Lightweight metal matrix nano-composites (MMNCs) (metal matrix with nano-sized ceramic particles) can be of significance for automobile, aerospace and numerous other applications. However, it is extremely difficult to disperse nano-sized ceramic particles uniformly in molten metal for casting. This paper presents a fabrication method for casting of bulk aluminum MMNCs by use of ultrasonic nonlinear effects, namely transient cavitation and acoustic streaming. Nano-sized SiC particles have been dispersed in molten aluminum alloy A356 for casting. Microstructural study was carried out and it validates a good distribution and dispersion of nano-sized SiC in aluminum alloy matrix. Hardness of the as-cast MMNCs have been improved significantly even with a low weight fraction of nano-sized SiC. The ultrasonic fabrication methodology is promising to produce a wide range of other MMNCs.

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