Abstract

In this review paper, the Properties obtained from Metal Matrix Composites of
Aluminium by Stir Casting process discussed from the experiments conducted by various
authors. This paper shows a few reinforcements like Silicon Carbide, Titanium Boride,
Titanium Carbide, Fly ash, Aluminium oxide reinforced with Aluminium as base metal. The
Metal Matrix Composites of manufacturing and forming techniques is compared for the
selection of best technique. The properties obtained from various reinforcements is discussed
separately. The methodology of selected technique is discussed step by step with all
depending factors. The effect of addition on different reinforcements in aluminium alloy
highlighting their merits and demerits. Effect of different reinforcement on AMCs on the
mechanical properties like tensile strength, strain, hardness, wear and fatigue is also
discussed in detail. Major applications of different AMCs are also highlighted in this work.

Introduction

Metal Matrix Composite:

 A metal matrix composite (MMC) is composite material with at least two constituent parts,
one being a metal necessarily, the other material may be a different metal or another material,
such as a ceramic or organic compound. When at least three materials are present, it is called
a hybrid composite.

Flow Diagram: Manufacturing and forming methods of MMC (created in draw.io software)

Supporting factors for liquid state methods with other manufacturing

techniques:
 Low coefficient for thermal expansion.
 Fire resistance and wear resistance is more’s
 High transverse stiffness, strength and modulus.
 Casting is low cost and net shaped process.
 High level of mechanical properties of the composite.
 Good interfacial bonding (wetting) between the dispersed phase.
These enable to choose the liquid state method manufacturing processing rather than above
mentioned process in flow diagram.

Selection of process for fabrication of metal matrix composites:

Stir Casting Process:
Stir Casting is a liquid state method of composite materials fabrication, in which a dispersed
phase (ceramic particles, short fibres) is mixed with a molten matrix metal by means of
mechanical stirring. The liquid composite material is then cast by conventional casting
method sand may also be processed by conventional Metal forming technologies
Infiltrations:
Infiltration is a liquid state method of composite materials fabrication, in which a preformed
dispersed phase e.g. ceramic particles, fibres, are soaked in a molten matrix metal, which fills the
space between the dispersed phase inclusions. The motive force of an infiltration process may be
either capillary force of the dispersed phase or an external pressure applied to the liquid matrix
phase. Infiltration is one of the methods of preparation of tungsten-copper composites.
Gas pressure infiltration:
Gas pressure infiltration is a forced infiltration method of liquid phase fabrication of metal matrix
composites, using a pressurized gas for applying pressure on the molten metal and forcing it to
penetrate a preformed dispersed phase. In contrast to the methods using mechanical force, Gas
Pressure Infiltration results in low damage of the fibres. The Figure 1.2 shows the Schematic view of
Gas pressure infiltration.

Squeeze Casting:
Squeeze Casting Infiltration Squeeze casting infiltration is a forced infiltration method of liquid phase
fabrication of metal matrix composites, using a ram for applying pressure on the molten metal and
forcing it to penetrate a dispersed phase, placed into the lower fixed mild part. Infiltration method is
similar to the squeeze casting technique used for metal alloys casting.

Conclusion for Selection

Stir casting is also a most effective and economical method for the fabrication of metal
matrix composite. By the analysis of various methods of liquid state fabrication of metal
matrix composites and their advantages and disadvantages. The simplest and the most cost-
effective method of liquid state fabrication is Stir Casting.
 Methodology:

Fabrication of metal matrix composite by using stir casting:

Preparation of raw material(alloy) suitable for melting

Heating the alloy in a graphite crucible above the liquidus temperature to become the
alloy completely liquid

Start stirring to homogenize the temperature and then add the reinforcement into molten
alloy

Complete stirring process according to selected parameters and then pouring the molten
metal into the mould

Allow the composite to solidify the composite according to their solidification rate

Withdrawal of composite from the mould and machining the metal matrix composite
according to requirements

A stir casting setup including resistance Muffle Furnace and a stirrer assembly is used to
synthesize the composite. The stirrer assembly consisted of a graphite stirrer, which is
connected to a variable speed vertical drilling machine with range of 80 to 290 rpm by using
a shaft. The stirrer consisted of three blades at an angle of 120° apart. Graphite crucible
placed inside the furnace. During melting operation, approximately 1Kg of alloy in solid
form melted at its melting point in the resistance furnace and then preheating of
reinforcement material is done for one hour to remove moisture and gases. The speed of the
stirrer gradually rose to 290 rpm and the preheated reinforced particles added with a spoon at
the rate of 10- 20g/min into the melt. The speed controller maintained a constant speed of the
stirrer, as the stirrer speed slow down by50-60 rpm due to the increase in viscosity of the melt
when particulates added into the melt. After the addition of reinforcement, stirring continued
for 8 to 10 minutes for proper mixing of prepared particles in the matrix. The melt kept in the
crucible for approximate half minute in static condition and then it was poured into the mould
and solidification of the metal matrix composite starts according to the solidification rate and
solidification time of composite material. After solidification, metal matrix is removed from
the mould and ready for use and testing after machining.

Fig 1 – Stir Casting Setup Fig 2 – Stirring of Molten Metal

Fig 3- Pouring MMC’s in Mold. Fig 4- Solid MMC’s in Mold. Fig 6- Specimen from
Stir Casting Process .
The following factors which affect the stir casting process are:
1. Speed of stirring
2. Time duration of stirring
3. Stirring temperature

1)Speed of stirring

It is reported by several authors that uniform distribution of the reinforcement particles is

necessary for the improvement in the properties of the particulate MMC’s like hardness,
toughness, tensile strength etc. The low rpm of the stirrer applies less shearing force on the
matrix metal and there is no space for the reinforcement particles (dispersed phase) to
distribute uniformly throughout the matrix. Moreover, the dispersed phase has the tendency
to agglomerate and form clusters. This happens due to the absence of the required force to
resist it. At higher speeds of the stirrer the shearing force applied on the matrix metal is
higher which creates the passage for the dispersed phase to move inside through the vortex
created by stirring. The energy supplied by high speed rotation of the stirrer is strong enough
to disperse the particles of the dispersed phase which causes uniform distribution of the
dispersed phase into the matrix. It was also founded out by the researchers that on increased
stirrer speeds there is chance for the gas particles to move inside the matrix and increase the
porosity.

2)Time duration of stirring

It plays a very important role in uniform distribution of dispersed phase into the matrix. Less
Time duration of stirring causes the clustering of the particles of reinforcement. It is also seen
that some portions of the matrix were found without inclusions of the reinforcement particles.

3)Stirring temperature

It is also one of the most prominent parameters which affect the stir casting process. On
increasing the temperature of the matrix metal, the viscosity decreases, and the distribution of
the particles is affected. The chemical reaction between reinforcement particles and metal
matrix is accelerated on increasing the temperature of the melt.

On increasing the speed of the stirring the properties of the composite material improves but
Not uniformly, this discontinuity is seen due to increase in porosity which deteriorates the
Mechanical properties of the composite material. On increasing the rotation speed of stirrer,
the shear force applied on liquid metal increases results in the more uniform distribution of
reinforcement particles distribution over the molten matrix.
 Applications of Aluminium Metal Matrix Composites.

• Ford offers a Metal Matrix Composite (MMC) driveshaft upgrade. The MMC
driveshaft is made of an aluminium matrix reinforced with boron carbide, allowing
the critical speed of the driveshaft to be raised by reducing inertia. The MMC
driveshaft has become a common modification for racers, allowing the top speed to be
increased far beyond the safe operating speeds of a standard aluminium driveshaft.

• Honda has used aluminium metal matrix composite cylinder liners in some of their
engines, including the B21A1, H22A and H23A, F20C and F22C, and the C32B used
in the NSX.

• Aluminium-Graphite composites are used in power electronic modules because of

their high thermal conductivity, the adjustable coefficient of thermal expansion and
the low density.

• Some automotive disc brakes use MMCs. Early Lotus Elise models used aluminium
MMC rotors, but they have less than optimal heat properties and Lotus has since
switched back to cast-iron. Modern high-performance sport cars, such as those built
by Porsche, use rotors made of carbon fibre within a silicon carbide matrix because of
its high specific heat and thermal conductivity. 3M developed a preformed aluminium
matrix insert for strengthening cast aluminium disc brake callipers, reducing weight
by half compared to cast iron while retaining similar stiffness. 3M has also used
alumina preforms for AMC pushrods.

• Specialized Bicycles has used aluminium MMC compounds for its top of the range
bicycle frames for several years. Griffin Bicycles also made boron carbide-aluminium
MMC bike frames, and Univega briefly did so as well.

Reference: Wikipedia 2018

 Discussions:

Reinforcement with Silicon Carbide

Ultrasonic treatment significantly reduced stir time. Long semi-solid stir time tended to cause
particle cluster. Liquid stirring after ultrasonic treatment was very necessary to the further
improvement of particle distribution. Thus, with the increase of volume fraction of SiC
particles, the yield strength of composite significantly increased. Under external load, the
unformed SiC particles could cause stress concentration around particles.

Mechanical properties of stir cast composite depend upon factors like fabrication techniques,
volume fraction, shape and size of reinforcement particles and the distribution and properties
of constituents. Improve fracture toughness it is necessary that reinforcement should be
uniformly distributed.

Carbide led to increment in hardness. Addition of graphite slightly affects the hardness.
Addition of 15% silicon carbide and 10% Alumina gives greater hardness comparing with
other compositions. Addition of graphite to this composition leads to greater reduction in
hardness. The hardness of the composites increases with the increase in silicon carbide
content. Upon excess addition of silicon carbide decreases the hardness. Moreover, addition
of graphite in excess quantities decreases the hardness.

Addition of ceramic reinforcement such as Sic particles improved the wear resistance of the
alloy. Transition in wear mechanism from micro-cutting/ploughing dominated to micro-
cracking and fracturing dominated wear took place when abrasive size increased from 100 to
120 mm.

The wear resistance increased linearly with increase in Sic content and decreased with
increase in reinforcement size. Fine Al2O3 particles were well distributed in the inter-
particles spacing of coarse Sic particles within the matrix which hardened the matrix and
decreased the wear rate.

The addition of the Sic particulates improved the wear resistance by a factor of two in the
mild wear region. The addition of higher amount of reinforcement resulted in a reduction in
wear rate and further led to the retardation of the load at which wear coefficient increases.
The dendrite lengths decreased by adding SiC particles. The micro SiC particles showed the
best modifying effect on dendrites. It was found that the SiC particles accelerate the
nucleation rate of dendrites by acting as the preferential nucleation sites in the melt.

T6 heat treatment could result in the dissociation of dendrites and globalization of Si plate
likes. Some new complex inter metallics of Al, Mg, Si and Fe and Nano sized Mg2Si
particles were also distinguished in the T6 treated microstructure.

The mechanical strength of A356 considerably increased by a combination of T6 heat

treatment and adding micro/Nano SiC particles. The increase in strength was in expense of
ductility.

The highest tensile and compression strengths was found in the composite containing 1.5
wt.% Nano SiC The highest strength was attributed to the optimized combination of particles
size, particle spacing and volume fraction.

The SEM observations showed the inter dendritic fracture for the cast A356. However, the
alloy with T6 treatment condition showed a dual inter dendritic cleavage fracture surface. The
same dual fracture surface was observed for the composite of A356 with 0.5 wt. % Nano SiC
The brittle fracture in these cases were attributed to the existence of SiC and/or intermetallic
compounds in the matrix. The fracture mode for other composites with 1.5 wt.% Nano SiC
and 5 w.% micro SiC was fully cleavage.

Liquid metallurgy techniques were successfully adopted in the preparation of Al7075-SiC

composite containing the filler contents up to 6 wt. %age. The densities of the composites are
found improved than their base matrix. The micro-structural studies revealed the uniform
distribution of the particles in the matrix system. Micro-hardness of the composites found
increased with increased filler content and the increase in hardness of Al7075-SiC composites
were found to be about 10%.

The tensile strength properties of the composites are found higher than that of base matrix
and Al7075-SiC composites superior tensile strength properties than that of Al7075-Al2O3
composites. The wear resistance of the composites is higher, further the SiC contributed
significantly in improving the wear resistance of Al7075-SiC composites. From the studies in
overall it can be concluded that Al7075-SiC exhibits superior mechanical and tribological
properties.
Reinforcement with Titanium Carbide:
The wear rate of unreinforced aluminium is found higher than that of Al-Tic MMCs.
Increasing the content of Tic from 5 to 15 weight percentage showed higher wear resistance.
At low loads, the specimens were demonstrated abrasion while delamination wear is
dominant at higher load. The presence of porosity which could be due to improper
compaction and particles pull out during grinding and polishing.

Al MMCs containing 5, 10 and 15 weight %. The wear rate of unreinforced aluminium is

found higher than that of Al-TiC MMCs. Increasing the content of TiC from 5 to 15 weight
percentage showed higher wear resistance. The amount of wear rate is observed to be a
function of hardness, delamination and decohesion of the particles.

With the erosion of specimen’s surface, the matrix tends to work hardened and provided
necessary resistance against abrasion. At low loads, the specimens were demonstrated
abrasion while delamination wear is dominant at higher loads.

The main and the interaction effects of significant combination of influencing factors within
the range of investigation of Al alloy-TiC composites were studied by central composite
rotatable design technique. Weight loss of composite decreases with rise in weight
percentage of TiC particles and increases with rise in applied load and sliding distance.
Rockwell hardness of aluminium composites increases significantly with decreasing content
of TiC particles. Microstructure studies clearly reveal a non- uniform wear consisting of
grooves, micro cutting and scratch marks indicating abrasion wear and delamination.

Al MMCs containing 5, 10 and 15 weight % Tic have been successfully developed. The
microstructure study revealed a uniform distribution of Tic particles within the Al matrix.
The wear rate of unreinforced aluminium is found higher than that of Al-Tic MMCs.
Increasing the content of Tic from 5 to 15 weight percentage showed higher wear resistance.
The amount of wear rate is observed to be a function of hardness, delamination and
decohesion of the particles. With the erosion of specimen’s surface, the matrix tends to work
hardened and provided necessary resistance against abrasion.

AA6061/15%TiC AMCs were produced using the stir casting method. An empirical
relationship incorporating the stir casting parameters was developed to predict the UTS.
Various stir casting parameters such as stirring speed, stirring time, blade angle and casting
temperature considerably influenced the UTS.
A lower or higher combination of those parameters resulted in lower UTS. This was
attributed to the formation of porosity, cluster of particles and segregation of TiC particles at
the grain boundaries. An intermediate range of parameters yielded castings with
homogeneous distribution of TiC particles and minimum porosity. The UTS was high when
the porosity was low and the distribution was homogenous.

The present research work revealed an existence of optimum range of parameters to produce
AA6061/15%TiC (mass fraction) AMCs with high UTS. The selection and control of stir
casting parameters are essential to minimize porosity content and achieve uniform
distribution to enhance the load bearing capacity of the AMCs.

Reinforcement with Silicon Carbide and Titanium Boride:

Micro structural analysis shows the presence of SiC and TiB2 and its distribution in the
metal matrix. Increase in weight percentage of reinforcement (SiC10%&TiB25%) leads to
cluster formation. Hence the maximum % of TiB2 into the matrix is limited to 2.5% for 10%
SiC It has been concluded from hardness measurement that, addition of reinforcements has
effect on hardness value, but addition of TiB2 up to 5% leads to porosity which affects
hardness value.

From tensile test results it has been observed that addition of reinforcement Sic to base
metal added 20% strength to the composite but addition of TiB2 reduction in 50 -60%
strength is recorded. It has been analysed from micro structure study and from tensile
specimen after experimenting that cluster formation leads to porosity and porosity leads to
reduction in strength than base aluminium alloy. It has been proved from wear analysis that
TiB2 particles increase the wear resistance behaviour of hybrid aluminium metal matrix.
Experimental results proved that the quantity of wear of Sic 10% - TiB2 0% is 20% more
than Sic 10% - TiB2 2.5% specimen.

It has been observed from the machining analysis that % of reinforcement of TiB2 is the most
significant factor on surface roughness and its contribution is 38.86 %. The addition of TiB2
reinforcement increases surface roughness value. Using Taguchi analysis the below optimal
machining parameters are tabulated for best surface roughness and its values are cutting
speed 120m/min, feed rate 0.3mm/rev, depth of cut 0.5mm and 0% of reinforcement of TiB2.

It has been concluded from tool wear analysis that the high tool wear is caused due to both
abrasive and adhesive actions. Low cutting speed, high depth of cut and increased wt. % of
TiB2 reinforcement causes as high tool wear. Built-up edge formation affects surface
quality.

Reinforcement with Silicon Carbide and Fly ash.

Sic and Fly ash were added in the composites in varying levels of 6%, 12% & 18%. The
specimens are subjected to micro structural analysis having 10% SiC and 15% fly ash and
also the distribution of reinforcement was found to be sparser. The grain growth in the
specimen having10% SiC and 5% fly ash was found to be increased and the distribution of
reinforcement was observed to be unchanged.

The grains of had become finer in the specimen having 5% Sic and 15% fly ash and the
distribution reinforcement was observed to be sparser. Where as in the specimens having
5%SiC 10% fly ash and 15%Sic and10%flyash the size of the grains had become finer and
the distribution of reinforcement was found to be coarser leading to less micro hardness
value. The grain growth in the specimen having 10%SiC and 10%flyash was found to be
increased and the distribution of reinforcement was found to be denser resulting in higher
micro hardness value.

Hence it is recommended to use aluminium alloy LM30 with reinforcements of 10%SiC and
10%flyash for I.C engine cylinder blocks due to sufficient changes in the mechanical
properties. k value varies between443 W/m.K to 406 W/m.K.

The hardness values of the specimens increased with the increase in the percentage addition
of silicon carbide and fly ash majorly due to the inherent properties of silicon carbide and fly
ash to impart hardness to the soft matrix phase of aluminium. The silicon carbide is a hard-
ceramic material which is often used as an abrasive and the fly ash on the other hand is a
compendious material which facilitates the agglomeration of silicon carbide around the
periphery and grain boundaries of aluminium atoms, thereby leading to increase in the
hardness of the Aluminium 5083 matrix /Sic p/Fly ash specimens.

The impact test results clearly indicate that the impact energy of the specimens increases with
the increase in the percentage addition of silicon carbide and fly ash, majorly due to the
coring (micro-segregation) of silicon carbide particulates in interstitial sites of aluminium
matrix which ultimately enhances the toughness of the material. The addition of fly ash on
the other hand brings lubricity in the material and increases the affinity of reinforcements to
bond together and blend into the matrix phase thereby enhancing the characteristic
phenomenon of the aluminium matrix composites to absorb more energy under impact
loading conditions.

The compressive strength of the specimens increased with the increase in the weight
percentage of silicon carbide from 3 to 9, but however the increase in the size and weight
percentage of fly ash in the composite specimen reduced its compressive strength.

The increase in compressive strength with the increase in weight percentage of silicon
carbide is majorly attributed to the hardening of the base metal by micro-coring of the silicon
carbide particulates in the aluminium matrix phase. This is a major precursor for enhanced
use of aluminium composites in vibration damping applications with improved damping
capacity.

Reinforcement with Quartz Particles.

The quartz particles were uniformly distributed in the composite irrespective of the volume
fraction. The distribution was independent upon the location within the stir zone. The quartz
particles underwent changes in size and shape due to high strain rate encountered during FSP.
The interface between the quartz particle and the aluminium matrix was observed to be clean
without the formation of any kind of intermetallic.

The grain size of the composite was refined extensively by the combination of intense plastic
deformation and the pinning effect of quartz particles. Dislocations were observed around
quartz particles due to thermal mismatch between the aluminium matrix and the quartz
particle.
Quartz particles increased the microhardness of the composite. The microhardness was
measured to be 62 HV at 0 vol.% and135 HV at 18 vol.%. Quartz particles enhanced the wear
resistance of the composite. The wear rate decreased as the volume fraction of quartz
particles was increased. The wear rate was found to be 583 × 10−5mm3/mat 0 vol.% and 258
× 10−5mm3/m at 18 vol.%.

Quartz particles influenced the wear mode in addition to the morphology of the wear debris.
The increased volume fraction of quartz particles changed the wear mode from adhesion to
abrasive. The wear debris transformed from thin plate at 0 vol.% at to spherical shape at 18
vol.%.

Reinforcement with Titanium Boride and Aluminium Oxide

Mechanical properties of composites, the yield stress, UTS, hardness, and more significantly,
ductility of nanocomposites is obviously higher than those of unreinforced and micro
composites reinforced with the same percentage reinforcements of TiB2 or Al2O3 particles.
Elimination of Al3Ti brittle phase by using this processing route greatly improved the
mechanical properties of the composites prepared compared to previous literatures.
Crack propagation in the nanocomposite’s region is retarded by blunting mechanism of
nanoparticles which is caused the high strain to failure. Processing, structure and property
relationships has been studied and it was found that the refining power of NPs is very
dependent on processing temperature but not time.

A reaction model is proposed to describe how the size of nanoparticles are controlled by
viscosity of the melt rather than precipitation and growth. The analysis of yield stress
measured in the nanocomposites considering stress- and energy-activated strengthening
mechanisms shows that not only grain boundary strengthening is present in the
nanocomposites, but also can indicate the activation of Orowan strengthening.

The higher strain hardening exponent for the nanocomposites is another indication of the
presence of Orowan strengthening due to the engulfment of nanoparticles within the grains.

Reinforcement with Fly ash and Aluminium oxide

The Tensile strength of the composite increases with the addition of alumina and fly-ash.
Tensile strength of the Al 6061 base alloy is 184Mpa, with the addition of 10% alumina and
flyash it increases to 260Mpa and with addition of 15% and 20% it increases to 350 Mpa and
399 Mpa. The increase in ultimate tensile strength may be due to segregation of particles at
some specific zone. With the 10% addition of particles the tensile strength increases by
76Mpa and with 15% and 20% it increases by 166Mpa and 215Mpa.The reason for increase
in tensile strength may be due to the presence of the interfacial gaps between the matrix and
the reinforcement.

The stir formed Al6061 with Al2O3/Fly-Ash reinforced composites is clearly superior to base
Al6061 in the comparison of tensile strength. The mismatch between reinforcement and
matrix leads to a large stress concentration near particulate and matrix in that region fails
prematurely under application of load. With the increase in vol. fraction a strong tendency of
clustering of particulates leads to a very inefficient load transfer mechanism causing low
strain to failure.

The tensile strength of aluminium alloy Al 6061 is 184Mpa. There is increase in hardness
from 184 to 399Mpa, on addition of 10%, 15% and 20% alumina and fly ash by vol.
respectively.
Reinforcement with Fly Ash.

Reinforcing Aluminium & its alloys with bottom ash may show an appreciable increase in its
mechanical properties Hardness of the composites was determined by using Brinell hardness
testing machine as we found increased in the BHN at A6 wt%. Microstructural observation
shows that addition of Bottom ash leads to agglomeration. Addition of bottom ash in
aluminium may improve the yield strength; tensile strength while ductility decrease. The
ultimate tensile strength (UTS) gradually increases with increase in weight % bottom ash
reinforcement particles. Reaches a maximum value of Bottom ash and then decreases.

Reinforcing Aluminium & its alloys with bottom ash may show an appreciable increase in its
mechanical properties. Hardness of the composites was determined by using brinell hardness
testing machine as we found increased in the BHN at A6 wt.%. Microstructural observation
shows that addition of Bottom ash leads to agglomeration.

The fly ash contents present in aluminium matrix resist the destructive action of the wear
tests and hence increases the wear resistance of the composites. The wear resistance of the
fabricated composites increases with the increase in the fly ash contents. The composites with
high fly ash contents resulted in 13.6% less wear as compared to low fly ash content
composites. Tribological behaviour of the aluminium matrix composites is generally, a
function of applied load, reinforcement particle size, nature and volume fractions.

The microstructural analysis revealed the nearly uniform distribution of the fly ash particles
in the matrix. Improved micro-hardness and tensile strength are observed with an Al7075
alloy having twelve weight fraction of fly ash addition. The mechanical properties of the
composites are found higher than that of the base matrix alloy.

Significant improvement in tensile properties, compressive strength and hardness are

noticeable as the wt. % of the flash increases. The tensile property of the composite material
compared to the as cast Al6061 alloy, increased significantly by 60-70%. The hybrid metal
matrix composites with fly ash and graphite reinforced Al6061 composites processed by stir
casting route.

Under 75 μm, it was found that SiO2 was a major constituent in BLA with major peaks of Si
and O along with other trace elements in BLA particles. The density of the fabricated
composites reduced with an increase in BLA content in comparison withAl−4.5%Cu alloy.
The maximum porosity observed in the prepared composite is 2.512% with 6% BLA.
The porosity level in prepared composite is lower than 4%which was the maximum porosity
level and might be acceptable in Al−4.5Cu−BLA composites. The hardness of the composites
increases with increase in BLA content compared with the matrix. The maximum hardness
attained at 4% BLA in the fabricated composites.

In the fabricated composites the tensile and yield strength of the composites with 2%, 4% and
6% Blain creased in comparison with the matrix. Similarly, the highest tensile and yield
strengths were observed at 4%BLA particle. The ductility of composite material in terms of
elongation decreased in comparison with the matrix. The fracture mode of the composites
revealed that the macroscopically brittle and microscopically ductile in nature.

Reinforcement with Copper powder .

The wear volume loss is less for composite for different applied loads, sliding velocities and
sliding distances as compared to both the alloys. The WVL is high in Al-5Wt%Cu alloy. The
hardness of the composite is high as compared to both alloys.

The COF is high in 10-Wt%-Cu alloy as compared to MMC and 5Wt%-Cu alloy for
different applied loads, sliding velocities and sliding distances, even though the percentage of
copper is same in the above alloy and composite. It is evident from the MMC microstructure,
that the reinforced copper powder is not alloyed, rather it is distributed in the Al-Cu alloy
matrix.

From the above conclusions we predict that sliding distance and applied load have the highest
influence on wear rate for both the alloys and composite. Similarly, applied load is only
parameter which is largely influence the coefficient of friction for both the alloys and
composite.

Reinforcement with Silicon Carbide and aluminium oxide.

The highest hardness value for casting and sintering samples have been obtained at 850 and
625°C respectively, in 5 vol. % of MgO. Compressive strength values of casting composites
were higher than sintered samples which were majorly due to the more homogeneity of Al
matrix, less porosity portions, and better wettability of MgO nanoparticles in casting method.

The highest compressive strength values for casting and sintered composites have been
obtained at 850 and 625 °C, respectively It was observed that the hardness of the composite is
increased with increasing of reinforced particle weight fraction. The tensile strength and
impact strength both are increased with rising of reinforced weight fraction. about Elemental
Mg and Mg-alloy (AZ91D) based composites reinforced with 15 vol.% silicon carbide (SiC)
particulates (average particle size 15 μm and 150 μm)

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 Al2O3.The tensile
strength of the as cast composites increases on increasing the weight fraction of Al2O3.
Microstructural observation suggests that electromagnetic stirring action produces cast MMC
with smaller grain size and there is a good particulate matrix interface bonding.

Fracture strength of composites (6, 9 and 12wt %) is higher when compared to as cast
6061Al, while ductility of composite is lesser that unreinforced alloy. The tensile strength
increases with increase in amount of reinforcement, while there is decrease in ductility with
increasing amount of reinforcement.

Increase in strength is possibly due to the thermal mismatch between the metallic matrix and
the reinforcement, which is a major mechanism for increasing the dislocation density of the
matrix. The composites containing 6061Al with 6, 9 and 12wt% of Al2O3 particulates were
successfully synthesized by melt stirring method using three stages mixing combined with
preheating of the reinforcing particles.

Feeding Mechanisms improves the uniform and Controlled spraying of Sic particles on
molten aluminium. By modifying Stirring Mechanisms and controlling feeding mechanisms
cluster formation is reduced. By above factors, the aluminium strength is increased

Reinforcement with Titanium boride and Boron Nitride:

The dispersion of TiB2 and BN particles in the aluminium matrix were homogeneous without
segregation. Both the particles acted as one type of reinforcement particle. The particle
dispersion was independent of position within the stir zone. The average grain size of
AA6082 and AA6082/ (TiB2 + BN) hybrid AMC were respectively 39.4 μm and 6.6 μm.
Extensive grain refinement was apparent in the Al matrix within the stir zone for the
composites containing TiB2 and BN particles.
TiB2 and BN particles were effectively bonded within the aluminium matrix with the
interface being devoid of porosity or any reaction products. The shape and morphology of the
TiB2 particles changed during FSP due to fragmentation. The nanosized BN particles did not
change during FSP.
The addition of TiB2 and BN particles enhanced the sliding wear resistance of the AMCs.
The wear rate of the AA6082/(TiB2+BN) hybrid AMC was lower than both the A6082/TiB2
AMC and the A6082/ BN AMC. The wear rate of AA6082 and AA6082/ (TiB2 + BN) hybrid
AMC were respectively 23.75 × 10−5 mm3/Nm and 13 × 10−5mm3/Nm. The nano-BN
particles enhanced wear resistance by acting as a solid lubricant and forming a tribo film.
During sliding wear the wear mode is transformed from an adhesive mode to a largely
abrasive mode because of the presence of deboned TiB2 and BN particles in the wear
interface. The addition of BN particles produced a visually clean and polished wear surface
when compared to the AA6082/TiB2 AMC.

The addition of TiB2 and BN particles altered the morphology of the wear debris from
relatively large platelet like structures to a much finer flake like debris. The addition of BN
particles reduced the presence of the larger flake like particles in the wear debris. The iron
content in the wear debris of AA6082/TiB2 AMC and AA6082/(TiB2+BN) hybrid AMC were
respectively 9.1 wt.% and 5.4 wt.%. The iron content in the wear debris of the AA6082/
(TiB2 + BN) hybrid AMC was less than the AA6082/TiB2 AMC which is advantageous for a
reduction in counter face wear.

Reinforcement with Magnesium and Zinc:

Pouring temperature plays a major role in the strength of the cast. Blow holes tend to reduce
the strength of the cast. The percentage of Magnesium and Zinc plays a major role in
determining the strength of the cast.

The percentage of Magnesium, more care should be taken during casting and sintering
because Magnesium tends to catch fire, vaporizes other reinforcements as well. The
composites containing Al6063 with 2wt% of MWCNT particulates synthesized by stirring
method using a pit furnace fuelled by coke.

The tensile tests revealed an increase in the yield strength and ultimate strength of the heat-
treated Al6063 samples (0wt% and 2wt% MWCNT) over the un-heat-treated samples.
Increase in the compressive strength of the heat treatedAl6063 samples (0wt% and 2wt%
MWCNT) over the un-heat-treated samples. Increase in the impact strength of the heat
treated Al6063 samples (0wt% and 2wt% MWCNT) over the un-heat-treated samples.

The presence of numerous dimples in fracture surfaces reveals that the mechanism of tensile
failure is ductile for both materials. Higher strength-ductility combination of composite is
attributed to the better interfacial bond strength between the matrix and the intermetallic
particles developed by in situ technique.
 Conclusions

Several confronts must be surmounted in order to strengthen the engineering usage of AMCs
such as processing methodology, influence of reinforcement, effect of reinforcement on the
mechanical properties and its corresponding applications. The major conclusions derived
from the prior works carried out can be summarised as below: -

 SiC reinforced Al MMCs have higher wear resistance than Al2O3 reinforced MMCs.

 SiC reinforced Al MMCs are suitable materials for brake drums as they have high
wear resistance but cannot be used in brake linings as it will damage the brake drum.

 It has been found that the increase in volume fraction of Al2O3 decreases the fracture
toughness of the Al MMC.

 The optimum conditions for fabricating Al2O3 reinforced Al MMC as pouring

temperature-700 N C, preheated mould temperature-550 N C, the stirring speed-900
rev/min, particle addition rate-5g/min, the stirring time - 5 min and the applied
pressure was 6 MPa. - The wear resistance of SiC reinforced Al MMC is higher than
B4C reinforced MMC.

 Al MMCs reinforced with diamond fibre exhibit high thermal conductivity and a low
thermal expansion co-efficient. - The wear resistance and compressive strength of Al
MMCs increase with the addition of Zircon sand reinforcement.

 The addition of flash reinforcement in Al increases the wear resistance but decreases
the corrosion resistance.
References