Study Of Mechanical Behaviour Of Nano Boron Carbide
Reinforced Al6063 MMC’s
Byra Reddy 1, Nikhil Kumar 2 , Ajith 3 , Prathap Reddy 4
1
Associate Professor, Department Of Mechanical Enginnering,AMCEC, Bangalore 560083, India
2
Student, Department of Mechanical Engineering, AMCEC, Bangalore 560083, India
3
Student, Department of Mechanical Engineering, AMCEC, Bangalore 560083, india
4
Student, Department of Mechanical Engineering,AMCEC, Bangalore 560083, India
Abstract
This paper deals with the fabrication and mechanical
investigation of Aluminium alloy 6063 and B 4C ( Nano boron
carbide) metal matrix composites. Aluminium is the matrix
metal having properties like light weight, high strength and
ease of machinability. Boron carbide which has excellent
hardness and fracture toughness is added as reinforcement.
Here, the fabrication is done by stir casting which involves
mixing the required quantities of additives into stirred molten
Aluminium. Aluminium alloy 6063 was reinforced with 3 wt.
% of Nano boron carbide (B4C) , 6 wt.% of Nano boron
carbide (B4C) and 9 wt.% of Nano boron carbide (B4C)
through liquid casting technique. After solidification, the
samples are prepared and tested to find the various mechanical
properties like tensile, compression, and hardness. And the test
reports were compared with the Al6063 mechanical properties.
The internal structure of the composite is observed using
Scanning Electron Microscope (SEM). It was used for the
characterization of composites.
Keywords: Al6063, Nano Boron carbide, Stir casting,
Mechanical properties, SEM.
1.Introduction
Aluminium matrix composites (AMCs) in the series of Metal
Matrix Composite (MMC) keeps the key factor to replace
conventional materials for wide range of
Structural/Mechanical applications such as those in the
automobile, aeronautical/aerospace, defense and sports
industries because of their superior properties. The excellent
mechanical properties and the comparatively low cost make
them as a best option large variety of applications. Stir casting
is a liquid fabrication techniques which is currently apply for
various reinforcement and it is used to manufacture the MMC
materials especially Aluminium matrix composites (AMCs) in
the recent years [1, 2]. Hamouda et al [3] developed a flow
stress model based on plasticity theory for two different types
of Aluminium metal matrix composite materials subjected to
high strain rate. Hamouda et al [4] experimented the A1/Cu
and AI/Li metal matrix composite (MMC) were subjected to
Dept. of Mechanical Engineering, AMCEC
Contact: Nikhilkumar4me17@gmail.com.
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dynamic compression at room temperature using an
experimental drop hammer.
Tham et al [5] investigated the influence of the processing
parameters on the near-net shape synthesis of Al–SiC
particulate reinforced metal matrix composites (MMCs) by the
disintegrated melt deposition (DMD) technique. Abouelmagd
[6] investigated hot compression and wear resistance as well as
hardness of powder metallurgy (P/M) Aluminium matrix
composites (AMCs). Generally, both hardness and compressive
strength were enhanced by the addition of Al 2O3 and Al4C3 and
their magnitudes continued to improve up to deformation
temperature of 150◦C. The ductile–brittle transition
phenomenon was obtained at an addition of Al 4C3. Also, the
addition of 4% Al4C3 improved the wear resistance of
composites, while its existence decreased the braking percent.
2. Experimental details
2.1. Materials
In this work for preparing metal–matrix composite,
Aluminium alloy 6063 is used as base material; Nano boron
carbide in powder form are used as the reinforcements.
Aluminium alloy ingots are required for the preparation.
Aluminium alloy ingot is cut into small pieces, so that it can be
easily placed in crucible for melting.
2.1.1. Aluminium Alloy 6063
AA 6063 is an aluminium alloy, with silicon and
mahnesium as the alloying elements.Generally AA 6063 is
weld able and heat treatable and it also has good mechanical
properties. The tensile strength of Aluminium alloy 6063 and
hardness decrease fairly regularly with increasing temperature
and become relatively poor at temperatures of the order of
250°C. The heat treated alloy has fairly good machining
properties. They are of high resistance to corrosive attack by
sea water and marine atmospheres.
2.1.2. Nano Boron Carbide
Boron carbide is one of the most promising ceramic
materials due to its attractive properties, including high
strength, low density, extremely high hardness, good chemical
stability and neutron absorption capability. Boron carbide has
stability to ionizing radiation. It has toughness similar to
diamond. It is difficult to sinter to high relative densities
without the use of sintering aids. It has good nuclear properties.
Table 1: Properties of Material Used
Material Tensile Density Coefficien Modulus
strength (g/cm3) t of of
(MPa) thermal elasticity
expansion (GPa)
(10ˉ⁶/°C)
Aluminiu 241 2.77 2 68.9
m 6063
B4C 261 2.3-2.55 5 362
2.2. Fabrication Procedure
The stir casting process is widely used for production of
MMC. The various advantages of stir casting are simplicity,
flexibility, applicability to large quantity, near net shaping,
lower cost of processing and easier control of matrix structure.
In this work, stir-casting method is used for preparing
Aluminium matrix composite. This whirlpool technique
provides high strength and homogeneous set of Aluminium
composite materials. Stir casting is a primary process of
composite production in which continuous stirring of molten
base metal is done followed by introduction of reinforcements.
The resulting mixture is poured into the die and allowed to
solidify. In stir-casting, the particles often tend to form
agglomerates, which can be only dissolved by vigorous stirring
at high temperature.
3. Experimentation
The experimental arrangement consists of the main furnace
and components along with three mild steel stirrer blades. The
first process in the experiment is preheating. Here, the empty
crucible and the reinforcement powders, namely boron carbide
is heated separately to a temperature close to that of the main
process temperature. The melting of the Aluminium alloy
(90%) ingot is carried out in the crucible inside the furnace.
Initially, the ingot was preheated for 3 – 4 hr at 550°C. At the
same time boron carbide is also preheated to 400°C in the
respective containers. Then, the crucible with Aluminium alloy
is heated to 800°C while the preheated powders are
mechanically mixed with each other below their melting points.
This metal–matrix is then kept into the furnace at the same
temperature. The furnace completely melts the pieces of
Aluminium alloy and Nano boron Carbide powder. The stirring
mechanism is lowered into the crucible inside the furnace and
set at the required depth. The vigorous automatic stirring of the
material takes place for 10 min with 550 rpm of stirring rate,
thereby uniformly dispersing the additive powders in the
Aluminium alloy matrix. The temperature rate of the furnace
should be controlled at 830 ± 10°C in final mixing process. The
degasser removes all the trapped gases from the mixture in the
crucible and ensures that the temperature of the mixture in the
crucible does not get transferred easily to the atmosphere. This
experiment is repeatedly done by varying the compositions of
the composite powder. For each composition, a total of 1.5 - 2
kg (1500 – 2000 g) material mix is used for preparing the
samples. Apart from the above compositions, the aluminum
alloy 6063 alone is melted and solidified in dies.
In this paper, sample 1 contains Aluminium alloy only,
sample 2 contains Aluminium alloy—97% and Nano boron
carbide—3%, sample 3 contains Aluminium alloy—94%, and
Nano boron carbide—6%, sample 4 contains Aluminium alloy
—91% and Nano boron carbide 9%.
4. Testing
The following tests are conducted on the Aluminium matrix
composites to evaluate their mechanical properties.
4.1. Tensile Test
The ability of a material to withstand a static load can be
determined by testing the material in tension or compression.
Mechanical testing plays an important role in evaluating the
fundamental properties of engineering materials as well as in
developing new composite materials. In this work the tensile
test is carried out using a universal testing machine. The
specimen is prepared as per ASTM-E8 standards.
4.2. Compression Test
The goal of a compression test is to determine the behavior
or response of a material while it experiences a compressive
load by measuring fundamental variables, such as strain,
stress, deformation. By testing a material in compression the
compressive strength , yield stress, elastic limit, and the elastic
modulus among other parameters and the values associated
with a specific material it may be determined whether or not
the material is suited for specific applications or if it will fail
under the specified stresses
4.3. Hardness Test
The hardness test measures the resistance of a solid to
permanent shape change when a force is applied. Brinell
hardness test is carried out in this work to find out the
deformation of the composite under constant compressive load.
5. Results and Discussion
The tested results of the each sample are discussed.
5.1. Tensile Test
The tensile test is done using universal testing machine and the
specimens are cut as per the ASTM: E-8 standard. The results
obtained are furnished in Table 2.
 Table 2: Tensile Properties of Composites Figure 2: Compression Test Results

Samp Compositio Break Maximu Tensile Elong

le n load m strengt ation
(kN) displace h (%)
ment (MPa)
(mm)

1 Al6063 5.88 37.80 108.0 5

2 Al6063 + 5.02 38.2 116.2 6.1

3% B4C
3 Al6063 + 6.09 42.76 118.1 18.8
6% B4C

4 Al6063 + 5.93 38.3 117.2 6.4

9% B4C 5.3. Hardness Test
The Vickers cum Brinell hardness test is carried out on the two
Figure 1: Tensile Test Results samples and the results are shown in Table 4.
Table 4: Hardness values of Composites

Figure 3: Hardness Test Results

5.2. Compression Test

The Compression test is done using universal testing machine
and the specimens are cut as per the ASTM: E-8 standard. The
results obtained are furnished in Table 3.
Table 3: Compression Properties of Composites

Sample Compositio Load C.H.trave Compressio

n at l at Peak n Strength
Peak (mm) (Mpa)
(kN)
1 Al6063 49.13 14.94 370.1
6. Morphological Analysis using Scanning Electron
2 Al6063 + 51.17 14.62 385.5 Microscope (SEM)
3% B4C
3 Al6063 + 52.84 14.88 398.1 The Scanning Electron Microscope (SEM) uses electrons
instead of light to form an image. The main principle of SEM is
6% B4C the bombarding of electrons and the secondary electrons which
4 Al6063 + 50.20 15.55 378.3 are reflected are formed as an image. After the sample is
9% B4C prepared, its microstructure is analyzed using SEM.
6.1. Microstructure of Samples Fig.1 – Al6063 + 0% B4C at 50x
Fig.1 shows the microstructure of the fractured surface of
sample 1 at 50x magnification. The general arrangement of the
composite is clearly visible in the image. Many micro cracks
and porous sites are observed in the sample which is attributed
to poor manufacturing and improper stirring of the composite.
Fig.2 shows the microstructure of sample 1 with a
magnification of 200x. Typical examples of crack paths on the
specimen surface of the composites are seen in the image.
However, only a few debonding particles are observed
compared to sample 2.

Fig. 3 shows the microstructure of sample 2 and the picture

shows the inner surface. It consists of tighter packing than the
other composites which explain the better tensile and other
properties of the sample 2 compared to samples 1.
From Fig.4, the images of sample 2 can be clearly
distinguished from those of samples 1 as these images lack the Fig.2 – Al6063 + 0% B4C at 200x
elliptical molecules of the reinforcements which are visible in
the cases of samples 2.

From Fig. 5 shows the microstructure of sample 3 and the

picture shows the inner surface. It consists of tighter packing
than the other composites which explain the better tensile and
other properties of the sample 3 compared to samples 2.
From Fig.6, the images of sample 3 can be clearly
distinguished from those of samples 2 as these images lack the
elliptical molecules of the reinforcements which are visible in
the cases of samples 3.

From Fig. 7 shows the microstructure of sample 4 and the

picture shows the inner surface. It consists of tighter packing
than the other composites which explain the better tensile and
other properties of the sample 4 compared to samples 3. Fig.3 – Al6063 + 3% B4C at 50x
From Fig.8, the images of sample 4 can be clearly
distinguished from those of samples 3 as these images lack the
elliptical molecules of the reinforcements which are visible in
the cases of samples 4.

Fig.4 – Al6063 + 3% B4C at 200x

Fig.5 – Al6063 + 6% B4C at 50x Fig.8 – Al6063 + 9% B4C at 200x

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