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Enhancement of Wettability of Aluminum

Based Silicon Carbide Reinforced Particulate
Metal Matrix Composite

Article in High Temperature Materials and Processes · April 2014

DOI: 10.1515/htmp-2014-0043

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V. K. Singh*, Sakshi Chauhan, P. C. Gope and A. K. Chaudhary
Enhancement of Wettability of Aluminum Based
Silicon Carbide Reinforced Particulate Metal
Matrix Composite
Abstract: Lately, materials research has shifted to compos-
ite materials from monolithic, adjusting to the global need
for light weight, low cost, quality, and high performance
in structural materials. Every effort aims to develop a
­material which can be appropriate for various industry
and machinery purpose. In the present study, a modest
attempt has been made to develop cast aluminum based
silicon carbide (SiC) particulate metal matrix composite
(MMC) and worked upon to raise the wettability factor
between the matrix and dispersion phase. Magnesium
(Mg) is used as wetting agent. It works by scavenging the
oxygen from dispersoids surface and thinning the gas
layer around dispersoids and this is done by forming
MgO  or MgAl2O4 or both according to concentration of
Magnesium added. Mg2Si is the compound responsible
for  strengthening. The combination of aluminum and
magnesium seems to have synergetic effect on wetting
and give appropriate strength. All mechanical properties
obtained are well correlated with microstructure obtained
by Scanning electron micrograph. Differential thermal
analysis (DTA) and thermo gravimetric analysis (TGA) also
justified the results obtained in present investigations.
Keywords: metal-matrix composite, mechanical proper-
ties, microstructure, TGA/DTA
PACS® (2010). 81.05.Bx
DOI 10.1515/htmp-2014-0043
Received March 7, 2014; accepted April 4, 2014;
published online June 10, 2014
*Corresponding author: V. K. Singh: College of Technology, G. B. P.
University of Agriculture and Technology, Pantnagar, Uttarakand,
India. E-mail: vks2319@yahoo.co.in
Sakshi Chauhan, P. C. Gope, A. K. Chaudhary: College of
Technology, G. B. P. University of Agriculture and Technology,
Pantnagar, Uttarakand, India
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High Temp. Mater. Proc. 2014; aop
1 Introduction
Conventional monolithic materials have limitations with
respect to achievable combinations of strength, stiffness,
and density. In order to overcome these shortcomings
and to meet the ever-increasing engineering demands of
modern technology, metal matrix composites are gaining
importance. In recent years, discontinuously reinforced
aluminum based metal matrix composites have attracted
worldwide attention as a result of their potential to replace
their monolithic counterparts primarily in automobile and
energy sector [1].
Metal matrix composites (MMCs), such as SiC particle
reinforced Al, are one of the widely known composites
because of their superior properties such as high strength,
hardness, stiffness, wear and corrosion resistance. SiC
particle reinforced Al based MMCs are among the most
common MMC and available ones due to their econom­
ical  production. They can be widely used in the aero-
space,  automobiles industry such as electronic heat
sinks, automotive drive shafts, or explosion engine com-
ponents. The physical and chemical compatibility be­
tween SiC particles and Al matrix is the main concern
in  the preparation of Al-SiC composites. Therefore, the
particle reinforced metal matrix composites can be syn-
thesized by such methods as powder metallurgy (PM),
casting. Different method results in different properties.
In this study, the liquid route method is carried out to
prepare SiC particle reinforced Al MMC. The effect of
weight percentage of the reinforced particles on mechan­
ical behavior such as hardness and microstructure of the
composites can be investigated. Disadvantage related to
casting is the uniform distribution of ceramic particle
­reinforcements and on the other hand, the liquid state
process maximizes the r­ eactions between the metal matrix
and the ceramic reinforcement, and thus reduces the
bonding between reinforcement and the matrix, non
­wettability of ceramic particles by liquid aluminum, seg-
regation of particles, higher porosity level and extensive
inter-facial reaction due to higher processing tempera-
ture. While fabricating Al-SiC composite, Al does not react
with SiC particles up to its melting point i.e 660 °C, but
2   V. K. Singh et al., Enhancement of Wettability of Aluminum Metal
molten Al reacts promptly with SiC, giving different
­products depending on temperature. Needle shape, very
brittle and hydrophobic compound Al4C3, is formed during
temperature range of 650 °C to 920 °C. This compound
­increases the material property to great extent even it
­increases wettability to some extent, but because of this
brittleness, hydrophilic nature and other deleterious
properties crack propagate through the interface of com-
pound without transferring load to the reinforcement
­particle. This gives idea to further work for better improve­
ment. Wettability of the particles can be improved
by  coating the particles with metals such as Ni and Cu,
or  addition of active elements such as Mg into liquid
­aluminum or preheating of the particles before addition
into liquid aluminum [2]. The most conventional method
of production of composites by casting route is vortex
method, where the ceramic particles are incorporated
into  liquid aluminum and then stirring of the liquid
melt  is  done. Wettability improvement is based on three
parameters (i) increasing the surface energies of the
solid,  (ii) decreasing the surface tension of the matrix
alloy (iii) decreasing of the solid/liquid interfacial energy
[3, 4].
Magnesium is efficient wetting agent since it fulfill
above three conditions. Magnesium improves wettability
between Al and SiC particle by thinning the gas layer i.e by
reducing the SiO2 layer on the surface of SiC [5]. Since Mg
is powerful surfactant therefore it helps in scavenging the
oxygen from dispersoids surface by forming MgO and
MgAl2O4 according to concentration of Mg hence increas-
ing the surface energy of solid [6, 7]. Surface tension of Mg
(0.577 N/m) is lower than Al (0.871 N/m) at about 660 °C
hence, the addition of Mg reduces the surface tension of
the molten Al. Decrease in interfacial energy is assured by
having interfacial reaction to occur and producing reac-
tion production like Mg2Si [8]. Addition of Mg into the
liquid metal reduces the surface tension [9] and there
by  avoids the rejection of the particles from the melts.
Without addition of Mg recovery of the particles into the
melt is quite low. However, the chemistry of the particles
of an Al alloy is changed with addition Mg that can be
­deleterious to the mechanical properties of the compos-
ites if not properly controlled. Amount of Mg is needed to
be controlled for proper effect; too high concentration will
lead to agglomeration of particles since Mg addition to Al
reduces casting fluidity [10], it even ceases Mg effect and
makes Al and SiC to participate in reaction and form Al4C3
at interface; this is a brittle phase and sensitive to mois-
ture. Leads to depletion in properties as Al-Al4C3 inter-
face is energetically weak which is due to covalent bonds
[11].
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Now a days the particulate reinforced Al matrix com-
posite are gaining importance because of their low cost
with advantage like isotropic properties. The strengthen-
ing of aluminum alloys with dispersion of fine ceramic
particulate composite materials were developed as an
­alternative of unreinforced alloy, for obtaining materials
with high stiffness (high strength/modulus and low den­
sity) with special interest for the wear resistant and struc-
tural application [12]. The dispersion strengthened alloys
can be classified, based on the size and volume % of
­particles uniformly dispersed in the matrix. Aluminum
alloys reinforced with ceramic particles exhibit superior
mechanical properties to unreinforced Al alloys and hence
are candidate for engineering applications. The alumi-
num metal matrix composites are produced either by
casting route or by power metallurgy. The former has
the  advantages of producing the composites as lower
cost  of production and possibility of producing larger
components.
There are mainly two major areas used in the present
investigation i.e. material science, material testing and
microscopic investigation. Material science and testing is
used to develop the composite material and determine the
mechanical properties. Microscopic investigation is used
to determine the microstructure of the developed hybrid
composite material. It is also used to see dispersion and
interaction of the filler material within the matrix. Fur­
ther  thermal gravimetric (TG) test determine weight loss
of  sample during heating. DTA provides the detailed
knowledge of physicochemical changes occurring during
heating.
2 Material and method
2.1 Materials
2.1.1 Matrix materials
Aluminum is used as matrix material since it has the most
favorable properties for being a matrix. Aluminum used
has a composition shown below in Table 1 as determined
on the basis of energy dispersive spectrometry with equip-
ment JSM-6610lV.
Table 1: Composition of aluminum used as matrix material
Element Al C Ag Fe Mg Si Others
wt% 92.54 1.00 1.96 0.97 0.77 0.35 2.41
  V. K. Singh et al., Enhancement of Wettability of Aluminum Metal   3
2.1.2 Reinforcing material
Silicon carbide used is Bluish Black fine powder of mesh
size 220 mesh produced at Central Drug House (P) Ltd.
Generally SiC powder is colorless but it has its bluish
black color due to presence of iron, manganese and copper
impurities. Magnesium used as wetting agent is produced
at Otto Kemi, Mumbai. Mg used is 99% pure. Its color
varies from silvery to gray color.
2.2 Methodology
The composites have been prepared by the conventional
casting. Raw Aluminium has been melted in a crucible
by  heating in a coal fired furnace at 800 °C. Particles of
silicon carbide have been preheated up to a temperature
of 1100 °C to make their surfaces oxidized. Crucible used
for pouring of composite slurry in the mold has been also
heated up to 760 °C. The stirrer has been preheated before
immersing into the melt, located approximately to a depth
of 2/3 height of the molten metal from the bottom. The
furnace temperature has been first raised above the liqui-
dus temperature of aluminium near about 760 °C to melt
the aluminum completely and then cooled down just
below the liquidus to keep the slurry in a semi-solid state.
Particles of silicon carbide have been introduced into the
molten metal in a semi solid state and manual mixing was
carried out for 10 minutes. Manual mixing has been used
because it was very difficult to mix using automatic device
when the alloy was in a semi-solid state. After sufficient
manual mixing has been done, the composite slurry was
reheated to a fully liquid state and then automatic me-
chanical mixing was carried out for about 10 minutes at a
normal stirring speed. After stirring process, mixture has
been poured in the mould to get desired shape of the com-
posite. The weight percentages of silicon carbide particles
have been varied as 5, 10, 15, 20, 25 and 30 for each com-
posite. Further in order to reduce floating of silicon carbide
particles on the molten surface and to increase wettability
between the contact surfaces, magnesium has been added
in small amount (1 wt%) in silicon carbide particles. Air
cooling has been opted for solidification of the casted
composites. Similar procedure, as explained above has
been adopted to make the composites having particles of
silicon carbide and magnesium. Size of the casted com-
posites was 150 mm long, 120 mm wide and 12 mm thick.
Before actual melting is started, furnace is prepared by
putting sufficient amount of coal and air draft is been
­provided after aluminum is completely melt and reached
800 °C, SiC is added to the melt. This mixture is then
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stirred using mechanical stirring with 500 RPM. Then,
mixture is poured to the mould.
3 Results and discussions
3.1 Scanning electron micrograph
The state of dispersion of reinforcing particles into the
metal matrix plays a significant role on the mechanical
properties of the composite. SEM can be used to evaluate
the particle dispersion in the composite. Even the mode of
fracture can be understood by the micrograph. Figure 1(a)
shows the micrograph of aluminum at 55×. SEM observa-
tion of fractured matrix of aluminum consists of dimpled
morphology, elongated grain and fracture along the grain
boundaries. All these behavior are the evidence of natural
ductile fracture mode.
SEM was carried out for composite containing differ-
ent weight percentage of silicon and 1% magnesium to
evaluate the particle matrix interface and dispersion of
the silicon particle in the aluminum matrix. The presence
of SiC in the matrix produces small grain size. At 55×
­aluminum with no SiC has large grain size while the grain
size of composite with various wt% of SiC has smaller
grain size. Reducing grain size has positive effect on
various mechanical properties like machinability, fatigue
properties etc.
Figures 1(b) to 1(d) shows the some SEM micrographs
of different composite material investigated in the present
work. In all the cases, good dispersion of silicon carbide
particle in the aluminum matrix has been observed.
Figure 1(b) shows the SEM micrograph of aluminium have
15 wt% of SiC particles at 55×. No clustering seen is this
micrograph but in the case of 30 wt% of SiC particle
­reinforcement in Al, the clear clustering is seen as white
portion. In Fractured surface of composite essentially
consist of bimodal distribution of dimples, large sized
dimples for particulate fracture while, small one are asso-
ciated with ductile fracture of matrix material. Even pres-
ence of Al3C4 which is black needle shape compound can
be markedly seen in Al composite with 30 wt% of SiC as
seen in Figure 1(c).
In case of wettability, fractured surface is smooth in-
dicating particulate fracture rather than decohesion of
particle from matrix material i.e interface strength domi-
nates and composite fail through particulate fracture.
But  in case of 15 wt% of SiC and 1 wt% of Mg in Al as
shown in Figure 1(d), particle clustering and agglomera-
tion result in partial ductile and particle brittle fracture.
4   V. K. Singh et al., Enhancement of Wettability of Aluminum Metal

Fig. 1: (a) Scanning micrograph of Al. (b) Scanning micrograph of Al composite with 15 wt% of SiC. (c) Scanning micrograph of Al composite
with 30 wt% of SiC. (d) Scanning micrograph of Al composite with 15 wt% of SiC and 1 wt% of Mg

Since, somewhere presence of SiC is extreme and some-
where no SiC can be found therefore dislocation lines
move freely in the matrix. Hence, strength of material de-
creases to great extent.
3.2 Differential thermal analysis and thermo
gravimetric analysis (DTA and TGA)
Peak on DTA curve represent phase transformation during
heating or cooling cycle. SiC particles have lower thermal
conductivity and lower heat of diffusivity than that of
­aluminum i.e. it store stores heat rather than conducting.
Therefore, in Al-SiC composite temperature of particles is
always somewhat higher than that of liquid alloy. The
hotter SiC particles heat up the Al particle in their sur-
rounding and thus delayed complete solidification of the
composite. The more the particle of SiC is added, the more
is delay in solidification.
The DTA shows endothermic peak between 650 °C to
665 °C and represent phase transformation from solid to
liquid (melting). There is not much change in melting point
because both phase (matrix and reinforcement) have their
own identity in the material and exist as free state. As the
melting point of aluminum (660 °C) is reached during
heating, matrix material starts softening and then pro-
ceeds to melting leaving SiC in the melt. Small change in
heat of fusion can be seen, due to presence of SiC. Com-

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  V. K. Singh et al., Enhancement of Wettability of Aluminum Metal   5
Table 2: Melting point and heat of fusion of various composition of
composite
S. no. % Composition Melting Heat of fusion
point (°C) (mj/mg)
1 Al 657 149
2 Al + 5% SiC 664 148
3 Al + 25% SiC 663 155
4 Al + 15% SiC + 1% Mg 664 157
5 Al + 10% SiC + 1% Mg 658 158
posites do not melt at a single temperature; rather they
melt on range of tempera Small change in heat of fusion
can be seen, due to presence of SiC as shown in Table 2.
Composite starts melting at solidus temperature while
melt completely at liquidus temperature.
Figure 2(a) represents the DTA and TGA for Al and
Figure 2(b) represents the differential thermal analysis
and thermo gravimetric curve for Al composite with 10
wt% of SiC with 1 wt% of Mg. These curves provide thermal
behavior of composite during heating cycle in air at the
rate of 1000 °C. The initial decrease in mass of every
sample upto 100 °C is due to loss of moisture. While
further slight loss in mass is due to decomposition of ma-
terial on increase in temperature. Somewhere increase in
mass can be seen which is due oxidation of composite.
3.3 Tensile tests
The mechanical properties of the aluminum, aluminum-
silicon and aluminum–silicon-magnesium composite ma-
terials were determined by 100 kN ADMET make servo
controlled universal testing machine at cross head speed
of 1 mm/min under displacement control mode. The re­
sults are presented in Figures 3 and 4.
The tensile stress-strain curves for aluminum and alu-
minum based silicon carbide composites containing 5, 10,
15, 20, 25 and 30 wt% of silicon carbide are shown in
Figure 3. Ultimate tensile strength of aluminum composite
keeps on increasing with addition of SiC reinforcing parti-
cles due to dispersion hardening but, after 25 wt% of SiC
decrease in strength is seen due to clustering of reinforc-
ing particles as white portion are present in SEM photo
graph shown by Figure 1(c). In present investigation, ulti-
mate strength of Al base metal is found to be 32 MPa
which is increased to 88.46 MPa at 25 wt% of SiC. There­
after decrease in strength is seen due to clustering of SiC
particles.
The tensile stress-strain curves for aluminum based 5,
10, 15 wt% of SiC composite material containing 1 wt%
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magnesium are shown in Figure 4. Present investigation
involve enhancement of wettability of the composite by
addition of 1 wt% magnesium. Magnesium behaves like
surfactant and scavenging the oxygen from SiO2 by oxida-
tion and formation of MgO and MgAl2O3 due to this fusion
temperature increases as compared to Al composite with
SiC as given in Table 2. Residual silicon element com-
bines  with magnesium to make Mg2Si. This whole pro­
cess increases strength of composite further by improving
bonding or intimacy of liquid aluminum with SiC parti-
cles. The addition of 1 wt% Mg increased the ultimate
tensile strength to large extent. 5 wt% SiC in the Al matrix
gives strength of 69 MPa while strength increased to 84
MPa due to addition of 1 wt% Mg. Similarly Al and 10 wt%
SiC composite result in strength of 72 MPa while 1 wt%
Mg  in that upgraded it to 104 MPa. Unlikely, composite
of  15 wt% SiC with 1 wt% Mg resulted in decrement of
strength to 87 MPa, this is due to clustering and agglomer-
ation of particle and formation of Al3Mg2 as seen in SEM
micrograph in Figure 1(d). Further investigation of com-
posite with 20 wt% SiC and 1 wt% Mg leads to the fact that
no more casting is possible because clustering of particle
occurred to such extent that fluidity of liquid melt is
reduced and its moulding is not possible.
Figure 5 shows the percentage increase in ultimate
tensile strength of various composite compared to parent
Al metal used. Ultimate tensile strength of aluminum
composite keeps on increasing with addition of SiC rein-
forcing but, after 25 wt% of SiC decrease in strength is
seen due to clustering of reinforcing particles. On applica-
tion of stress, dislocation motion is impeded by particles
of silicon carbide in the composite, which are not present
in pure material, hence increase in strength occurs. On
further increase in stress to enough level dislocation lines
tears and move through the distance between two rein-
forcing particles. Therefore the more is the amount of SiC
particle, the more will be the stress required to tear the
dislocation line. After 25 wt% of SiC particles clustering
occurs as shown in Figure 1(c) and hence dislocation ex-
perienced no hindrance.
Figure 6 compares effect of addition of Mg on Al-SiC
composites on ultimate strength of Al composite. On
adding just 1 wt% of Mg to 5 wt% of SiC, ultimate strength
increases from 69 MPa to 84 MPa, which is nearly equal to
strength observed in the case of 25 wt% of SiC in Al matrix.
While, adding 1 wt% Mg to 10 wt% SiC produce ultimate
strength of 104 MPa which is more than three times of
base Al metal having strength of 32 MPa. Magnesium plays
a vital role in strengthening, but it also decreases fluidity
of the melt during casting and starts clustering on further
addition to 15 wt% of SiC.
6   V. K. Singh et al., Enhancement of Wettability of Aluminum Metal

Fig. 2: (a) DTA and TGA of Al. (b) TGA and DTA of Al composite with 10 wt% of SiC with 1 wt% of Mg

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  V. K. Singh et al., Enhancement of Wettability of Aluminum Metal   7

Fig. 6: Effect of adding 1 wt% Mg to Al-SiC composite on ultimate

Fig. 3: Stress-strain curve of Al and Al based composite with various
strength
wt% of SiC

Fig. 7: % elongation of various compositions of SiC and Mg in Al

Fig. 4: Stress-strain curve of Al based composite with various wt% matrix
of SiC and 1 wt% of Mg

Figure 7 shows the variation of ductility of various

composites. Materials with more than 5% of elongation
are known to be ductile material. Above figure explains
that all composite fabricated are ductile whereas compos-
ite with 30 wt% SiC and 15 wt% SiC with 1 wt% Mg are
brittle in nature. Elongation is different for different gauge
length. Ductility is of major concern because it has its
direct effect on toughness of the material.

3.4 Hardness

Hardness values measured on the Rockwell B-Scale show­

ing the effect of weight percentage of silicon carbide and
1 wt% of magnesium on the hardness values of aluminum
Fig. 5: % increase in ultimate strength of various composites from composite are shown in Figure 8(a) and 8(b). Figure 8(a)
base Al metal and 8(b) shows hardness of the fabricated composite

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8   V. K. Singh et al., Enhancement of Wettability of Aluminum Metal
Fig. 8: (a) Variation in Hardness of the composites with wt% of SiC.
(b) Hardness of the composites v/s wt% of SiC with 1 wt% of Mg
made of aluminum and 25 wt% of SiC has hardness of 59
HBR while hardness of composite with 10 wt% of SiC and
1 wt% of Mg is maximized and is equal to 64 HBR.
The results as indicated in Figure 8(a) show the in-
creasing trend of hardness with increase in weight per-
centage of SiC up to 25% weight fraction. Beyond this
weight fraction the hardness trend started decreasing as
SiC particles interact with each other leading to clustering
of particles and consequently settling down. Eventually
the density of SiC particles started decreasing locally
thereby lowering the hardness. Directly below the inden-
tation the density of the particles increased locally, com-
pared to regions away from the depression. The hardness
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increases with the amount of silicon and the presence of
1  wt% of Mg just aids to the hardness. But clustering of
particles affects the hardness to extent of concern.
4 Conclusions
The results indicate that the mechanical properties of the
composite, including tensile strength and hardness are
enhanced by the increment of the weight fraction of rein-
forcing phase but the elongation of the composite de-
creased as the reinforcing phase increased. This is mainly
due to the brittleness of the SiC particles which act as
micro void initiator. The Ultimate tensile strength of the
composites increases, on increase in wt% of SiC. Maximum
strength of 88 MPa is achieved on 25 wt% of SiC which can
be further increased to 104 MPa on addition of 1 wt% of
Mg by increasing of wettability of Al composite.
Funding: The authors express their gratitude and sincere
thanks to Dean, College of Technology, GBPUA&T, Pant-
nagar for providing finance to carry out this research work
smoothly.
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