Development of Mxene-Reinforced AA5083 H111 Marine Aluminium Composites: Experimental Investigation, Hollomon Constitutive Modeling and Finite Element Validation Introduction

Abstract

Response Surface Methodology (RSM) was used to optimally manufacture AA2024–TiC nanocomposites using stir
casting and Box–Behnken design to enhance the mechanical properties for marine structural applications. The selected process variables included TiC content (2–8 wt.%), stirring speed, time, and melt temperature. The results show that TiC content is a significant factor affecting mechanical behavior, with optimal performance at approximately 5 wt.% due to uniform dispersion and effective load transfer. Optimization conditions yielded maximum tensile strength (~398 MPa) and hardness (~144 HV), while elongation decreased with increasing reinforcement due to brittleness and particle clustering. ANOVA confirmed the significance of quadratic models with high prediction accuracy (R² > 0.96). Optimal processing conditions were identified as ~580 rpm, ~11 min, and ~748 °C, and were validated through confirmation tests within a 95% confidence interval. The developed nanocomposites exhibit improved strength–ductility balance, making them suitable for lightweight marine load-bearing structures.