composite of Al6061 alloy incorporating 60Pb40Sn solder alloy and NiTi wire as reinforcements was synthesized to investigate the improvement in damage tolerance behavior under mechanical loading conditions. This composite is prepared by combining the low melting point solder alloy and NiTi wire into the machined grooves of the Al6061 matrix alloy. The mechanical behavior of the hybrid composite was investigated through tensile test, Charpy impact test, and three-point bend test. The findings revealed that the tensile strength of the developed hybrid composite is 194&#xa0;MPa while the same property of the monolithic alloy was found to be 245&#xa0;MPa, whereas the elongation increases from 11.8% to 14.2%, which represents better ductility. The improvement in dynamic fracture toughness is also remarkable, as the impact energy value increases from 28.6&#xa0;J for monolithic to 61.3&#xa0;J for hybrid composites, which represents 114.3% improvement. Similarly, the flexural strength was raised from 121.4&#xa0;MPa to 183.6&#xa0;MPa, which shows a positive change of 51.2%. This improvement in behavior can be associated with the effect created by the use of 60Pb40Sn solder alloy in conjunction with NiTi wire, where the former can act as a crack filling material, while the latter helps in bridging cracks and stress distribution. The SEM observations of fracture morphology showed that crack deflection was present along with strong bonding at the interface, suggesting efficient transfer of load and high resistance to crack propagation, resulting in improved impact and flexural properties. The fabricated hybrid composite possesses an effective compromise among ductility, impact behavior, and flexural performance.</p>

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Development and mechanical characterization of hybrid self-healing Al6061 composite reinforced with 60Pb40Sn alloy and NiTi shape memory wire

  • 期刊论文

  • 发表日期：

    2026年8月5日

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  • Nitin Kumar Gupta,
  • Nalin Somani,
  • Yogesh Kumar Tyagi,
  • Anupam Alok

摘要

A hybrid self-healing composite of Al6061 alloy incorporating 60Pb40Sn solder alloy and NiTi wire as reinforcements was synthesized to investigate the improvement in damage tolerance behavior under mechanical loading conditions. This composite is prepared by combining the low melting point solder alloy and NiTi wire into the machined grooves of the Al6061 matrix alloy. The mechanical behavior of the hybrid composite was investigated through tensile test, Charpy impact test, and three-point bend test. The findings revealed that the tensile strength of the developed hybrid composite is 194 MPa while the same property of the monolithic alloy was found to be 245 MPa, whereas the elongation increases from 11.8% to 14.2%, which represents better ductility. The improvement in dynamic fracture toughness is also remarkable, as the impact energy value increases from 28.6 J for monolithic to 61.3 J for hybrid composites, which represents 114.3% improvement. Similarly, the flexural strength was raised from 121.4 MPa to 183.6 MPa, which shows a positive change of 51.2%. This improvement in behavior can be associated with the effect created by the use of 60Pb40Sn solder alloy in conjunction with NiTi wire, where the former can act as a crack filling material, while the latter helps in bridging cracks and stress distribution. The SEM observations of fracture morphology showed that crack deflection was present along with strong bonding at the interface, suggesting efficient transfer of load and high resistance to crack propagation, resulting in improved impact and flexural properties. The fabricated hybrid composite possesses an effective compromise among ductility, impact behavior, and flexural performance.