In this paper, HSC software was used to perform a thermodynamic analysis of A5083/ZrO2 metal matrix composite to predict the phases which formed during the manufacturing processes (vortex method). The base matrix was purchased commercially and the zirconia particles were extracted from Egyptian zircon as a reinforcing material by alkaline fusion technique. The base material was melted in an electric furnace at 750°C, and the extracted zirconia particles were added while stirring. Thermodynamic diagrams predicted that ZrO2 would react with the matrix to produce new phases such as MgO and Al2O3 in preference to the formation of MgO. Characterization of the fabricated zirconia and composites was performed by various methods; Scanning Electron Microscopy (SEM), Energy Distributed X-ray (EDS) and X-ray Diffraction (XRD). The results demonstrate successful extraction of high purity zirconia (98.85%) and fabrication of composites during stir casting. Furthermore, SEM mapping of the fabricated composite revealed the presence of MgO and Al2O3 consistent with thermodynamic studies.
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