Numerical Modeling and Optimization of Mechanical Properties in Porous Aluminum Matrix Composites Reinforced with SiC Particles

This study investigates the impact of porosity on the mechanical properties of aluminum matrix composites reinforced with ceramic particles, focusing on the optimization of volume fraction and porosity to enhance tensile strength. Using Finite Element Analysis (FEA) and Analysis of Variance (ANOVA), the effects of varying volume fractions (5%, 10%, 15%, 20%, and 25%) and porosity levels (1%, 2%, 3%, 4%, and 5%) on Von Mises stresses were systematically analyzed. The results demonstrated that as porosity increased, Von Mises stress also increased, while higher volume fractions contributed to better stress distribution and enhanced mechanical properties. Optimization analysis identified the optimal parameters as a volume fraction of 25%, porosity level of 1.01%, particle size of 30.083 µm, and pore diameter of 9.020 µm, achieving a desirability score of 0.895 and a Von Mises stress of 9.06E-08 N/µm2. The ANOVA results confirmed the statistical significance of these parameters, with a P-value threshold of <0.05. These insights are crucial for understanding how to optimize porosity and reinforcement in composite materials, providing valuable guidance for applications in the aerospace and automotive industries, where lightweight and high-strength materials are vital.