Microstructure Evaluation and Mechanical Properties of PMMA/Al₂O₃ Nanocomposite Fabricated via Friction Stir...

This study aimed to develop polymer matrix nanocomposites reinforced with Al₂O₃ nanoparticles to enhance the mechanical properties of PMMA. The composite was fabricated via friction stir processing (FSP) to ensure the homogenous dispersion of Al₂O₃ nanoparticles in the polymer. A grid of 5 holes in a 7 × 7 mm² area was made in which the hole diameter was varied from 1.77 mm to 2.28 mm to obtain different volume fractions of reinforcement ranging from 15% to 25%. The holes were made with a depth of 3 mm in a 4 mm-thick PMMA sheets. After packing the Al₂O₃ powder in the holes, a 2 mm-thick PMMA sheet was used as a cover to prevent the sputtering of nanoparticles. A number of FSP parameters were examined. The tool rotation rates ranged from 800 to 1200 rpm, traverse speeds of 25 and 50 mm/min, and tool tilts of 1 and 2° were used. A soft paraffin (Vaseline) layer was used on the top surface to prevent severe shoulder friction with the PMMA plate, which caused severe wear and thinning on the surface. For the developed PMMA/Al₂O₃ nanocomposites, the surface quality, SEM microstructure, impact energy, and transverse hardness were investigated. Good surface quality and dispersion of nanoparticles were attained by employing adequate processing conditions. The experimental results indicated that as the nanoparticle percentage increased, impact energy, hardness, and tensile strength increased, reaching 2 kJ/m², 14.7 HV, and 52.1 MPa at a nanoparticle concentration of 25%. This means that the polymer ceramic composite's toughness, hardness, and tensile strength are higher than those of unprocessed PMMA by 66%, 33%, and 23%, respectively.