Microstructure and mechanical properties of aluminum–fly ash nano composites made by ultrasonic method

In this paper an attempt has been made to modify the micro sized fly ash into nano structured fly ash using high energy ball mill. Ball milling was carried out for the total duration of 30 h. The sample was taken out after every 5 h of milling for characterizing. The nano structured fly ash was characterized for its crystallite size and lattice strain by using X-ray diffractometer. It was found that a steady decrease in the crystallite size and increased lattice strain was observed with milling time; the crystallite size at 30 h milling time was found to be 23 nm. The fresh fly ash particles are mostly spherical in shape; whereas the shape of the 30 h milled fly ash particles is irregular and the surface morphology is rough. Al–fly ash nano composites were produced by ultrasonic cavitation route successfully. Scanning electron microscopy images of nano composites reveal a homogeneous distribution of the nano fly ash particles in the AA 2024 matrix. Energy dispersive spectroscopy analysis of nano composites reveals that the fabricated nano composite did not contain any additional contamination from the atmosphere. As the amount of nano fly ash is increasing the hardness of the composite also increasing. The nano fly ash addition leads to improvement in the compression strength of the composites.

► Nano structured fly ash has been produced by 30 h milling time.
► Al–fly ash nano composites were produced by ultrasonic cavitation route.
► A homogeneous distribution of nano fly ash particles was observed in the matrix.
► No additional contamination in the nano composites from the atmosphere.
► Presence of nano fly ash leads to improvement in the strength of the composites.