INTERNATIONAL JOURNAL OF PRODUCTION (IJPTM), ISSN 0976 6383 International Journal of Production Technology and Management TECHNOLOGYAND (Print),

ISSN 0976 6391 (Online) Volume 3, Issue 1, January- December (2012), IAEME MANAGEMENT (IJPTM)
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INVESTIGATION OF MECHANICAL BEHAVIOUR IN FORMING OF SINTERED COPPER-15%TUNGSTEN NANO POWDER COMPOSITE

N.Vijayponraj1, Dr.G.Kalivarthan2, Vetrivel.S.C3 Research Scholar, CMJ University, Meghalaya, Shillong, India Principal/Dept of Mech. Engg, PSN Institute of Technology and Science, Tirunelveli, Tamilnadu, India, Supervisor CMJ University, Shillong. 3 Asso.Prof/Dept. of Mech. Engg, PET Engineering College, Tirunelveli, Tami nadu, India, E mail: vijay_ponraj@yahoo.com , Sakthi_eswar@yahoo.com
2 1

ABSTRACT Experimental investigations are performed in order to predict the mechanism of deformation and densification behaviour during cold upset forming operation on sintered Cu15%W Nano composite. High-energy mechanical milling was used to produce Cu and W Nano powder composites. Cylindrical preforms with initial theoretical density of 85% possessing three different aspect ratios of 0.40, 0.60 and 0.80 were prepared using a die and punch assembly with a hydraulic press. The preforms are sintered in an electric muffle furnace at 650C, and subsequently the furnace was cooled. Cold deformation experiments are conducted in incremental deformation steps. The relationships between various parameters are evaluated Keywords: Metal-Matrix Composites (MMCs), Nano-structures, Preform, Mechanical properties, Sintered copper-15% Tungsten 1. INTRODUCTION

Composite material is the combination of two or more materials which are having different phases and the properties superior to the base materials. Composite materials are produced by casting and powder metallurgy methods. By means of casting methods, composite materials reinforced by dispersion particles [1, 2], platelets [3], non-continuous (short) fibres and continuous (long) fibres [4-5] as well as composite materials with hybrid reinforcement composed of particles and fibres [6] are produced by powder metallurgy methods, composite materials reinforced by dispersion particles [7-9], platelets [13], noncontinuous fibres [10-11] and continuous fibres [12] are manufactured. High-energy mechanical ball milling can be used to produce nano powders from micron size. When mechanical milling is used in the traditional sense, the process does not generate a new material, since the microstructure of the powder does not change. Particulate composites are prepared by mixing reinforcement and matrix material in powder form and
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International Journal of Production Technology and Management (IJPTM), ISSN 0976 6383 (Print), ISSN 0976 6391 (Online) Volume 3, Issue 1, January- December (2012), IAEME

cold pressing to near theoretical density. An important aspect of composites is their fabricability to near-net shapes. To develop and improve near-net shape forming process the study on analyzing the fabrication process is necessary as well as experimental study on fabrication of composites. Most of the authors were reported the deformation behaviour of various powder composites in micro and nano particle sizes except Cu-W. The material properties of the sintered compacts were ascertained from the uniaxial compression test with 15% Tungsten with copper three aspect ratios 0.40, 0.60 and 0.80. Graphite was used as surface preform lubricant. From this study, it was also attempted to establish the relationship between the fractional theoretical density, the Poissons ratio and other parameters namely the stress, strain and strain factor under Cu-10%W preform compositions. Table 1 Characteristics of powder Test Standard Property EC/86 Grade IS 5461 (a) Copper Powder ASTM B-417 Apparent density (g/cc) 1.56 ASTM B213 Flow rate Sec(50g-1) Nil ASTM E194 Acid Insoluble Nil Value 99.00 3.90 1.87 0.22 97.90

Sieve analysis, % +75m +45m -45m 0.40 5.40 94.20

Characteristics Sieve analysis : - 45 m Average Particle Size, Fisher Number Oxygen Content (Hydrogen Loss) Other Impurities Purity

(b) Tungsten Powder Test Standard ASTM D-185 ASTM B-330 ASTM E-159 AAS

2. EXPERIMENTAL DETAILS 2.1 Materials and characteristics Copper and Tungsten powders were used in the present investigation. These powders were purchased from M/s. Metal Powder Company (P) Ltd., Tirumangalam, Madurai, Tamilnadu, India. Electrolytic copper and atomised tungsten were obtained with 100% and 99.00% purity respectively. The characteristic of the copper and Tungsten powder is shown in Table 1 (a-b). The individual powders were pulverized in a high energy ball mill (Fritsch, Germany - Pulverisette - 6) for four hours after that it was mixed on weight basis with 5% Tungsten and rest Copper powder. These composite powders were pulverized in a high energy ball mill and after 10 hours milling, the obtained particle size was approximately below 400nm. SEM was used for evaluation of morphological changes of the particles after milling and is shown in Fig. 1(a-c). Fig. 1(a) shows the SEM image of the Cu particles at 9500X magnification and has a structure of a cluster of tiny particles and like small flattened flake particles due to severe plastic deformation of copper, micro-welding and fracture of the large flakes due to typical mechanical milling. Fig. 1(b - c) shows the SEM image of the W powders at 6000X and 2000X magnification respectively, It is in the formation of flattened particles with pancake structure. Fig. 1(d) shows the SEM image of the Cu-10%W Powder
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International Journal of Production Technology and Management (IJPTM), ISSN 0976 6383 (Print), ISSN 0976 6391 (Online) Volume 3, Issue 1, January- December (2012), IAEME January

Composite at 8000X particles. It shows the morphological changes of Cu 10%W powder Cu-10%W mixture after 10 hours milling. No significant difference between the Cu morphology in the significant composite and the monolithic W powder is observed at low milling times; that means the fine W elements distributed throughout the Cu matrix and represents the particle size in the range between 200-400nm.

(a)

(b)

Fig. 1 SEM micrograph after ball milling (a) Cu powder 9,500 X (b) W powder 6,000X . 2.2. Compacting Cylindrical compacts of 20 mm diameter with an aspect ratio of 0.40, 0.60 and 0.80 were prepared. The compacts were prepared using ball milled Cu-10% W composite. The mi 10% composite powders were compacted by using suitable punch and die set assembly on a Universal Testing machine having 1 MN capacity. Compacting pressure was applied gradually and it was 1.2 GPa for three aspect ratios. Graphite was used to lubricate the punch, was die and the butt. When preparing the compacts, the initial density and aspect ratio were maintained by precisely controlling the mass and accurately monitoring the compacting pressure employed. 2.3 Sintering After the compaction, the compacts were immediately taken out from die set action, assembly and loaded into the furnace for sintering. To prevent oxidization, the green compacts were initially covered with inert argon atmosphere in the furnace. The sintering was carried out in an inert gas circulated electric muffle furnace at 650C for a holding period of one hour. As soon as the sintering schedule was over, the sintered preforms were cooled inside the furnace itself to the room temperature. After the completion of sintering, t the preforms were cleaned by using a fine wire brush. 2.4 Cold Deformation Experiments Deformation experiments were carried out by using flat faced dies and a hydraulically operated compression testing machine of having 1MN capacity. The flat dies were machined m and tempered. Flat faces of the dies were ground after heat treatment in a grinding machine, in order to obtain the final dimensions and surface quality and its hardness was measured as 91 HRB after tempering. Graphite was well applied as lubricant on the ends of preforms and contacting surfaces of flat dies, which created a situation for almost frictionless ideal deformation. In general, each compact was subjected to an incremental compressive loading in steps of 50kN until the appearance of visible cracks on the free surface. Immediately, after visible
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International Journal of Production Technology and Management (IJPTM), ISSN 0976 6383 (Print), ISSN 0976 6391 (Online) Volume 3, Issue 1, January- December (2012), IAEME

the completion of each step of loading, the height, the contact diameters at the top and bottom, the bulged diameter and the density were measured for each of the deformed preforms. The density measurements were carried out using Archimedes principle. Experimental measurements were also used to calculate the various parameters namely the stresses, the Poissons ratio, density ratio and the strain. The Theoretical approach to calculate the above parameters are discussed in detail under ref. [13]. 3. RESULTS AND DISCUSSION 3.1. Deformation Behaviour of Preforms The results of deformation behaviour of 85% initial fractional density, Cu-15%W composite preforms are discussed in this section. The following stress strain relationship concerning the plastic deformation is discussed in detail for the various aspect ratios with graphite lubricants 3.1.1. Various stresses and axial strain Using the simple theory of plasticity, the axial stress (z), the hoop stress () and the hydrostatic stress (m) were calculated and plotted against the axial strain (z) for different aspect ratios in Figures 2(a c) for the Cu-15%W composite preforms. The hoop stress is tensile in nature because during compressive loading the bulged diameter expands. Meanwhile, for any deformation level, the increase in the hoop stress due to loading is very low compared to that of the axial stress. However, the value of the hydrostatic stress is much less than the other stresses, namely the axial stress (z) and the hoop stress () and it is also compressive in nature, at different strain level. For all preforms, the axial and the hoop stress level also increases for a given aspect ratio. The values of the axial stress, the hoop stress and the hydrostatic stress are high for the lower aspect ratio (0.40) than higher aspect ratios (0.60and 0.80) preforms.

600 400 200

Initial Fractional Density 0.85 Cu -15%W Aspect Ratio:0.8 Lubricator: Graphite

Stess,Mpa

0 0 -200 -400 -600 0.5 1 1.5

Axial Stress Hoop Stress Hydrostatic Stress

(a)

Axial Strain

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International Journal of Production Technology and Management (IJPTM), ISSN 0976 6383 (Print), ISSN 0976 6391 (Online) Volume 3, Issue 1, January- December (2012), IAEME

600 400 200

Initial Fractional Density 0.85 Cu -15%W Aspect Ratio:0.6 Lubricator: Graphite

Stess,Mpa

0 0 -200 -400 -600 0.5 1 1.5

Axial Stress Hoop Stress Hydrostatic Stress

(b)

Axial Strain

600 400 200 0 0 -200 -400 -600 0.5 1 1.5

Initial Fractional Density 0.85 Cu -15%W Aspect Ratio:0.4 Lubricator: Graphite

Stress,Mpa

Axial Stress Hoop Stress Hydrostatic Stress

(C)

Axial Strain

Fig. 2.The Variation of stresses with respect to axial strain for various aspect ratios (a) 0.80 (b) 0.60 (c) 0.40 3.1.2 Axial stress and axial strain Fig.3 shows the effect of aspect ratio on the characteristic features of the axial stress (z) against the axial strain (z) for a given initial fractional density of 0.85 of Cu-15%W composite. These plots are similar in nature irrespective of the aspect ratio values. It is observed that the true axial stress increases rapidly as the true axial strain is increased, followed by a gradual increase in the true axial stress with further increase in the axial strain. Further, it is found that the 0.80 preform improved load bearing capacity compared to that for other aspect ratios, while the initial fractional density remains constant.

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International Journal of Production Technology and Management (IJPTM), ISSN 0976 6383 (Print), ISSN 0976 6391 (Online) Volume 3, Issue 1, January- December (2012), IAEME
Initial Fractional Density 0.85 Cu -15%W

1000 Axial Stress 800 600 400 200 0 0 0.5 Axial Strain 1 1.5 Aspect ratio 0.4 Aspect ratio 0.6 Aspect ratio 0.8

Fig.3 The relationship between z and z 3.2 Densification Behaviour of preforms In densification behaviour of preforms the following relationships are discussed in detail by varying the initial aspect ratio provided the initial fractional density value is kept constant for Cu-15%W composites. f e ( z ) Fractional density and strain parameter th 3.2.1. Fractional density and strain parameter Figure 4 has been drawn to establish the relationship between the fractional density
value f of the deforming preform and the value of e ( z ) in accordance with the th

theoretically-derived relationship [16] for sintered P/M preforms during cold axial deformation. The plots show the existence of power law relationship between the fractional theoretical density f and e ( z
th

. However the lower aspect ratio shows better

fractional density values because it has lesser porosity.

1.04 1.02 Fractional Density 1 0.98 0.96 0.94 0.92 0.9 0.88 0 0.5 1 1.5 Aspect ratio 0.4 Aspect ratio 0.6 Aspect ratio 0.8

Cu -15%W

Strain Parameter

Fig.4 The relationship between Fractional Density and Strain parameter

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International Journal of Production Technology and Management (IJPTM), ISSN 0976 6383 (Print), ISSN 0976 6391 (Online) Volume 3, Issue 1, January- December (2012), IAEME

4. CONCLUSION The study has been carried out of cold upset forming of sintered Cu-15%W nano composites performs. The basic conclusions that can be drawn from the present investigations are as follows. The axial stress has an increased trend with higher level of deformation till failure. This is because, at the time of increasing the load, the pores in the preforms are flattened and contact surfaces are increased. So the load bearing capacity increasing steeply by increase of strain. Lower aspect ratio exhibits improved densification and load bearing capacity compared to that of higher aspect ratio performs densify uniformly and quite easily due to rapid load transfer resulting in extensive work-hardening. REFERENCES [1] Corbin S F, Wilkonson D S. The tensile properties of a particulate reinforced Al alloy in the temperature range 196-300C. Canad Metall 1996; 35:189-198. [2] Gupta M, Lai M O, Soo C Y, Effect of type of processing on the microstructural features and mechanical properties of Al-Cu/Si metal matrix composites. Mater Sci Eng 1996; A 210:114-122. [3] Kainer K U. Cast magnesium alloys reinforced by short fibre. In: Proceedings of the International Conference on Magnesium Alloys and their Applications. GarmischPartenkirchen 1992; p. 415-422. [4] Bowman R R, Misra A K, Arnold S M. Processing and mechanical properties of Al2O3 fiber-reinforced NiAl composites. Metall Mater Trans 1995; 615-628. [5] Schroder J, Kainer K U. Magnesium base hybrid composites prepared by liquid infiltration. Mater Sci Eng 1991; 243-246. [6] Abkowitz S, Weihrauh P F, Abkowitz S M. Particulate-reinforced titanium alloy composites economically formed by combined cold and hot isostatic pressing. Ind Heating 1993; 32-37. [7] Doel T J A, Bowen P. Tensile properties of particulate-reinforced metal matrix composites. Composites A 27 1996; 655-665. [8] Mordike B L, Kaczmr J, Kielbinski M, Kainer K U. Effect of tungsten content on the properties and structure of cold extruded Cu-W composite materials. Powder Metall Int 1991; [9] Kainer K , Schroder J, Mordike B L. Influence of various P/M production methods on the properties of magnesium-SiC-Composites. In: Proceedings of the International Conference on Advanced Composites 1993; p.1061-1065. [10] Kaczmar J W, Kainer K U, Effect of alumina fibre content on properties of PM 6061 aluminium alloys based composite materials, Powder Metall 1992; 35:133-135. [11] Kuhn H A, Downey C L, How flow and fracture affect design of preforms of powder forging. Powder Metal Powder Technol 1974; 10 (1): 5966. [12] Kuhn H A. Deformation processing of sintered powder materials. In: Powder Metallurgy Processing Academic Press. New York 1978; p.99138. [13] Selvakumar N, Narayanasamy R. Deformation Behavior of Cold Upset Forming of Sintered Al-Fe Composite Preforms. J Eng Mater Technol 2005; 127: 241-246. [14] Vetrivel.s.c., N.Selvakumar, N.Vijay Ponraj. Mechanical Behaviour of Copper-5%W Nano Composite. Journal of Procedia Engineering.

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