CHAPTER 1

1.1 INTRODUCTION:

Now days with the modern development need of developments of advanced engineering
materials for various engineering applications goes on increasing. To meet such demands
metal matrix composite is one of reliable source. Composite material is one of the reliable
solutions for such requirement. In composites, materials are combined in such a way as to
enable us to make better use of their parent material while minimizing to some extent the
effects of their deficiencies. The simple term „composites‟ gives indication of the
combinations of two or more materials in order to improve the properties. In AMC one of the
constituent is aluminum, which forms percolating network and is termed as matrix phase. The
other constituent is embedded in this aluminum and serves as reinforcement, which is usually
nonmetallic and commonly ceramic such as SiC , Al2O3,B4C etc., Al 6061 is quite a popular
choice as a matrix material to prepare MMCs owing to its better formability characteristics. It
is widely used in numerous engineering applications including transport and construction
where superior mechanical properties such as tensile strength, hardness etc. are essentially
required.

Metal matrix composites are combinations of two or more materials in such a way that the
resulting materials have desired design properties or improved mechanical properties.
Aluminium Silicon carbide metal matrix composites are widely used in engineering
structures, industry electronic applications, sporting goods and aerospace etc. Its properties
mostly depend on the processing method and the different compositions which are capable of
producing desired properties to meet the industry need. Al-SiC composites can be more easily
produced by the stir casting technique due to its good casting ability and relatively
inexpensive. Analyzing the wear properties of Al-SiC composite is found that wear rate
decreases linearly with increasing SiC content. Mechanical characterization of Al-SiC
composite like density, hardness, elongation%, toughness, bending, Poisson ratio, modulus of
elasticity, young‟s modulus and tensile strength were evaluated.

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The improved value of tensile strength is one of the key reasons they are widely used in
industry. It has been found that particle reinforced Aluminium matrix composites can
improve considerably the strength and hardness of Aluminium and its alloys. But at the same
time, the plasticity and ductility is substantially reduced and thus it severely affects the safety
and reliability of components fabricated from Aluminium matrix composites (AMCs).
Mechanical characterization of Aluminium silicon carbide by mass fraction of SiC (5%, 10%,
15%, 20%, 25% and 30%) with Aluminium is analyzed. The maximum tensile strength has
been obtained at 15% SiC ratio according to other parameters. Mechanical and Corrosion
behavior of Aluminium Silicon Carbide alloys is suitable for water-cooled manifolds, motor
housings, engine piston, spur gear, shaft and many other mechanical components. The
development of stress and strain fields in the MMC was analyzed and physical phenomenon,
particle bonding, displacements and homogeneous deformation of matrix material were
explored. MMC‟s were recommended as a possible replacement for Aluminium and it is seen
that the exact set of properties depend on certain% of composition. Therefore these factors
such as reactivity at the interface, volume fraction of the reinforcing material , type of the
reinforcing material and distribution of the reinforcing material are reviewed using the
existing literature.

1.2 COMPOSITE MATERIAL:

A composite is combination of two materials in which one of the materials, called the
reinforcing phase, is in the form of fibers, sheets, or particles, and is embedded in the other
materials called the matrix phase. The reinforcing material and the matrix material can be
metal, ceramic, or polymer. Composites typically have a fiber or particle phase that is stiffer
and stronger than the continuous matrix phase and serve as the principal load carrying
members. The matrix acts as a load transfer medium between fibers, and in less ideal cases
where the loads are complex, the matrix may even have to bear loads transverse to the fiber
axis. The matrix is more ductile than the fibers and thus acts as a source of composite
toughness. The matrix also serve fibers to protect from environmental during
damage before and after composite processing. When designed properly, the new combined
material exhibits better strength than would each individual material. Composites are used
not only for their structural properties, but also for electrical, thermal, Tribological, and
environmental applications. Composites are multifunctional material systems that provide

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characteristics not obtainable from any discrete material. They are cohesive structures made
by physically combining two or more compatible materials, different in composition and
characteristics. In the broader significance; the combination has its own distinctive properties.
In terms of strength to resistance to heat or some other desirable quality, it is better than
either of the components alone or radically different from either of them. The composites are
compound materials which differ from alloys by the fact that the individual components
retain their characteristics but are so incorporated into the composite as to take advantage
only of their attributes and not of their short comings”, in order to obtain improved materials.
Composite materials as heterogeneous materials consisting of two or more
solid phases, which are in intimate contact with each other on a microscopic scale. They can
be also considered as homogeneous materials on a microscopic scale in the sense that any
portion of it will have the same physical property. The following are some of the reasons why
composites are selected for certain applications: High strength to weight ratio (low density
high tensile strength) High creep resistance, High tensile strength at elevated temperature,
High toughness.

Figure 1.1 Particulate Metal Matrix Composite

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1.3 CLASSIFICATION OF COMPOSITES:

Fig 1.2 Classification of Composites

1.3.1 Based on the type of reinforcing material, composites can be classified as:

A .Fibrous Composite:

A fiber is characterized by its length being much greater compared to its cross-sectional
dimensions. The dimensions of the reinforcement determine its capability of contributing its
properties to the composite. Fibers are very effective in improving the fracture resistance of
the matrix since a reinforcement having a long dimension discourages the growth of incipient
cracks normal to the reinforcement that might otherwise lead to failure, particularly with
brittle matrices. Man-made filaments or fibers of non-polymeric materials exhibit much
higher strength along their length since large flaws, which may be present in the bulk
material, are minimized because of the small cross-sectional dimensions of the fiber. In the

4
caseof polymeric materials, orientation of the molecular structure is responsible for high stren
-gth and stiffness.

B .Particulate Composites:

In particulate composites the reinforcement is of particle nature. It may be spherical, cubic,

tetragonal, a platelet, or of other regular or irregular shape. In general, particles are not very
effective in improving fracture resistance but they enhance the stiffness of the composite to a
limited extent. Particle fillers are widely used to improve the properties of matrix materials
such as to modify the thermal and electrical conductivities, improve performance at Elevated
temperatures, Reduce friction, Increase wear and Abrasion resistance, Improve machinability,
Increase surface hardness and Reduce shrinkage.

C .Structural Composites:

The properties of structural composites depend on: Constituents & Geometrical design.
Structural composites are of Laminar and Sandwich type. Laminar Is composed of two-
dimensional sheets or panels that have a preferred high strength direction .The layers are
stacked and cemented together such that the orientation of the high-strength direction varies
with each successive layer. Sandwich Panels consist of two strong outer sheets which are
called face sheets and may be made of aluminum alloys, fiber reinforced plastics, titanium
alloys, steel. Face sheets carry most of the loading and stresses. Core may be a honeycomb
structure which has less density than the face sheets and resists perpendicular stresses and
provides shear rigidity.

1.3.2 According to type of matrix material they are classified as:

1 .Metal Matrix Composites (MMC)

2 .Ceramic Matrix Composites (CMC)
3 .Polymer Matrix Composites (PMC)

1 .Metal Matrix Composites:

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Higher strength, fracture toughness and stiffness are offered by metal matrices. Metal matrix
can withstand elevated temperature in corrosive environment than polymer composites.
Titanium, aluminium and magnesium are the popular matrix metals currently in vogue, which
are particularly useful for aircraft applications. Because of these attributes metal matrix
composites are under consideration for wide range of applications viz. combustion chamber
nozzle (in rocket, space shuttle), housings, tubing, cables, heat exchangers, structural
members etc.

2. Ceramic matrix Composites:

One of the main objectives in producing ceramic matrix composites is to increase the
toughness. Naturally it is hoped and indeed often found that there is a concomitant
improvement in strength and stiffness of ceramic matrix composites.

3 .Polymer Matrix Composites:

Most commonly used matrix materials are polymeric. In general the mechanical properties of
polymers are inadequate for many structural purposes. In particular their strength and
stiffness are low compared to metals and ceramics. These difficulties are overcome by
reinforcing other materials with polymers. Secondly the processing of polymer matrix
composites need not involve high pressure and doesn‟t require high temperature. Also
equipment‟s required for manufacturing polymer matrix composites are simpler. For this
reason polymer matrix composites developed rapidly and soon became popular for structural
applications.

1.4 REINFORCEMENT :

The reinforcement material is embedded into the matrix .The reinforcement does not always
serve a purely structural task (reinforcing the compound), but is also used to change physical
properties such as wear resistance ,friction coefficient or thermal conductivity the
reinforcement can be either continuous or discontinuous. Discontinuous MMC‟s can be
isotropic, and can be worked with standard metal working techniques, such as extrusion,

6
forging or rolling. In addition, they may be machined using conventional techniques but
commonly would need the use of Polycrystalline Diamond Tooling(PCD). Continuous
reinforcement uses monofilament wires or fibers such as Carbon fiber or Silicon Carbide.
Because the fibers are embedded into the matrix in a certain direction, the result is an
anisotropic structure in which the alignment of the material affects its strength. One of the
first MMC‟s used Boron filament as reinforcement. Discontinuous reinforcement uses
“Whiskers”, Short fibers, or particles. The most common reinforcing materials in this
category are Alumina and Silicon Carbide. Examples of some current applications of
composites include the Tyres, Diesel Piston, Brakes shoes and pads.

1.5 FLYASH AS REINFORCEMENT:

There has been an increasing interest in composites containing low density and low cost
reinforcements. Among the various reinforcements used, Fly Ash is one of the most
inexpensive and low density reinforcements available in large quantities as solid waste by
product from combustion of coal in thermal power plants. Fly ash particles are classified as
two types, precipitator and cenosphere. Generally, the solid spherical particles of flyash are
called precipitator fly ash and hollow particles of flyash with density less than 1.0gm/cm3 are
called cenosphere flyash. The precipitator flyash , which has a density in range of 2.0-2.5
gm/cm3 can improve various properties of selected matrix materials including stiffness
,strength ,wear resistance & reduce the density. Cenosphere flyash which consists of hollow
fly ash particles can be used for the synthesis of ultra light composite materials due to its
significantly low density, which is in the range of 1.6-11.0 gm/cm3 .one common type of fly
ash is generally composed of crystalline compounds such as quartz, mullite, hemitate, glassy
compounds such as silica glass and oyher oxides .hance composites with fly ash as
reinforcement are likely to overcome the cost barrier for wide spread applications in
automotive and small engine applications. It is therefore expected that the incorporation of
flyash particle in aluminium alloy will promote another use of this low cost waste by product
and at the same time has the potential for conserving energy intensive aluminium and there
by reducing the cost of aluminium products.

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 Table 1.1 Properties of Fly Ash
PROPERTIES VALUES
3
Density(gm/cm ) 1.15
Bulkdensity(gm/cm3) 2.19
Moisture content (%) 0.02
Fineness 318

Figure 1.3 Fly Ash

1.6 DESIGNATION OF ALUMINIUM ALLOYS:

Table 1.2 Aluminium alloy in present thesis work

Chemical Composition Weight Percentage

Copper 0.1
Magnesium 0.10 max
Silicon 11
Iron 0.6
Manganese 0.5 max
Nickel 0.1 max
Zinc 0.1 max
Tin 0.05 max
Titanium 0.2
Aluminium Remainder

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The Aluminium Association of America has classified the wrought aluminium alloys
according to four-digit system. The classification is adopted by International Alloy
Development System(IADS). The first digit identifies the alloy type and second digit shows
the specific alloy modification. The last two digits indicate the specific aluminium.

Table 1.3 Applications of Aluminium Alloys

Aluminium Alloy Alloy Characteristics
1050/1200 Non-heat treatable, Good
formability, Weld ability and
Corrosion resistance
2014 Heat-treatable, high strength,
non weldable, poor corrosion
resistance
5251/50582 Non-heat treatable, medium
strength work hardening
alloy, good weld ability,
formability and corrosion
resistance
6063 Heat-treatable, Medium
strength alloy, good weld
ability and corrosion
resistance. Used for intricate
profiles
6061/6082 Heat-treatable, Properties
very similar to 6082,
Preferable as air quenchable,
therefore has less distortion
problems, not notch sensitive
7075 Heat-treatable, Age hardens
naturally, therefore will
recover properties in heat
affected zone after welding
Common Use
Food and Chemical Industry
Air Frames
Vehicle paneling, structures
exposed to marine
atmosphere, mine cages.
Architectural extrusions
(internal and external)
window frames, Irrigation
pipes
Stressed structural members,
bridges, cranes, roof trusses,
beer barrels
Armored vehicles, military
bridges, motor cycle, bicycle
frame

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1.7 SILICON CARBIDE AS REINFORCEMENT:

Silicon carbide (SiC) is now manufactured from silica and carbon. The sources of carbon are
coke, pitch, petroleum cokes and anthracite. The sand contains pure silica (98 – 99.5%).
Silicon carbide known as carborundum. It is a compound of silicon and carbon with chemical
formula SiC. It occurs in nature as the rare mineral Moissanite.

Table 1.4 Properties of SiC

Properties Values
Molecular Weight(gm/mole) 40.10
Boiling Point (oC) 2815
o
Melting Point( C) 2730
Density(gm/cm3) 3.21
Refractive Index 2.55

Figure 1.4 Silicon Carbide

1.8 STIR CASTING :

In a stir casting process, the reinforcing phases (Usually in powdered form) are distributed
into molten aluminium by mechanical stirring. Prior to mechanical stirring, the surfaces of
both must be properly cleaned. In order to minimise the reaction between these two,
Introducing reinforcing particles to the stirred molten matrix sometimes will entrap not only

10
the particles but also other impurities such as metal oxide and slag, which is formed on the
surface of melt. During pouring air envelops in a form between particles, which can alter the
interface properties between particles and the melt, and also retarding the wettability between
them.The major concern associated with the stir casting process is the segregation of
reinforcing particles which is caused by surfacing or settling of reinforcing particles during
melting and casting process. To prevent settling of particles, a motor driven agitator is
used.Alumi9nium Silicon Carbide metal matrix composite will reach a state called Mushy
State before solidification. Once the Mushy state is reached, the reinforcing particles remain
in its position during solidification. The final distribution of particles in the solid depends on
the material properties and process parameters such as wetting condition of the particles with
the melt, Strength of mixing, Relative Density & Rate of solidification. The distribution of
particles in molten matrix also depends on the geometry of the mechanical stirrer, Stirring
parameters, Placement of mechanical stirrer in the melt, Melting temperature And the
characteristics of particles added. To create and maintain a good distribution of the
reinforcement material in the matrix, a vortex method is used. In this method, after the matrix
material is melted, it is stirred vigorously to form a vortex at the surface of melt, and the
reinforcement material is then introduced at the side of vortex. The stirring is continued for a
few minutes before the slurry is cast.

Figure 1.5 Stir Casting

1.9 IMPACT TESTING:

In an Impact test, a notched bar of material, arranged either as a cantilever or as a simply

supported beam, is broken by a single blow in such a way that the total energy required to

11
fracture it may be determined. The energy required to fracture a material is obtained from the
K.E of a moving object.

Often a structure must be capable of receiving an accidental shock load without failing
completely, and whether it can do this will be determined not by its strength but by its ability
to absorb energy. A combination of strength and ductility will be required, since large
amounts of energy can only be absorbed by large amounts of plastic deformation. The ability
of a material to absorb a large amount of energy before breaking is often referred as
toughness, and the energy absorbed in an impact test is an obvious indication of this property.

Impact tests are carried out on notched specimens, and the notches must not be regarded
simply as a local reduction in the cross – sectional area of the specimen, Notches – and , in
fact, surface irregularities of many kind – give rise to high local stresses, and are in practice, a
potential source of cracks.

Figure 1.6 Impact test specimen Dimensions

The specimen may be of circular or square cross – section arranged either as a cantilever or a
simply supported beam.

1.10 Hardness Testing:

Hardness can be defined as resistance to deformation or indentation or resistance to scratch.

Brinell hardness uses either 10 or 5mm diameter ball indenter made of either hardened steel
or tungsten carbide. The applied load depends on the hardness of material. As a thumb rule
the load used for measuring the hardness of steel = 30D2 kg; where D is the diameter of the
ball. If D = 10mm the load to be used = 3000kg. The machine consists of a loading device

12
connected to the indenter and a moveable stand to place the sample. The sample stand is
raised so that it touches the indenter. Thereafter the specified load is applied. After a
specified length of hold time (~10s) the load is withdrawn. This leaves an indentation mark.
Its diameter (d) is measured using a graduated eyepiece. If P is the applied load the Brinell
hardness number (BHN) of the material is given by load / area of the indentation. Unlike
Rockwell hardness which is just a number BHN has a dimension of kg/mm2 .

1.11 Tensile Strength:

A specimen of a standard size and shape made of the material is pulled in tension while the
load and elongation are continuously (or periodically) monitored. The data thus collected are
used to generate stress strain curve. Figure shows a sketch highlighting the important parts of
the testing system used to perform a tensile test. Modern machines have an intelligent
computer interface and have facility to perform tests under various user defined modes (for
example load control, displacement control and strain control). Usually tensile tests are
performed under displacement control mode where the moveable end of the grip is made to
move at a constant speed. The load and displacement (strain) records are stored at specified
intervals of time. Once the sample breaks the machine stops. The data can then be displayed
on the computer screen. There gives a typical load displacement plot which is converted to
stress strain plots using the following expressions given after figure.

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 Figure 1.7 Ultimate Testing Machine
1.12 SCANNING ELECTRON MICROSCOPE:

A Scanning Electron Microscope (SEM) is a type of electron microscope that produces

images of a sample by scanning the surface with a focused beam of electrons. The electrons
interact with atoms in the sample, producing various signals that contain information about
the surface topography and composition of the sample. The electron beam is scanned in
a raster scan pattern, and the position of the beam is combined with the intensity of the
detected signal to produce an image. SEM can achieve resolution better than 1 nanometer.
Specimens are observed in high vacuum in conventional SEM.

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Figure 1.8 Scanning Electron Microscope

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 CHAPTER 2

LITERATURE REVIEW:

This chapter presents a review of the literature data available on the effect of various
reinforcements in different proportions, their size and volume fraction.

The reinforcements can be combined with the different matrices, resulting in large composite
systems. Furthermore, several different processing routes, such as powder metallurgy, stir
casting, squeeze casting, hot extrusions etc.

K R Jayadevan[1] analyzed about the stir casting process on sic composite and concluded
that clustering of reinforcement particles, wettability ofreinforcement (SiC) in molten
aluminium are the prime concern in the production of composites through stir casting.Further,
the studies clearly show that mechanical properties of stir cast composite depend upon factors
likefabrication techniques, volume fraction, shape and size of reinforcement particles and the
distribution and propertiesof constituents. Also, it is evident that addition of reinforcement up
to a particular level increases the mechanicalproperties. But composites fracture toughness is
decreased by the addition of reinforcement.To improve fracture toughness it is necessary that
reinforcementshould be uniformly distributed.

J.Jebeen Moses [2] Studied about the effect of sic on the composite material with different
proportions and developed a fairly homogeneous aluminum metal matrix ,the distribution of
sic is observed to be intra granular .The interface between the sic particle and the aluminium
matrix was clean without the presence of reaction products,pores and voids.the increase in sic
content progressively ,shifted the fracture mode from ductile to brittle.

Prabhat kumar sinha[3] focused on the behavior of aluminium silicon carbide (AlSiC) hybrid
metal matrix composites. The study was aimed at evaluating the mechanical properties of
Aluminium in the presence of silicon carbide with different weight percentages of silicon
carbide (10%, 15%, 20%) combinations. Consequently aluminium metal matrix composite
combines and exhibit huge strength of the reinforcement with the toughness of the matrix to

16
achieve a combination of desirable properties not available in any single conventional
material. The compositions were added up to the ultimate level and stir casting method was
used for the fabrication of aluminium metal matrix composites. To investigate the properties
of AlSiC, experiments have been conducted by varying weight fraction of SiC (10%, 15%
and 20%) while keeping all other parameters constant. The results indicate the behavior and
properties of material is quite successful to obtain exact use of aluminum silicon carbide
according to the requirement. the elongation tends to decreases according to the increase in
weight percentage of silicon carbide and hence it leads to increase in hardness.

R.D.Shelke[4] Analyzed that according to recent scenario, Stir casting is most efficient and
effective in all aspects such as cost, simplicity of operation, distribution of particles etc.
compared to all other composite manufacturing methods. Stir casting method is suitable up to
30 wt % of reinforcement material.Most of Al Alloys supports reinforcement of material and
due to this, the properties of metal material increases.Some Alloys supports reinforcement
upto 50% of wt.% but increase in properties is limited to some wt%.In case of Aluminium,the
properties gets decreased after wt% of SiC crosses 25%.

N.Parthipan[5] Analyzed the hardness and tensile properties of Aluminium Alloy Al6061
reinforced with Silicon Carbide and Flyash to improve the strength of the piston material.
There will be several failures occurring in the piston due to continuous working. To eradicate
the failure, the composition of aluminium alloy material is made through the stir casting
technique in various composition and tested as per ASTM standard size. Aluminium alloy
will have the good weight to strength ratio. It implies that the Aluminium silicon carbide
material exhibits less weight and more strength. The base material Al6061 with reinforcement
of SiC, Al2O3 for increasing the hardness and their tribological properties.

R. I. Ganguly[6] Conducted experiments and studied the properties of Al6061 reinforced with
insitu ceramic mixture (SiC).The strength values for Al-6061-flyash (FA) composites are
35% higher than that of the Al-6061 alloy.The unique property of the developed alloy
composite is due to harder SiC particle reinforcement. SiC in the form of whiskers have
improved strength as well as specific strength.

17
Soheil Mahdavi[7] Investigated Aluminum matrix composites reinforced with SiC particles
are a unique class of advanced engineered materials that have been developed to use in
tribological applications. The stir casting and the powder metallurgy synthesizing processes
are combined into an integrated net shape forming process. Homogenous distribution of the
SiC particles within the powder mixtures and the hybrid composites is clear from the SEM
images. The results also show that the SiC particles decrease the compressibility of the hybrid
powders and improve the hardness of composites. The SiC particles are distributed uniformly
within the matrix alloy using Stir Casting method. The coefficient of friction is decreased by
increasing SiC content up to 30 vol.%, and it will be minimum at 30 vol.% SiC contained
hybrid composite.

F. Akhlaghi[8] Studied the effect of size of silicon carbide particles on properties of

composites with SiC particles.Composites are processed by In situ Powder Metallurgy
technique(IPM). The IPM method is a combination of the stir casting and powder metallurgy
(P/M) synthesizing processes in an integrated net shape forming process. It is well known
that the production method has a strong influence on the mechanical and properties of such
composites.It was found that the increased SiC particle size reduced the hardness of
composites. The higher hardness values obtained for composites as compared with the base
alloy compact is due to the presence of hard SiC particles.

M. Velmurugan[9] Investigated tensile, compression and impact characterization of SiC,

Al2O3 reinforced Aluminium 6061 matrix composite. Hybrid matrix composite fabrication
was done by stir casting method. The tensile strength of aluminum composites was studied
and the maximum tensile strength observed at 20 wt% of SiC. The maximum yield strength
observed at 20 wt% of SiC and maximum fracture stress observed at 20 wt% of SiC. On
increasing the amount of SiC into the matrix, the ceramic will develop a strong interface bond
with the matrix and this bond, in turn, improves the properties of composites.

18
Gaurav Saini[10] Studied composites made of Aluminium6061 (97.0 and SiC has been
chosen as matrix andreinforcement material. Experiments have been conducted by varying
weight fraction of SiC (2.5%, 5%, and 10%) while keeping all other parameters constant. The
results indicated that the developed method is quite successful to obtain uniform dispersion of
reinforcement in the matrix. An increasing trend of Tensile Test with increase in weight
percentage of SiC has been observed. The results obatained are good because the load at yield
point,Ultimate load,Elongation is gradually increasing with increase in SiC percent in the
composites.

S. Boopathy[11] Studied the change in the mechanical behaviour of aluminium alloy 6061
with different weight percentage of Silicon Carbide (SiC) and Alumina (Al2O3) ceramic
powders and change in processing temperature. The purpose of designing Metal Matrix
Composite is to figure the desired qualities of metals and ceramics. The fabrication of the
MMC was done by stir casting process. The tensile test, hardness test and impact test were
performed on these composite samples to study the mechanical behavior. Tensile strength
value is higher for the samples made at 750oC. These samples exhibit better wettability and
little agglomeration of particles which impede the dislocation of molecules. The sample with
more percentage of SiC possesses higher tensile strength.The sample with more percentage of
alumina possesses increased percentage of elongation.

C. S. P. Rao[12] Studied that the ceramic particles reinforced aluminum composites are
termed as new generation material.Particle reinforced composites have a better plastic
forming capability than that of the whisker or fiber reinforced ones, and thus they have
emerged as most sought after material with cost advantage and they are also known for
excellent heat and wear resistance applications.This paper is aimed to present the
experimental results of the studies conducted regarding hardness, tensile strength properties
of Al6061-SiC composites. Microhardness of the composites found increased with increased
filler content and the increase in hardness of Al6061-SiC composites. The tensile strength

19
properties of the composites are found higher than that of base matrix and Al6061-SiC
composites superior tensile strength properties than that of Al7075- Al2O3 composites.

Azad Alam [13] study is focused on the fabrication of aluminium 6061 based metal matrix
composites, Reinforced with silicon carbide and Al2O3 by stir casting technique. The
percentage of one reinforcement particulate is kept constant and varying other. The various
mechanical tests like tensile strength test, hardness test, wear test and Impact strength
performed on the samples obtained by stir casting technique for comparison purpose. The
result indicated that there is an increase in the value of tensile strength, hardness value and
Impact strength of newly developed composite having (SiC + Al2O3) particulates in
comparison to the Aluminium. Hardness of the SiC & Al2O3 filled Al6061 alloycomposites
found increased with increased ceramic particulates content.

Ajay Singh Verma[14] Studied that Particulate Aluminium Metal Matrix Composites possess
high specific strength, greater strength to weight ratio at elevated temperature. stir casting is
cheapest and simple route for fabrication of Aluminium Metal Matrix composites. Numerous
types of reinforcements in particulate like SiC, Al2O3 is used to improve the metallurgical as
well as mechanical properties as compared to its base matrix. reported that Metal Matrix
Composites possess high specific strength, greater strength to weight ratio at elevated
temperature, greater wear resistance as compare to matrix phase.

Prashant Kumar Suragimath[15] attempted to develop a conventional low cost method of

producing Aluminium MMCs and to obtain homogeneous dispersion of reinforced material.
To achieve this objective stir casting technique has been adopted. Aluminium6061,SiC, Fly
Ash has been chosen as matrix and reinforcing material respectively. Experiment has been

20
conducted by varying weight fraction of Fly Ash (5% and 15%) while keeping SiC
constant(5%). The result shown that the increase in addition of Fly Ash increases the Tensile
Strength, Impact Strength, Wear Resistance of the specimen and decreases the percentage of
Elongation. It appears in this study that Tensile Strength starts increases with increase in
weight percentage of Fly Ash.It found that elongation tends to decrease with increasing
particles weight percentage which confirms that addition of SiC and Fly Ash increases the
brittleness. The impact strength of Hybrid composite increases with increase in weight
percentage of Fly Ash.

Swapnil S.Mukadam[16] Fabricated Al Composites by Stircasting method by varying weight

percentages of samples by increasing SiC and Fly ash percent accordingly decreasing Al6061
percent. The hardness, wear test and tensile test were performed to study the mechanical
behavior of all the test specimens.The results reveal that it improves the micro hardness and
tensile strength. From the test result the tensile strength of different wt.% composite sample is
increased gradually and addition of 5%SiC+5% fly ash sample is to get higher tensile
strength compared with other Samples that has only Al6061. Al6061 with SiC + fly ash
composite material is less in weight than the Al of the same dimensions. This indicates that
the AMMCs having low weight and high strength.

Omkarnath Mishra[17] emphasized the production of metal-matrix Al6061 & Si alloy with
fly ash composites by the continuous stir casting method. Samples are prepared as per the
standard and finally tested by hardness using Brinell hardness machine, impact strength by
using Charpy-V-Notched machine, Compression test by using Universal Testing
Machine.Al6061- Si Alloy reinforced with Fly ash of irregular shape has shown more Impact
strength,Micro hardness and the one reinforced with fly ash of cenospherical shape has
shown more Compression strength.

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Achutha Kini[18] Studied the effect of Silicon carbide on Stir cast Aluminium Metal Matrix
Composites.Different researchers have been made to consolidate some of the aspects of
mechanical and wear behavior of Aluminium Metal Matrix Composites reinforced with
Silicon carbide particles in both untreated and precipitation hardened condition. The
Aluminum metal matrix composite material has been prepared by stir casting
method.Wettability is increased due to the presence of ceramic like SiC.

David Raja Selvam. J[19] focuses on the fabrication of AMCs reinforced with various weight
percentages of SiC particulates and a constant weight percentage of Fly Ash by modified stir
casting route. The wettability of SiC and Fly ash particles in the matrix was improved by
adding magnesium into the melt. The microstructure and mechanical properties of the
fabricated AMCs were analyzed. The mechanical properties like hardness and tensile strength
were improved with the increase in weight percentage of SiC particulates with constant
weight percentage of Fly Ash in the aluminum matrix. The hardness of the composites were
increased with respect to addition of weight percentage of SiC and constant weight
percentage of Fly ash particles. The reinforcement of particles has enhanced the tensile
strength of aluminum matrix composites.

S.M. Seyed Reihani [20] Investigated the microstructural features, aging behavior,
mechanical properties and wear characteristics of the composites with Al6061 as metal
matrix and 30vol% SiC. Higher strength and lower wear rates were observed in the composite
materials than the unreinforced aluminum alloy part. However, a marked decrease in ductility
of the composites arising from adding of SiC particles was obtained. The thermal mismatch
between the metal matrix and the reinforcement increases the dislocation density of the
matrix. The mechanical strength of Al6061– 30vol% SiC composite is superior to those of
the unreinforced material. Decreasing the particle size of the reinforcement phase leads to
better mechanical properties.

22
R. Assadifard [21] analyzed the variation of properties of SiC reinforced Al6061 composites.
Microstructure by scanning electron microscopy (SEM) technique & hardness of materials
were investigated and noted. The effect of mechanical alloying process on hardness is more
significant compared to reinforcement particles.The evolution of relative density and
hardness with milling time is due to the morphological and microstructural changes imposed
on the composite powder. The particles tend to agglomerate to form coarse particles and the
SiC reinforcements were embedded into Al6061 matrix to form composite powders.Hardness
of powders maybe affected by two factors : Addition of reinforcement particles and MA
process.

23
 CHAPTER 3

PROBLEM FORMULATION

3.1 OBJECTIVES OF PRESENT WORK

The problem is to study the mechanical properties before and after heat treatment
of Al-Flyash/Silicon Carbide metal matrix composite (MMC) of Aluminium alloy of grade
Al6061 with addition of varying weight percentage composition of Silicon Carbide particles
with constant Flyash weight percentage and made by stir casting technique. The Tensile
strength, Toughness, Hardness like mechanical properties will also be taken into
consideration. For the achievement of the above, an experimental set up is prepared where all
the necessary inputs were made. The aim of the experiment is to study the effect of variation
of the percentage composition and also the effect of heat treatment to predict the mechanical
properties of metal matrix composites (MMC). The experiment was carried out by preparing
the sample of different composition by stir casting technique. The present work emphasizes
the literature review of Al-Flyash alloys, its composites and its heat treatment. There are
many manufacturing processes to form composites commercially. But the technique adopted
here is rapid solidification process. The objectives of present proposal are as follows:

 To prepare the cost-effective MMC material by taking Al-Flyash alloy with matrix
ceramic particulate like Silicon Carbide as reinforced phase using stir casting
technique.
 To heat treat the material by solution heat treatment process followed by ageing.
 To analyze and compare the micro structural characteristics of the as cast material
before and after heat treatment.

Tensile strength, Impact strength & Hardness measurements of the as prepared MMC.

24
 CHAPTER 4

EXPERIMENTAL WORK

4.1 EXPERIMENTAL SET UP USED IN STIR CASTING OPERATION

Equipments used to perform the stir casting operation

Table 4.1 List of Equipment used for stir casting

S.No Equipment Used

1 Muffle Furnace

2 Stainless Steel Stirrer

3 Power Hacksaw

4 Graphite Crucible/Mould

Muffle Furnace

Muffle Furnace,used to heat the material to the desired temperature by conduction,

convection or black body radiation from electrical resistance heating elements.

Table 4.2 Specifications of Muffle Furnace

Specifications Range

Temperature range (oC) 0-800

Rating Power (KW) 2.5

Operation (V) 230

25
 Figure 4.1 Muffle Furnace

Stainless Steel Stirrer

The function of a stirrer was to agitate liquids for speeding up reactions.Stirrer was
designed to homogeneous mixing of liquid, oilment, solution, viscous material and solid
liquid.

Figure 4.2 Stainless Steel Stirrer

Power Hacksaw

A power hacksaw (Electric Hacksaw) was powered by its own electric motor.A
hacksaw is a fine tooth saw with a blade under tension in frame used for cutting materials
such as Aluminium alloy into small pieces so as to keep the alloy into crucible.

26
 Figure 4.3 Power Hacksaw

Graphite Crucible

A Crucible is a refractory container used for metal, glass and pigment production
as well as a number of modern laboratory processes which can withstand temperatures high
enough to melt or otherwise alter its contents. Historically, they have usually been made of
clay but they can be made of any material with a higher temperature resistance than the
substances they are designed to hold.

Figure 4.4 Graphite Crucible

27
 Table 4.3 List of Equipment used for testing of samples

S.No Equipment Used

1 Impact Toughness Machine

2 Hardness Testing Machine

3 INSTRON-Tensile Testing Machine

4 Scanning Electron Microscope

4.2 EXPERIMENTAL PROCEDURE:

4.4 Flowchart showing experimental procedure

Starting aluminium alloy Al6061 with reinforcement Flyash and SiC

Making of composite by stir casting

Non heat treated Heat treated in

Muffle furnace

Tensile Impact Hardness SEM

Strength Test Test Analysis

Results and Conclusion

28
4.2.1 PREPARATION OF SAMPLES:

Figure 4.5 Stir Casting

Stir casting process is mainly used for manufacturing of particulate reinforced metal matrix
composite (PMMC). It is a primary process of composite production whereby the
reinforcement ingredient material is incorporated into the molten metal by stirring. The stir
casting of metal matrix composites involves producing a melt of the selected matrix material
followed by the introduction of a reinforcement material into the melt before adding the
reinforcement material the melt should be subjected to 29egassing by a suitable medium,
because the molten metal reacts with atmospheric oxides and undergoes oxidation by
degrading the properties of the base material.

The next step is the solidification of the melt containing suspended dispersoids under selected
conditions to obtain the desired distribution of the dispersed phase in the cast matrix. In the
stir casting with bottom pouring technique, the mold is kept just below the furnace with an
opening at the bottom for pouring. This type of arrangement enhances the incorporation of
particulates and reduces the time of pouring. The reduction in time of pouring and due to a
better particulate introduction to the mold the composite properties are more nearer to
improvement.

29
Fig.1 shows the matrix material melted in a crucible by heating it in a crucible furnace. The
stirring is activated by means of a motor at the top of the stirrer. The stirrer can be moved up
and down by means of a rack and pinion arrangement. Reinforcement is added to the matrix
after stirring the matrix material for a certain amount time. Preheating is also carried out to
avoid thermal distortion of the composite material. Mixing techniques are used for
introducing and homogeneously dispersing the discontinuous phase since most of the ceramic
reinforcement materials are denser compared to matrix alloy, otherwise the reinforcement
material may settle at the bottom of the crucible if not agitated properly. Mixing techniques
generally used for mixing of ceramic reinforcement into a melt are: a. Adding particles to a
vigorously agitated molten alloy b. Injection of the discontinuous phase into the melt with an
injection gun c. Dispersion of pellets or briquettes of a discontinuous phase [2] Stir casting is
attractive since a conventional metal processing route is used and is the most economical
route of all the available routes of metal matrix composite production. The cost of preparing
composite material using this method is about one third to half of the other competitive
methods, and for high volume production, it is projected that the cost will fall to one tenth
[3]. Some of the important factors that need attention during stir casting are:

 The difficulty of achieving a uniform distribution of the reinforcement material.

 Wettability between two main substances (matrix and reinforcement substances).
 Porosity in the cast metal matrix composites.
 Chemical reactions between the reinforcement material and matrix alloy [4]
 Reaction of matrix and reinforcement substances with atmospheric elements.

4.2.2 ADDITION OF SIC:

Silicon carbide is a well known abrasive material having silicon and carbon with a chemical
formula SiC. It has excellent Thermal Conductivity, Hardness, Corrosive Resistance and
Stiffness. The density of Silicon carbide is 3.21gm/cc and the melting point is 2730
Centigrade. Silicon Carbide powder has been mass- produced for the use as an abrasive.
Grains of Silicon carbide can be bonded together by sintering to form a very hard ceramics
that are widely used in applications requiring high endurance such as car brakes, car clutches
and ceramic plates in bullet proof vests. The Silicon Carbide is added as 10,15,20 weight
percentages for the composite materials.

30
 Figure 4.6 Samples Obtained after Stir Casting

4.3 PROCEDURE FOLLOWED AFTER CASTING PROCESS:

For Izod Impact Test:

The Samples obtained after casting process were machined using Lathe machine
and Shaper to the standard specimen size required for Izod impact test.

Figure 4.7 Impact testing machine Figure 4.8 Fractured Specimens

31
For Brinell Hardness Test:

Brinell Hardness Test is done on the specimens used for SEM Analysis. In Brinell
Hardness Test, the Brinell hardness number is calculated by using below formulae. Initially
different diameter indentors are selected and are fixed in the arbour and then the load is
applied at different positions. An impression is found after removing the load and by using
the low-magnification portable microscope, the diameter of indentation is noted. Finally this
diameter of indentation is taken for calculation of Brinell hardness number.

For Tensile Test:

Tensile test is also known as tension testing is a fundamental materials science in

which a sample is subjected to a controlled tension until failure. The results from the test are
commonly used to select a material for an application and to predict how a material will react
under other types of forces. Properties that are directly measured via a tensile test are ultimate
tensile strength, maximum elongation and reduction in area. A tensile specimen is a
standardized sample cross-section. It has two shoulders and a gauge in between. Fig.4 Sample
of AlSiC for tensile test The shoulders are large so they can be readily gripped, whereas the
gauge section has a smaller cross-section so that the deformation and failure can occur in this
area. The repeatability of a testing machine can be found by using special test specimens
meticulously made to be as similar as possible. A standard specimen is prepared in a round or
a square section along the gauge length, depending on the standard used. Both ends of the
specimens should have sufficient length and a surface condition such that they are firmly
gripped during testing. The initial gauge length Lo is standardized (in several countries) and
varies with the diameter (Do) or the cross-sectional area (Ao) of the specimen Necking in
engineering or materials science, is a mode of tensile deformation where relatively large
amounts of strain localize disproportionately in a small region of the material. The resulting
prominent decrease in local cross-sectional area provides the basis for the name “neck”.
Because the local strains in the neck are large, necking is often closely associated with
yielding, a form of plastic deformation associated with ductile materials, often metals or
polymers. Necking results from instability during tensile deformation when a material‟s
cross-sectional area decreases by a greater proportion than the material strain hardens. During
tensile deformation the material decreases in cross-sectional area. During tensile deformation
the material strain hardens. The amount of hardening varies with extent of deformation. Fig.

32
sample of AlSiC after tensile test The test process involves placing the test specimen in the
testing machine and slowly extending it until it fractures. During this process, the elongation
of the gauge section is recorded against the applied force. The data is manipulated so that it is
not specific to the geometry of the test sample.

Figure 4.9 Specifications of Tensile test specimens

Figure 4.10 UTM Machine

33
4.4 COMPOSITION OF SAMPLES:

Table 4.5 Composition of Sample 1

Material Composition(%)

Aluminium 85

Silicon Carbide 10

Fly Ash 5

Table 4.6 Composition of Sample 2

Material Composition(%)

Aluminium 80

Silicon Carbide 15

Fly Ash 5

Table 4.7 Composition of Sample 3

Material Composition(%)

Aluminium 75

Silicon Carbide 20

Fly Ash 5

34
 RESULTS AND DISCUSSION

5.1 IMPACT TEST RESULTS:

The Izod impact test, also known as Izod square-notch test is a standardized high

strain rate test which determines amount of energy absorbed by a material during fracture.

This absorbed energy is a measure of toughness for a material provided. Impact strength of

composites with different weight percentage of reinforcement is shown in Table 5.1 and

Impact strength is compared in Figure 5.1

Table 5.1: Result of Impact Test

S.No Specimen Composition Impact Strength (J/mm2)

1 Al6061+10% SiC+5% Flyash 1.52

2 Al6061+15% SiC+5% Flyash 1.60

3 Al6061+20% SiC+5% Flyash 1.59

1.62

1.6
Impact Strength (J/mm2)

1.58

1.56

1.54

1.52

1.5

1.48
Specimen 1 Specimen 2 Specimen 3

Figure 5.1: Comparison of Impact Strength of different specimens

35
5.2 HARDNESS TEST RESULTS:

A Brinell‟s Hardness testing machine is used to measure the hardness of material.

The load used on specimen by hardness tester was 500 kgf with an indenter of 5mm diameter.

The results of hardness measurement for different weight percentages of reinforcements is

shown in the Table 5.2 and Figure 5.2. They show the comparison of hardness of the

composites with varied reinforcement weight percentage.

Table 5.2: Result of Hardness

S.No Specimen Composition Indenter Load Applied Hardness

Diameter (BHN)

1 Al6061+10% SiC+5% Flyash 5 mm 500 Kgf 58

2 Al6061+15% SiC+5% Flyash 5 mm 500 Kgf 62

3 Al6061+20% SiC+5% Flyash 5 mm 500 Kgf 64

65

64

63

62

61

60

59

58

57

56

55
Specimen 1 Specimen 2 Specimen 3

Figure 5.2: Comparison of Hardness of different specimens

36
5.3 TENSILE TEST RESULTS:

Table 5.3: Tensile test results

S.No Specimen Maximum Load at Ultimate Yield Ultimate Tensile

Composition Load (KN) Break(KN) Strength (MPa) Strength (MPa)

1 Al6061 +

10% SiC + 7.89 5.36 98 120

5% Fly ash

2 Al6061+

15% SiC + 14.21 14.21 92 140

5% Fly ash

3 Al6061+

20% SiC+ 10.53 10.52 88 134

5% Fly ash

Tensile tests were used to assess the mechanical behavior of the composites

materials. For that, the composites are casted in form of shafts and are then machined to

required shape. The results obtained after tensile testing is shown in the Table 5.3 and the

Yield and Tensile strength values of the composites are compared in Figure 5.3.

37
 Figure 5.3: Comparison of Stress Strain Curve for different specimens

Tensile Stress on X-axis ; Tensile Strain on Y-axis ; The Blue line indicates

SPECIMEN 6 ;The Green line indicates SPECIMEN 7;The Red line indicates SPECIMEN 7.

As we can see from the above figure that the tensile strength first increases with

an increase in SiC wt % upto 15% keeping Fly ash as 5% constant. If the wt% of SiC is

further increased, then the tensile strength is decreased. But the yield strength is decreasing

with increase in wt% of SiC.

145
Ultimate Tensile Strength (MPa)

140

135

130

125

120

115

110
Specimen 1 Specime 2 Specimen 3

Figure 5.4: Comparison of Ultimate Tensile Strength for variable weight percentage SiC

38
 100

98
Ultimate Yield Strength (MPa)

96

94

92

90

88

86

84

82
Specimen 1 Specimen 2 Specimen 3

Figure 5.5: Comparison of Ultimate Yield Strength for variable weight percentage SiC

5.4 SCANNING ELECTRON MICROSCOPE RESULTS:

This Analysis is used to know the distribution of reinforcement particles in the

composite and to know how well the casting process is done. From the figures, We are able

to tell how well the casting is done ,Whether the distribution of reinforcement particles is

uniform or not.

From the Figure 5.6, the particles are distributed non- uniformly because we can

see that the SiC particles are distributed in the centre of the image more rather than the top

and bottom edges of the figure and also the blowholes we see are more in number.

39
 Figure 5.6: SEM analysis Result for Sample 1

From the Figure 5.7, we can see that the SiC particles are distributed uniformly in

the matrix but the Fly Ash particles are concentrated on the bottom right of image. And also

the Blow holes are less in number when compared to composites with other composition.

From this, we can say that the stir casting is done properly for the Specimen 7.

From the Figure 5.8, We can say that the SiC particles are distributed uniformly in

the composite. But the blowholes are more that indicates that the Stirring is done properly but

there is defect while pouring the molten composite.The Reason behind the occurrence of

blowhole in large number might be because of the ill preheating of the reinforcement SiC.

40
 Figure 5.7: SEM analysis Result for Sample 2

Figure 5.8:SEM analysis Result for Sample 3

5.5 DENSITY CALCULATIONS:

Density is a measure of how heavy an object is for a given size. Changes

in temperature do not significantly affect the density of a material. An Increase in Density

usually increases the strength of material like Tensile Strength, Hardness, Toughness. Density

of Al6061 is 2.67 gm/cc .The Density of the composite is measured by the principle that

weight of the body submerged is equal to the weight of the water displaced.

41
 Table 5.4: Density Calculations

S.No Material Density (gm/cc)

1 Al6061+10% SiC+5% Fly ash 2.48
2 Al6061+15% SiC+5% Fly ash 2.52
3 Al6061+20% SiC+5% Fly ash 2.58

2.6

2.58

2.56

2.54

2.52
Density (gm/cc)

2.5

2.48

2.46

2.44

2.42
Specimen 1 Specimen 2 Specimen 3

Figure 5.9:Comparision of Density of different specimens

42
 CHAPTER 6

CONCLUSIONS

1. The Studies clearly shows that 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.

2. It is evident that addition of reinforcement upto a particular level increases the

mechanical properties like Density, Impact strength and Hardness.

3. Aluminium metal matrix composites have been successfully fabricated by Stir casting

technique with fairly uniform distribution of fly ash and SiC particles which improves

the Hardness of matrix material.

4. The Density of composites are found improved than their base matrix.

5. The tensile strength properties of the composites are found higher than that of base

matrix.

6. The Hardness of Specimen increases by 6.89% and 3.22% respectively and the

highest BHN value is obtained at 20 weight percentage of SiC.

7. The Hardness increases with increase of SiC by 5 weight percentage at constant 5

weight percentage of Fly ash.

8. The Ultimate Tensile Strength of 15 weight percentage of SiC is more when

compared with 10weight percentage and 20 weight percentage SiC.

9. The Impact strength is maximum at the 15 weight percentage of SiC which is 5.26%

more than that of 10 weight percentage of SiC.

10. The Density of composite is increased with increase in weight percentage of SiC.

11. The Density of composite material is increased by 1.61% and 2.38% respectively.

12. The Density at 20 weight percentage of SiC is more when compared with 15 and 10

weight percentage of SiC.

43
 13. The Mechanical strength of Al6061 – 15 wt % of SiC is superior to those of

unreinforced materials.

14. The Ultimate Yield strength decrease upon the addition of SiC which indicates that

the addition of SiC and Fly ash would increase the brittleness.

15. From this study, it is concluded that we can use Fly ash for production of Composites

and can turn industrial waste into industrial wealth. This can also solve the problem

for storage of Fly ash.

16. From the SEM analysis, it is clear that the stirring is done and the distribution of

reinforcement particles is uniform for specimens.

17. More number of blowholes indicates that the wettability of reinforcement particles is

more and the preheating of reinforcements is insufficient.

6.1 SCOPE FOR FUTURE WORK:

1. This can further be extended by varying geometrical angle of Stirrer and by varying

Stirring speed.

2. Result can be varied by varying Reinforcement Size.

3. Stir casting process,Stirrer Design and Position, Stirring Speed and time, Particle

preheating temperature, particle incorporation rate are important process parameters.

4. To improve the metallurgical as well as mechanical properties as compared to its base

matrix, We can use agro waste like Bauxite residue, Ground nut Shell, Rice Husk ash

reinforcement in Matrix phase.

5. Since Stir catsing method is suitable up to 30 wt % of reinforcement material we can

use other new technique for obtaining Hybrid composites which would increase the

mechanical properties.

44
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48