Experimental and Testing Mechanical Properties of Al 7075–Zrb–Sic–Gr Composites Using for Advanced Heat Sink Applications

Abstract

This study Experimental and Testing Mechanical Properties of Al 7075–Zrb–Sic–Gr Composites Using for Advanced Heat Sink Applications focuses on the development and characterization of a hybrid metal matrix composite (MMC) using Aluminium 7075 (Al 7075) as the base matrix reinforced with Silicon Carbide (SiC), Zirconium Diboride (ZrB₂), and Graphite (Gr). Generally, a heat sink is a passive thermal management device that dissipates heat from electronic components (like CPUs, GPUs, power transistors, LEDs, etc.) into the surrounding air or liquid. The primary objective is to enhance the mechanical and tribological performance of Al 7075 through the synergistic effect of ceramic and solid lubricant reinforcements. SiC provides improved hardness and strength, ZrB₂ offers high thermal stability and wear resistance, while Gr contributes to reduced friction due to its solid lubricating properties. The composites were fabricated using the stir casting process to ensure uniform distribution of the reinforcements. Mechanical properties such as compressive strength and hardness were evaluated, along with wear behavior under dry sliding conditions. The results indicated a significant improvement in all properties compared to the unreinforced Al 7075 alloy. The combined effect of SiC and ZrB₂ enhanced load-bearing capacity and thermal resistance, while the presence of Gr reduced the coefficient of friction and wear rate. The aim of the project is perform the 89%AL7075+8%Sic+2%ZrB2+1%Gr,90%AL7075+7%Sic+2%ZrB2+1%Gr,91%AL7075+6%Sic+2%ZrB2+1%Gr, 92% AL7075+ 5%Sic+2%ZrB2+1%Gr these compositions of Mechanical testing was perform to evaluate hardness, compressive strength, and wear resistance, while micro structural analysis was conducted, heat treatment after which composition have better results use the real time application created the heat sink using CATIA software and perform the Thermal analysis using ANSYS software and here find out the temperature distribution and Total heat flux. Finally concluded the material is best based on the testing.