Computational Model for Hot Deformation Behavior of AA2024/SiC Composites Emphasizing the Effect of Volume Fraction and Particle Size

The hot deformation behavior of AA2024/SiC composite was investigated by experimental and finite element simulation (FEM) methods. The influence of different particle volume fractions (VFs) and sizes on the mechanical behavior of AA2024/SiC composites was studied. An integrated numerical model was developed using a modified Johnson–Cook model for the AA2024 matrix implemented via VUHARD subroutine and the Johnson–Holmquist model 2 for the SiC particles. Simulations were performed at higher temperatures (673–753 K) and varying strain rates (0.01–1 s⁻¹) within a random microstructure-based FEM framework using ABAQUS. The FEM results are in close agreement with the experimental data, particularly in the true stress–strain curves, indicating that the developed FEM model effectively captures the hot workability of AA2024/SiC composites under varying temperature conditions, SiC volume fractions, and particle sizes (PSs). The results showed that the reinforcement of SiC particles into the AA2024 matrix significantly improved its hot workability by reducing dislocation mobility. The flow stress of composites increased with SiC content and decreased with the reinforcement particle size. The composites reinforced with 5 µm SiC particles had a higher peak flow stress of 145.945 MPa than the others at 673 K and a strain rate of 1 s⁻¹. Similarly, at constant temperature and strain rate, the peak flow stress of the composite material increased from 87 MPa to 145.945 MPa (PS = 5 µm at 673 K and strain rate 1 s⁻¹) as the VF increased from 1% to 20%.