Accepted Manuscript

Title: Fabrication of Al-SiC-B4C Metal Matrix Composite by

Powder Metallurgy Technique and Evaluating Mechanical
Properties
Author: Anil Kumar Bodukuri K. Eswaraiah Katla Rajendar
V. Sampath
PII:
DOI:
Reference:

S2213-0209(16)30120-3
http://dx.doi.org/doi:10.1016/j.pisc.2016.04.096
PISC 266

To appear in:
Received date:
Accepted date:

26-1-2016
9-4-2016

Please cite this article as: Bodukuri, A.K., Eswaraiah, K., Rajendar, K., Sampath,
V.,Fabrication of Al-SiC-B4C Metal Matrix Composite by Powder Metallurgy
Technique and Evaluating Mechanical Properties, Perspectives in Science (2016),
http://dx.doi.org/10.1016/j.pisc.2016.04.096
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Conflict of interest statement

Specify the Track Name and Number- (2)

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Fabrication of Al-SiC-B4C Metal Matrix Composite by Powder

Metallurgy Technique and Evaluating Mechanical Properties
2

Anil Kumar Bodukuri , Prof. K. Eswaraiah , Katla Rajendar and V. Sampath d

1&3

an

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Scholar, Department of Mechanical Engineering, Kakatiya University, Warangal506009 Mob No:+919700381439 anil.kucet@gmail.com.
2
Professor, Department of Mechanical Engineering Kakatiya institute of Technology
and Science, Warangal-506009

Abstract

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The applications of metal matrix composites are increasing day by day due to high strength to
weight ratio. In the present work Al- SiC-B4C metal matrix composite is prepared from sintering
of mechanically alloyed powder (ball milling) in powder metallurgy processes. Three different
combinations of compositions in volume fraction were chosen namely 90%Al 8%SiC 2%B4C,
90%Al 5%SiC 5%B4C and 90%Al 3%SiC 7%B4C. An attempt has been made to study the
characteristics of developed metal matrix composite. As increase in percentage of B4C the micro
hardness of the metal matrix composite has increased significantly. The microstructure of the
prepared metal matrix composite reveals the uniform distribution of particles in metal matrix.

Total Word Count=309

Bibliography
1. Muhammad Hayat Jakhio. Manufacturing of Aluminum composite material using stir
casting process vol.28 January 2011 IISN 0254-7821
2. A.Chennakeshava Reddy Matrix Al-alloys for silicon carbide particle reinforced metal
matrix composites vol. 3 December 2010 ISSN 0974-6846
3. S.Naher . Simulation of the stir casting process journal of material processing
technology 143-144(2003) 567-571
4. A.Riaz Ahmed . Drilling of hybrid Al-5%SiC-5%B4C metal matrix composites 2009
December, 871-889.
5. V.C.Uvaraja . Tribological characterization of stir cast hybrid composite Aluminum
6061 reinforced with SiC and B4C Particulates ISSN 1450 VOL. 76 NOV.2012.

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Tracks for Oral/Poster Presentation

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Track 1- Civil Engineering

Track 2- Mechanical & Metallurgical Engineering
Track 3- Electronics & Communication
Track 4- Electrical & Electronics Engineering
Track 5- Computer Science
Track 6- Bio-Technology & Food Technology
Track 7- Physics
Track 8- Chemistry & Chemical Engineering
Track 9- Mathematics
Track 10- Material Sciences

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*Manuscript

Fabrication of Al-SiC-B4C Metal Matrix Composite by Powder

Metallurgy Technique and Evaluating Mechanical Properties
Anil Kumar Bodukuri

Scholar, Department of Mechanical Engineering, Kakatiya University, Warangal-506009

Professor, Department of Mechanical Engineering Kakatiya Institute of Technology and Science,

Warangal-506009

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, Prof. K. Eswaraiah , Katla Rajendar and V. Sampath

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a, c &d

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Abstract

The applications of metal matrix composites are increasing day by day due to high strength to weight

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ratio. In the present work Al- SiC-B4C metal matrix composite is prepared from sintering of
mechanically alloyed powder (ball milling) in powder metallurgy processes. Three different
combinations of compositions in volume fraction were chosen namely 90%Al 8%SiC 2%B4C, 90%Al

5%SiC 5%B4C and 90%Al 3%SiC 7%B4C. An attempt has been made to study the characteristics of
developed metal matrix composite. As increase in percentage of B4C the micro hardness of the metal

matrix composite has increased significantly. The microstructure of the prepared metal matrix composite
reveals the uniform distribution of particles in metal matrix.

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Keywords: (Powder Metallurgy, composite material, Metal matrix, milling)

1. INTRODUCTION

For AMCs generally used fibers are SiC, B4C, Al2O3, graphite etc. [1]. The effect of SiC particle
reinforced MMCs is investigated by Chennakeshwar Reddy [3]. He prepared all MMCs with 20% SiC
reinforcement of different Al alloys which gave a modulus of elasticity of 68Gpa. Effect of SiC on Al
matrix was studied by varying weight fraction of SiC 5% 10% 15% 20% 25% 30%. The best results
were obtained at 45.5 BHN and 36Nm impact strength at 25% weight fraction [14]. sing this template
will enable you to prepare your paper in accordance with the instructions for authors for OP- 2005
papers with a minimal amount of manual styling and formatting. Al2O3 is also used as fiber material in
Al MMCs. Manufacturing process of Al MMCs reinforced with Al2O3 particles was investigated by
A.Wlodarczyk [17].Blending of aluminum alloy powder with ceramic particulate fibers is versatile
Special Issue- ICEMS-2016
* Corresponding author. Tel: 9700381439
E-mail: anil.kucet@gmail.com

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technique for production of AMCs [1]. Al MMCs reinforced with 5 and 10% (weight) B4C particles is
processed using powder metallurgy technique. Hardness values observed are 78 and 82 BHN. [9].
Powder metallurgy techniques have advantages over casting method by eliminating segregation.
Blending the mixture to achieve homogenous distribution of reinforcement into base alloy is key step of

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powder metallurgy. [10]. Al SiC composites are also processed using powder metallurgy technique.
Here 0.5% (wt.) of Mg is added as binder. [12]. Research was also conducted for hybrid Al MMCs. Al

followed by forging. This shown an hardness value of 83BHN.[11]

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2. EXPERIMENTAL WORK

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MMCs reinforced with SiC and graphite particles is fabricated using powder metallurgy technique

2.1. Powder Characterization

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The powders of the matrix material and fiber particles characters are examined. The composites
prepared consists Aluminum, Silicon carbide and Boron carbide materials. Characteristics of powders
like particle size distribution, apparent density, and tap density are determined. Particle size distribution
is obtained with sieve analysis setup. Sieve analysis equipment is shown in fig.1. It consists of number
of pans with standard mesh openings.. The sieve analysis setup as is to be vibrated for about 30min for
separation of powder according to particle size. Aluminum powder was analyzed for 500gm, silicon
carbide for 250gm and boron carbide for 500gm.

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2.2. Apparent Density

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By visual inspection of powders, BSS number of pans to be used for a powder is decided. Aluminum
powders particle size was determined by pans of BSS number 144, 100, 120, 200, lid. Silicon
carbide powders were also characterized using same size pans separately. Boron carbide powders
were characterized by using pans of BSS number, 52, 60, 85, 120, 200, and lid.

Apparent density of a powder refers to the weight of a unit volume of loose powder, usually
expressed in gm/cc. The apparent density is usually determined by pouring a mass of powder into a
container of known volume and measuring the weight of powder which completely fills the space.
Apparent density of aluminum, silicon carbide, boron carbide particles are tabulated here.
2.2. Tap Density

Powder density to be estimated of known mass is poured into the tube in the setup, and the powder is
tapped with the help of handle and cam provided. Volume change is noted for every 5taps. The greatest
increase in density (decrease in volume) occurs during the initial tapping period and eventually the
density (volume) becomes constant. This process of tapping is done for, aluminum, silicon carbide and
boron carbide individually. Graphs are plotted variation of tap density for number of taps which is
shown in graph 1. Density value, when the graph touches Y-axis, i.e when X=0, which means number of
taps is zero, indicates the apparent density of the powder.

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2 Balls and Powders

3 Attrition Mill

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1 Sieve Analysis

3.1 BLENDING/MIXING.

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Blending of the powders is achieved by Attrition mill as shown in fig.3 to obtain homogenous
mixture. An attritor consists of a cylindrical chamber in which a shaft with impellers is placed. When the
shaft moves, impeller agitates the steel balls, which in turn taps, vibrates the powder placed in the vial as
shown in Fig.2. Because of this tapping, vibration, impact forces and shear forces, powder particles get
cold welded and uniform distribution is achieved. Process variables employed in the present work,
milling speed of 200rpm and milling time of 2hrs is maintained, BCR of 5:1 is maintained for
homogenous mixture.
This process is repeated for all the three compositions and the powders are again characterized
for apparent and tap densities.
3.3 COMPACTING

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In the process of compacting first the dies are cleaned with acetone so that the powders dont get
contaminated. Then a paste of zinc stearate (Zn0) and acetone is applied to the dies, for easy removal of
green compact specimen. After applying the paste, composite powders are weighted to 15gm, and are
flowed into the dies individually. Cylindrical sample and tensile specimen dies are employed in the
work. After flowing powders into the die, compacting pressure is applied gradually to a range of
150MPa. When the force is applied, dies are fixed to the upper and lower punch. After proper
compaction, green specimens are ejected from dies and it is ready for sintering.
Green density is one of the important parameter which decides shrinkage of specimens during
sintering. Higher the green density lesser the shrinkage hence green densities are calculated for the
green compacted specimens.
3.4 SINTERING

The green compacts prepared are kept in the electric furnace of sintering setup. Nitrogen gas cylinder
is connected to the furnace in such a manner that the gas is first purified from moisture content and any
0
0
impurities. Then the furnace is gradually heated at the rate of 20 C/min, till 610 C temperature is
achieved, then the specimens are maintained at this level for 15min and then heat source is put off. The
specimens are furnace cooled till room temperature is achieved.

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Graph.1 density variations of different powders in different stages of P/M route

CONCLUSIONS

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3.5 METALLOGRAPHIC STUDIES: The sintered samples are first rough grinded, then polished
on emery papers, and is polished using diamond paste. Then the sample is etched with kellers reagent
Then the samples were examined under a microscope. The setup of microscope used and the
microstructure of samples are presented here,
VICKERS HARDNESS TEST
Mechanical properties of sintered samples are determined by hardness measurement. In present study,
micro hardness test or Vickers hardness test is adopted. Hardness values obtained by the Vickers test are
90%Al 5%SicC 5%B4C 22.36 VHN, 90%Al 8%SicC 2%B4C 21.02VHN and 90%Al 3%SicC 7%B4C
32.7

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1. The tendency to shrink during sintering seems to decrease with increase in apparent density.
2. The greatest increase in tap density occurs during the initial tapping period and eventually the tap
density becomes constant.

3. Tap density of boron carbide is more than silicon carbide which is more when compared to that
of aluminum

4. Tap density of 90%Al 5%SiC 5%B4C is greater than tap density of 90%Al 3%SiC 7%B4C
which is greater than that of 90%Al 8%SiC 2%B4C
5. Green density of 90%Al 8%SiC 2%B4C is greater than green density of 90%Al 5%SiC 5%B4C,
which is greater than that of 90%Al 3%SiC 7%B4C
6. Sintered density of 90%Al 3%SiC 7%B4C is greater than that of 90%Al 8%SiC 2%B4C is
greater than that of 90%Al 5%SiC 5%B4C
7. Hardness value of 90%Al 3%SiC 7%B4C is greater than that of 90%Al 5%SiC 5%B4C, is
greater than that of 90%Al 8%SiC 2%B4C
8. As the percentage of boron carbide is decreasing the hardness value is also decreasing

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REFERENCES

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1. Aluminum matrix composites: challenges and opportunities by M.K.SURAPPA ( vol.28, April

2003 pp.319-314)
2. Manufacturing of Aluminum composite material using stir casting process by MUHAMMAD
HAYAT JAKHIO (vol.28 January 2011 IISN 0254-7821
3. Matrix Al-alloys for silicon carbide particle reinforced metal matrix composites by
A.CHENNAKESHAVA REDDY (vol. 3 December 2010 ISSN 0974-6846)
4. Simulation of the stir casting process by S.NAHER ( journal of material processing technology
143-144(2003) 567-571)
5. Drilling of hybrid Al-5%SiC-5%B4C metal matrix composites by A.Riaz Ahmed( 2009
December, 871-889)
6. Tribological characterization of stir cast hybrid composite Aluminum 6061 reinforced with SiC
and B4C Particulates by V.C.Uvaraja (ISSN 1450 VOL. 76 NOV.2012)
7. Tribological potential of hybrid composites based on zinc and aluminum alloys reinforced with
SiC and graphite particles by Slobodan Mitrovic May 2011
8. Tribolgical behavior of alumina and SiC hybrid metal matrix composites by Y.Q.Wang
9. Al/B4C Composites with 5% and 10% wt. reinforcement content prepared by powder metallurgy
by Yusof Abdullah ( volume9 june 2012).
10. Production of boron carbide reinforced 2024 aluminum matrix
composites by mechanical
alloying by Cun-Zhu vol.48 2007 pp.990to995.
11. Development of aluminum based hybrid composites for heavy duty application by M.Asif (vol.
10 2011 pp1337-1344)
12. Fabrication of Al-SiC composites through powder metallurgy process and testing of properties
by Rajesh Purohith (vol.2 may 2012 pp.420-437)
13. Parametric studies on the tribological behavior of aluminum matrix hybrid composites by
Suresha.S (vol.4 Jan. 2010)
14. Development of aluminum based silicon carbide particulate metal matrix composites by Manoj
Singla (vol.8 pp.445-467 2009)
15. A review of recent applications and future prospectus of hybrid composites by Gururaja, vol.1
ISSN: 2231-2307 Jan. 2012)
16. Hybrid metal matrix composites and further improvement in their machinability by
Harish.K.Garg (May 2012 ISSN 2278-5299)
17. Manufacturing of aluminum matrix composites reinforced by alumina particles by
A.Wlodarczyk-Fligier(vol.27 Mar.2008)
18. Experimental investigations on machining charecters of Al6061 MMCs processed by EDM by
Velmurugan (vol.3 2011 pp. 87-101)
19. Development of iron based brake friction MMC used for military aircraft application by a new
P/M route by M.Asif (vol.10 2011, pp. 639-705)
20. Material selection method in design of automotive brake disc by M.A.Maleque (vol.3 July 2010)
21. Extrusion characterizes of Al/SiC by different manufacturing process by V.Jayaseelan (vol.1
Nov.2010 ISSN 0976-4259)
22. Processing of silicon carbide boron carbide- aluminum composites by Gursoy Arslan (2009)

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