Studies On Microstructure and Mechanical Properties of Flyash Reinforced Al2024 Composites

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Volume 1, Issue 3, Mar 2017 Available at: www.dbpublications.org
International e-Journal For Technology And Research-2017
Studies On Microstructure And Mechanical

Properties Of Flyash Reinforced Al2024
Composites
Sathisha N 1, Tejas G2, Praveen kumar R A 3, Manjunath Vajjaramatti4, Avinash L5
UG student, Department of Mechanical Engineering, NMIT Bengaluru, Karnataka, India1, 2, 3, 4
Assistant professor, Department of Mechanical Engineering, NMIT, Bengaluru, Karnataka, India 5
Abstract: composites (MMCs) possess significantly improved

The aim is to study the mechanical property and properties including high specific strength; specific
Tribological behavior of Al2024/flyash composite modulus, damping capacity and good wear resistance
with various weight fractions (3%, 6%, 9%) were compared to unreinforced alloys. There has been an
prepared by squeeze casting method. The average increasing interest in composites containing low
particle size of flyash is 45-50 m. In addition, Al2024 density and low cost reinforcements. Among various
alloys were cast for comparison purposes. discontinuous dispersoids used, fly ash is one of the
Microstructure, hardness and tensile properties of
most inexpensive and low density reinforcement
these composites were evaluated and compared with
as-cast alloy and the composites. In addition, available in large quantities as solid waste by-product
tribological properties of these composites were during combustion of coal in thermal power plants.
evaluated using a Pin-on-Disc apparatus with different Hence, composites with fly ash as reinforcement are
parameters of varying loads of 10N and 50N and(with likely to overcome the cost barrier for wide spread
constant parameters such as time of 10 minutes, applications in automotive and small engine
sliding velocity of 3 m/s, track diameter of applications. It is therefore expected that the
150mm).The microstructure of the composites shows
incorporation of fly ash particles in aluminium alloy
homogenous distribution of flyash particles in the Al
matrix composite. The wear and mechanical properties will promote yet another use of this low-cost waste by-
of composites improve with increasing the weight product and, at the same time, has the potential for
fraction of flyash. The aim of present study is to conserving energy intensive aluminium and thereby,
evaluate the effect of microstructure, mechanical and reducing the cost of aluminium products [1-3].
tribological properties of aluminium alloy Now a days the particulate reinforced aluminium
Al2024/flyash metal matrix composites matrix composite are gaining importance because of
their low cost with advantages like isotropic properties
Keywords: Al2024 alloy, Flyash, microstructure,
and the possibility of secondary processing facilitating
Hardness, Wear.
fabrication of secondary components. Cast aluminium
matrix particle reinforced composites have higher
specific strength, specific modulus and good wear
1. INTRODUCTION resistance as compared to unreinforced alloys [4-
Conventional monolithic materials have 6].While investigating the opportunity of using fly-ash
limitations in achieving good combination of strength, as reinforcing element in the aluminium melt,
stiffness, toughness and density. To overcome these R.Q.Guo and P.K.Rohatagi [7-8] observed that the
shortcomings and to meet the ever increasing demand high electrical resistivity, low thermal conductivity
of modern day technology, composites are most and low density of fly-ash may be helpful for making a
promising materials of recent interest. Metal matrix light weight insulating composites. The particulate
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composite can be prepared by injecting the reinforcing pure aluminium was also melted and casted. Then
particles into liquid matrix through liquid metallurgy particle size and chemical composition analysis for
route by casting [9-10]. Casting route is preferred as it fly-ash was done. Mechanical, physical and wear
is less expensive and amenable to mass production. properties of the composite were evaluated and
Among the entire liquid state production routes, stir compared with the commercially pure aluminium.
casting is the simplest and cheapest one. The only Moreover, the composite was characterized with the
problem associated with this process is the non help optical microscope, hardness test and tensile
uniform distribution of the particulate due to poor wet tester.
ability and gravity regulated segregation. Mechanical
properties of composites are affected by the size,
shape and volume fraction of the reinforcement,
matrix material and reaction at the interface. These
aspects have been discussed by many researchers. 2. OBJECTIVES
Rohatgi [1] reports that with the increase in volume The need of a systematic study of various mechanical
percentages of fly ash, hardness value increases in Al properties of fly ash reinforced Al2024 composites.
fly ash (precipitator type) composites. He also reports This study can lead one to explore the possibility of
that the tensile elastic modulus of the ash alloy identifying the use of these composites as
increases with increase in volume percent (310) of fly tribomaterials especially for automobile applications.
ash. Aghajanian et al. [11] have studied the Al2O3 Therefore the work taken up had the following
particle reinforced Al MMCs, with varying particulate objectives:
volume percentages (25, 36, 46, 52 and 56) and report 1. Fabrication of Al2024/ fly ash composites by
improvement in elastic modulus, tensile strength, Liquid metallurgy route.
compressive strength and fracture properties with an 2. Microstructure characterization of the
increase in the reinforcement content. The interface composites using optical microscopes.
between the matrix and reinforcement plays a critical 3. Evaluation of mechanical properties of the
role in determining the properties of MMCs. composites.
Stiffening and strengthening rely on load transfer 4. Comparing the results of mechanical
across the interface. Toughness is influenced by the properties of as-cast alloy with composites.
crack deflection at the interface and ductility is 5. Validating the experimental results with
affected by the relaxation of peak stress near the Design of Experiments
interface [12-14]. Extensive studies on the tribological 6. Drawing Conclusion based on the obtained
characteristics of Al MMCs containing reinforcements result.
such as SiC and Al2O3 is available in the literatures The present study is thus aimed at producing MMCs
[15-18]. However, reports on friction and wear with Al2024 as the matrix material with fly ash as
characteristics of fly ash reinforced AMCs are very reinforcement processed by stir casting route of these
limited. Rohatgi has reported that the addition of fly composites in order to obtain mechanical properties
ash particles to the aluminium alloy significantly suitable for a wide range of engineering applications.
increases its abrasive wear resistance. He attributed the 3. METHODOLOGY
improvement in wear resistance to the hard
aluminosilicate constituent present in fly ash particles.
In the present work, fly-ash which mainly consists of
refractory oxides like silica, alumina, and iron oxides
is used as reinforcing phase. Composite was produced
with 10% fly-ash as reinforcing phase. Commercially

Figure(a),(b),(c),(d)shows the micro photographs

of both the matrix alloy Al2024 and its composites
Fig. Flow Chart of Experimental Work system. Figure (b). (c), (d) revealed that presence of
fly ash particles in Al2024 alloy matrix and further
4. IMPLEMENTATION confirms that there was a uniform distribution of fly
2024 is typically used in:
1. Architectural applications ash particles in the base matrix of Al2024 alloy .The
2. Extrusions images clearly shows that there were no voids and
3. Window frames discontinuities in the composite and also there was a
4. Doors
5. Shop fittings good interfacial bonding between the fly ash particles
6. Irrigation tubing and matrix materials.
7. In balustrading the rails and posts are
Hardness Test Result:
normally in the T6 temper and formed elbows
and bends are T4. T4 temper 2024 aluminium
is also finding applications in hydro formed
tube for chassis.
5. OUTCOMES
1. It is widely used in aircraft structures.
2. The material is susceptible to thermal shock.
3. Good improvement in mechanical properties.
4. High strength to weight ratio.
Optical Microstructural Characterization

Fig: UTS values of Al2024 alloy and its Composites
From above Figure it is found that Ultimate tensile

strength increase with increasing Flyash content in the
Fig: Hardness values of Al2024 alloy and its material. As compared to as-cast (AL2024 alloy), 3%
composites Flyash addition shows an increase of 30.16 MPa
(24.45%). In contrast 6% and 9% Flyash addition
From above Figure it is found that hardness increase shows an increase of 39.32 MPa (31.88%) and 45.95
with increasing Flyash content in the material. As MPa (37.25%) respectively. The improvement in
compared to as-cast (AL2024 alloy), 3% Flyash strength in casted composites may be ascribed to
uniform distribution of reinforcement (Flyash) in the
addition shows an increase of 5.56 BHN (11.44%).
matrix material. The fly ash particles help in
In contrast 6% and 9% Flyash addition shows an strengthening the matrix, acting as barriers to the
increase of 17.35 BHN (35.72%) and 26.32 BHN dislocations when taking up the load applied.
(54.20%) respectively. The improvement in hardness
in casted composites may be ascribed to uniform Table : YTS of Al2024 alloy and its Composites
distribution of reinforcement (Flyash) in the matrix

material
TENSILE TEST RESULTS:

UTS of Al2024 alloy and its Composites
Fig: YTS values of Al2024 alloy and its Composites
From Figure it is found that Yield tensile
strength increase with increasing Flyash content in the
material. As compared to as-cast (AL2024 alloy), 3%
Flyash addition shows an increase of 30.16 MPa
(28.34%). In contrast 6% and 9% Flyash addition


shows an increase of 39.32 MPa (35.31%) and 45.95 Dry sliding wear tests were conducted as per
MPa (39.24%) respectively. The improvement in ASTM-G99 norms. The wear rate was based on the
strength in casted composites may be ascribed to average value of 3 tests. Two loads of 10N and 50N at
uniform distribution of reinforcement (Flyash) in the a sliding velocity of 3.0m/sec and sliding distance of
matrix material. The fly ash particles help in 1800m. During the test the following specifications
strengthening the matrix, acting as barriers to the were used:
dislocations when taking up the load applied.
Table : Specifications used in wear studies
Table : Ductility of Al2024 alloy and its
Composites
CALCULATIONS:
1. SlidingVelocity(V)=
3.= ..(i)
Fig: Ductility values of Al2024 alloy and its

Composites Where, D is track diameter in mm, N is speed in rpm
From Equation (i) N=382 rpm
The results of the ductility test carried out on
2. SlidingDistance(S)
all the MMCs taken up for investigations are shown in
Table The percentage decrease in ductility with = = ..(ii)
different weight fractions of reinforcements is also
given. Figure shows the effect of the weight fraction of Where, T is time in minutes.
fly ash on the ductility of Al2024 alloy matrix by From Equation (ii) S=1800meters
reinforcements. Figure shows that the ductility of the
composite decreased with the increase in weight
fraction of the fly ash. This may be due to the hardness
of the fly ash particles or clustering of the particles.
WEAR STUDIES


Fig(c): Effect of load on wear (m) of the Al2024
Table: Wear behavior of Al2024 alloy and its Composites
alloy and its Flyash composites
(Sliding Velocity : 3.0m/s, Sliding distance: 1800m,
load: 10 and 50N)
From the above figs it can be see that as the
load increases the wear rate increases. Maximum wear
rate can be observed in Al2024 alloy and least wear
rate is observed in As-cast alloy with 9% alumina. The
decrease in wear rate may be attributed to the Flyash
particles which act as load bearing in the Al2024
matrix and resist wear. Due to the absence of Flyash
particle as reinforcement in as-cast alloy it has a
maximum wear rate. The wear rate in composites is
less due to the fact that ploughing of the fly ash
becomes difficult as the particle size increases.
CONCLUSION
From the test conducted I order to determine the
Fig(a): Wear graphs of Al2024 alloy and its
mechanical properties of flyash reinforced Al2024
AL2024 alloy +3% Flyash Composites composites of different weight fractions of the
respectively at 10N and 50N respectively reinforcement, it was found that
i. flyash particles as reinforcements helped in
increase of UTS of Al2024 from 110.02 MPa
as per the following
3%flyash141.20MPa(46%
increases)
6% flyash-148.87MPa(46% increases)
9% flyash-153.20MPa(46% increases)
It can be noted that UTS of the composite
Fig(b): Wear graphs of Al2024 alloy +6% Flyash increased with increase in weight fraction of flyash
and AL2024 alloy +9% Flyash Composites ii. flyash particles as reinforcement helped in the
respectively at 10N and 50N respectively
increasing the hardness of Al2024 from
48.6BHN as per the following
3%flyash54.12BHN (21% increase).


iii. The increase in weight fraction of the flyash [5] Basavarajappa, S., Chandramohan, G.,
Subramanian, R., Chandrashekhar, A. (2006). Dry
reinforcement had a significant increase in
sliding wear behaviour of Al2024/ SiC metal matrix
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its composites, it was observed that:
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Flyash particles as a reinforcement helped in
Production Engineering and Automation, Wroclaw
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University of Technology, Poland
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