International Journal of Emerging trends in Engineering and Development

ISSN 2249-6149 Issue 2, Vol.1 (January-2012)

Distribution of SiC particulates in stir cast Aluminium alloy Metal matrix composites and its effect on mechanical properties
2

Faculty, Department of mechanical Engineering, Seemanta Engineering College, Orissa,India Professor, Department of mechanical Engineering, Jadavpur University, Kolkata, West Bengal, India Corresponding Author: Mr. Rabindra Behera, Asst. Professor, Department of Mechanical Engineering, Seemanta Engineering College, Orissa,India Tele. Phone No.:-09438461747 E-mail Address: - rabi_lisha@yahoo.com

Rabindra Behera1*,Nihar Ranjan Mohanta1,G.Sutradhar2

ABSTRACT
The mechanical properties of metal matrix composites are deeply influenced by the distribution of reinforcement particulates in the matrix and the morphology of secondary matrix. Earlier researchers have shown that SiCp reinforcements can acts as heterogeneous nucleation sites for Si during solidification of LM6-SiCp composites. The present study investigates the distribution of SiC particulates in a stepped (3-step) cast LM6-SiCp metal matrix composites, which are reinforced by SiCp at different weight fraction i.e. 5, 7.5,10 & 12.5wt%. The mechanical properties such as hardness/micro hardness, tensile properties etc. and forgeability of stir cast MMCs examined at different step of the castings. The experimental results show that the mechanical properties and forgeability of cast MMCs are different at different step of castings. The morphology of cast MMCs indicates that the distribution of SiCp is not uniform through out the casting and it changes on changing the thickness of the casting.

Keywords: Metal matrix composites, stir casting, particle distribution, hardness, tensile
strength, forgeability.

1.1 Introduction
The ever rising of fuel price day to day has led to a renewed urgency to concentrate on the issue of weight reduction in the aerospace and automotive sectors. As monolithic alloys possess low strength to weight ratio, hardness, stiffness etc. so the area of application of these alloys restricted. This limitation has circumvented by incorporation of harder and stiffer ceramic particulates in the matrix, which known as composite material. Composite materials are significant engineering materials due to their excellent mechanical properties over monolithic alloys. Metal matrix composite (MMC) materials are one of the widely known composites because of their superior properties such as high strength to weight ratio, hardness, stiffness, wear and corrosion resistances etc. over monolithic metals & its alloys. Aluminum and its alloys based metal matrix composites (MMCs) have attracted considerable interest because of their
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attractive mechanical properties over monolithic alloy [1]. The prime support for these composites has come from the aerospace industry for airframe and spacecraft structures. More recently, the automotive, electronic and recreation industries have been working diligently with these composites. Silicon carbide particle (SiCp) reinforced aluminium-based MMCs are among the most common MMC and commercially available ones due to their economical production [2]. The distribution of particulates in cast MMCs is a major factor in determining the in-service properties of engineering components [3]. Extensive experimental and theoretical studies [3, 4-6] have been made to investigate this subject. They all confirmed that one of the most important factors affecting the final microstructure is solidification rate of cast MMCs. Another important factor influencing the particle distribution in casting is the settling of SiC particles during melt holding and during casting due to gravity. Settling of SiC particles will yield to a non-uniform distribution of reinforcement in the matrix, which in turn has significant effect on the mechanical properties. Models have been proposed to describe the settling phenomenon of the particles. Stokes developed an expression for the settling velocity of spherical particles moving relative to a continuous fluid [7]. d 2 ( p ) g Vs 18 Where d is the particle diameter, p is the density of the particles, is the density of the liquid, is the viscosity of the liquid and g is the acceleration due to gravity. At higher volume fractions particles generally interact with each other reducing in the process the settling velocity. Richardson and Zaki [8] have explained the settling of particulates with a size greater than 100m, using the hindered Stokes velocity V p. Vp = Vs (1- C) 4.65, Where C is the true concentration of particles. Several investigators have reported their research data on the settling of SiC particle reinforcement in liquid aluminium matrix composites produced by liquid metallurgy route [7, 9, 10]. Lafreniere and Iron [9] observed that the settling rate of 82m SiC particles in aluminiumsilicon alloy (A356) is much slower than those predicted by Stokes law, where as Gallerneaut and Smith [11] reported higher rates of settling for SiC particles having diameters ranging from 10 to 155m in A356 alloy. There are also number of studied on the mechanical properties of SiCp reinforced Al-based MMC. Embury [12] reported that multi-axis surface tension in MMCs decreased the ductility of matrix element of MMC. These tensions and pores in matrix rapidly increased the factor that determines the ductility is the formation phase of the pores. Moreover, it has stated that since these tensions and the pores in matrix increase rapidly, the factor that determines the ductility is the formation phase of these pores. Ejiofor and Reddy [13] explains the strengthening mechanism of discontinuously reinforced metal and inter metallic matrix composites with constipation of matrix and the strength of the basis structure. Zaklina Gnjidic et al. [14] observed that the addition of the SiC particles increased the yield strength and elastic modulus while decreasing the ultimate compressive strength and ductility of the CW67 alloy in both the peak-aged and under-aged conditions. The greatest strengthening effects have achieved with the
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CW6715 mm SiC composite material. Both the presence of agglomerations of small (0.7 mm) SiC particles and the cracking of large (33 mm) SiC particles had detrimental effects on CW67 alloy strengthening. The higher compressive strength and lower ductility has achieved with the peak-aged matrix compared with the under-aged matrix. The presence of SiC particles causes the aging process to be accelerated due to an increase in dislocation density, which provides more sites for the nucleation of precipitates. However, the stiffness, hardness and strength to weight ratio of cast MMCs has increased due to addition of very hard SiC particles in the matrix metal, but a substantial decrease in ductility is obtained. It has observed that some improvements in strength and ductility due to the application of plastic forming process i.e. forging to the composites. The forged MMCs have better mechanical properties compared to cast MMCs, i.e. high density, hardness and tensile strength etc. and the forging process also avoids the use of secondary operation like machining. The forgeability is one of the important tools, which indicates the limit of forging for any metal either at cold or hot condition of the metal. A number of reports [15, 16, 1721] are available on Al-alloys + SiCp composites and the effects of SiC particle size on the microstructure and mechanical properties. But, therefore, the objective of the present study is to develop a stir casting process to produce SiCp reinforced step cast Alalloy (LM6) metal matrix composites, and to investigate of distribution silicon carbide particles at the different step of the casting and their effect on the mechanical properties.

2. Experimental Procedure 2.1 Materials

In the present experiment metal matrix composites including various weight fractions of SiC particles were produced by stir casting method. Al alloy (LM6) was used as the matrix material; while SiC particles with an average size of 400 mesh were used as the reinforcement material. The SiCp used in the experiments were supplied by HiMedia Laboratories Pvt. Ltd, Mumbai, INDIA. The chemical composition of LM6 alloy, used in this study is given in Table 1. Table 1 The chemical composition of aluminium alloy (LM6) Elements Si Cu Mg Fe Mn Ni Zn Pb Sb Ti Al Percentage (%) 10-13.0 0.1 0.1 0.6 0.5 0.1 0.1 0.1 0.05 0.2 Remaining

2.2 Fabrication of composites

The composite fabrication technique is an important consideration. The aluminiumsilicon alloy i.e.LM6 is used as the matrix metal in the experiments for the fabrication of the composites that has been reinforced with 5 wt%, 7.5 wt%, 10 wt% and 12.5 wt. % of SiCp of average 400 mesh size. The composites have fabricated by the liquid metal stir casting technique. The weighted quantity of aluminium alloy is melted to desired temperature of 750 0C in graphite crucible 3phase electric resistance furnace with stirring system (shown in Fig.1). Then 3wt. % Mg has been added with the liquid metal, in order to achieve a strong bonding by decreasing the surface
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energy (wetting angle) between the matrix alloy and the reinforcement particles. The addition of pure magnesium has also enhanced the fluidity of the molten metal. The melt has mechanically stirred for 10 to 15 minutes by using an impeller at a speed of 400-500rpm, during stirring condition the preheated silicon carbide particles (at about 850-9000C) introduced into the melt through the vertex of the molten metal. The composite melt has poured at a temperature of 720 0 C into the stepped green silica sand mould. After pouring is over the melt was allowed to cool and solidify in the mould. All the composites are produced in the same procedure and results were investigated. They are listed in the Table 2. The benchmark model of the casting has shown in Fig.2.

Fig.1. Electric resistance furnace with Stirring System for melting of matrix metal i.e. LM6 and mixing of SiCp with the Liquid LM6.
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Fig.2.Benchmark model of the stepped casting (Dimensions in mm) Table 2 List of aluminium alloy matrix composites reinforced with silicon carbide particles (wt%). Weight % of Explanation SiCp addition LM6- 0%SiCp LM6- 5%SiCp LM6- 7.5%SiCp LM6- 10%SiCp LM6- 12.5%SiCp 0 wt% particulate reinforced, green sand cast LM6 matrix 5 wt% particulate reinforced, green sand cast LM6 matrix 7.5 wt% particulate reinforced, green sand cast LM6 matrix 10 wt% particulate reinforced, green sand cast LM6 matrix 12.5 wt% particulate reinforced, green sand cast LM6 matrix

2.3. Metallography
Samples for metallographic examination were prepared by grinding through 320, 400, 600, 800, 1200 and 1500 grit papers followed by polishing with 6 m diamond pastes. Then the samples were etched with Kellers reagent (2.5 ml Nitric acid, 1.5 ml HCl, 1.0 ml HF, 95.0 ml Water). The etched samples were dried and the microstructure observed by using Scanning Electron Microscope (JEOL, JSM 6360). The microstructure of the as cast LM6 MMCs are shown in Fig. 3-6 at different modulus of the casting. The micrograph of MMC castings at different section shows that the distributions of SiC particles are not uniform throughout the casting and segregation of particles are more in the middle section of the castings. This tendency may be attributed to the fact that the rate of cooling is not uniform throughout the casting due to change in thickness of the casting and slower rate of cooling in the sand mould. The image analysis results (given in table-3) are also shows that the distribution of SiCp through the stepped casting is not uniform, the maximum volume percentage of SiC particles are accumulated in the step-II
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i.e. about 60%, whereas about 40% in section-I and 55% in case of section-III. The sample photograph of the image analysis of MMC has been shown in Fig.7.

(a) (b) (c). Fig.3. Microstructure of LM6/5wt% SiCp as cast MMC at different modulus of the casting. a. Section-I (Mod. 6.97) ; b. Section-II (Mod.8.69) and c. Section-III (Mod.8.95)

(a) (b) (c) Fig.4.Microstructure of LM6/7.5wt% SiCp as cast MMC at different modulus of the casting. a. Section-I (Mod. 6.97) ; b. Section-II (Mod.8.69) and c. Section-III (Mod.8.95)

(a)

(b)

(c)
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Fig.5.Microstructure of LM6/10 wt% SiCp as cast MMC at different modulus of the casting. a. Section-I (Mod. 6.97) ; b. Section-II (Mod.8.69) and c. Section-III (Mod.8.95)

(a) (b) (c) Fig.6. Microstructure of LM6/12.5wt% SiCp as cast MMC at different modulus of the casting. a. Section-I (Mod. 6.97); b. Section-II (Mod.8.69) and c. Section-III (Mod.8.95). Table 3 Distribution of SiCp in the stepped MMC castings Material LM6- 5%SiCp Section-I Section-II Section-III Section-I Section-II Section-III Section-I Section-II Section-III Section-I Section-II Section-III SiCp (vol. %) 40.51 59.4 54.16 40.73 59.8 54.07 41.79 60.18 54.38 43.03 62.16 56.33 Al alloy (vol. %) 59.49 40.6 45.84 59.27 40.2 45.93 58.21 39.82 45.62 56.97 37.84 43.67

LM6- 7.5%SiCp

LM6- 10%SiCp

LM6- 12.5%SiCp

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Fig.7. Image analysis photograph of as cast MMCs

3. Results and Discussion 3.1. Hardness of the as cast MMCs

Hardness is one of the important mechanical properties in case of composite material as the hardness of the matrix metal is very low, which limits its wide application. The hardness of the matrix metal enhances, due to reinforcement of ceramic particles with it. Theoretically, the hardness of the castings should be uniform through out the composite castings. This is, if the distribution of the particles through out the casting is uniform. However, other factors such as cooling rate, gravity effect and non-uniform distribution of reinforcement particles in the casting will give different values of hardness. In the experiment the hardness of aluminium alloy composites were measured by Vickers micro hardness testing machine at different section of the as cast composites. The experimental data shows the hardness of the cast metal matrix composites increase proportionally by increasing the weight percentage of SiC particles in the casting and the maximum hardness obtained at 12.5wt% of SiCp i.e. about 43% higher than the matrix metal. The experimental results also show that the hardness is different in different section of the castings. The hardness is higher in middle section i.e. section-II comparison to both end sections i.e. section-III and I for all composite castings. This may be occurred due to non-uniform cooling rate and non-uniform distribution of SiCp in the castings. The Fig. 8 shows the variation in hardness with respect to section of the as cast aluminium alloy composite castings reinforced with different weight fraction of SiCp. This has occurred because of nonuniform distribution of SiC particles in the stepped casting after solidification of the cast metal. Moreover, the presence of extremely hard (2480 Knoop Hardness) SiCp in the matrix LM6 plays
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a significant role in increasing the hardness value. This experimental result was more or less similar by some researcher (the details given below), however the have manufactured the MMCs in different technique.

Fig. 8. Variation in hardness with respect to section of the as cast aluminium alloy composite castings reinforced with different weight fraction of SiCp

3.2. Tensile Properties of the as cast MMCs

The tensile behaviour of all the prepared samples of composites has determined to examine the tensile properties. The specimens were loaded hydraulically in the universal testing machine. The loads at which the specimen has reached the yield point and broken were noted down. The tensile test specimens after tensile testing are shown in Fig.9. The experimental result shows that the tensile strength of the as cast MMCs produced are somewhat higher than that of the non-reinforced LM6 alloy. Fig.10 shows the effect of the weight percentage of SiCp on the ultimate tensile strength of as cast LM6 reinforced SiCp MMCs. It can be noted that the addition of silicon carbide particles improved the tensile strength of the composites. It is apparent that an increase in the weight percentage of silicon carbide particle results in an increase in the tensile strength. The tensile strength of LM6 in nonreinforced condition is 175N/mm2, and this value increases to a maximum of 281.6 N/mm2 for LM6/SiC/12.5wt% which is about 62% improvement on that of the non-reinforced matrix material. The tensile strength obtained in this study is compared to results from other researchers, given in the table-4. Fig.11 shows that the percentage of elongation of decreases gradually on increasing the percentage of SiCp in the matrix metal. The result reveals that the presence of hard reinforced particles like SiC in the matrix metal reduces the percentage of elongation during tensile testing as the brittleness of the metal increases.

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Fig.9. Tensile test specimens after tensile testing

Fig. 10. Tensile strength of the as cast composites at different weight fraction of SiCp

Fig.11.Percentage of elongation with respect to weight % of SiCp

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Table 4 Tensile Strength for Some Aluminium-Silicon Alloy Based MMC Produced by Casting Technique Researchers (MPa) Present Study Jasmi hashima Samuel et al. [10] Paray et al. [11] Shivkumar et al. [12] Cast MMC system (Sand Casting) LM6/SiC/10p 359/SiC/10p A359/SiC/10p A359/SiC/10p A359/SiC/5p Tensile Strength In Mpa 255.77 150 115 105 95.7

4.1 Conclusion
The non-uniform distributions of silicon carbide in the cast MMCs affect the mechanical properties. The accumulation of the silicon carbide particles in the cast MMCs results nonuniform properties throughout the casting, which reduced the application of the cast MMCs. The experimental investigation on the distribution of SiCp in the stepped casting and its effect on mechanical properties of the as cast MMCs at different weight fraction of SiCp concluded the following points: The SiC particles in the stepped casting are not uniformly distributed and the higher percentage of SiC particles are segregated at the middle section of the rectangular stepped casting. The hardness of the MMCs is higher than the unreinforced matrix metal and the hardness of the cast composites increases linearly with increasing the weight fraction of SiCp. The tensile strength of the as cast composites increases on increasing the weight fraction of SiCp. But, the percentage of elongation decreases on increasing the percentage of SiCp in the matrix metal i.e.LM6.

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