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European Journal of Scientific Research ISSN 1450-216X Vol.76 No.4 (2012), pp.539-552 EuroJournals Publishing, Inc. 2012 http://www.europeanjournalofscientificresearch.

com

Tribological Characterization of Stir-Cast Hybrid Composite Aluminium 6061 Reinforced with SiC and B4C Particulates
V. C. Uvaraja Corresponding Author, Bannari Amman Institute of Technology Sathyamangalam, Erode E-mail: c_uva@rediffmail.com Tel: +91-9894459784; Fax: +91-04295-223775 N. Natarajan RVS Faculty of Engineering, Sulur, Coimbatore Abstract An attempt has been made to study the influence of operating parameters such as applied load, sliding speed, percentage of reinforcement content and sliding distance on the dry sliding wear of 6061 aluminium with SiC and B4C particulate reinforced composite. The particulate reinforced 6061 aluminium alloy with a constant weight percentage of B4C particulate and varying range of SiC particulate is produced by stir casting technique. In order to achieve good binding between the matrix and particulates, 1% of magnesium alloy is added. Under dry condition the hybrid composite performances were investigated by pinon-disc with varying load conditions. The uniform distribution of particulates reinforced in the matrix was examined with the help of Optical-Microscope. The wear surfaces of the specimen at room temperature were examined before and after the wear test by using Scanning Electron Microscope (SEM). The hardness of the specimen at room temperature was also measured before the wear test by Rockwell hardness test machine. As the volume fraction of SiC and B4C reinforcement increases, the magnitude of hardness also increases. This investigation overviews that 6061 hybrid composite with high hardness can replace the conventional material used in automobile components for better performance and longer life.

Keywords: Wear, Stir-cast, Hybrid composite, Particulate Reinforcement, SEM

1. Introduction
The best part of effort in Al matrix composite has been directed towards development of high performance composite with high strength and good tribological properties for using in automotive and aerospace application. The Al matrix composite reinforced with SiC and B4C particulate are a new range of advanced materials. In general, a hard material is employed as reinforcement because of potential improvement in mechanical properties such as hardness and tensile strength which are the desirable properties in tribological application. This greatest improvement in mechanical properties is generally obtained by means of reinforcement with appropriate particulates. The sliding wear of the composite is a complex process involving not only mechanical but also thermal and chemical interaction between two surfaces in contact. The wear resistance of these materials is of our present interest because of their potential tribological characteristics that are very well applicable in automobile

Tribological Characterization of Stir-Cast Hybrid Composite Aluminium 6061 Reinforced with SiC and B4C Particulates

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such as IC engines components, brake disc etc. A number of studies have been engaged during the last twenty years on wear behaviour of Al based particulate reinforced composite. Reinforcement of Al based alloy with SiC or Al2O3 are usually been found to improve the wear resistance under abrasion and lubricated sliding condition. A literature survey on Al based composite has been done and related brief data are given; Yoshiro Iwai et. al. [1] found that the initial sliding distance require to achieve mild wear decreased with increasing volume fraction and also severe wear rate decrease linearly with volume fraction. A P Sannino [2] suggested that the increasing particle size of SiC from 4 to 29 micron increased the coefficient of friction. Ali Mazahery and Mohsen Ostacl Shabani [3] emphasized that higher hardness of composite could be achieved by ceramic reinforced particulate (B4C) because B4C particle acts as an obstacle to the motion of dislocation. Alpas and Zhang [4] while investigating the wear of particle reinforced Metal Matrix Composites (MMC) under different applied load conditions identified three different wear regimes. At low load (regime I), the particles support the applied load in which the wear resistance of MMCs are in the order of magnitude better than Al-alloy. At regime II, wear rates of MMCs and Al-alloy were similar. At high load and transition to severe wear (regime III), the surface temperature exceeded the critical value. According to J.Hashim [5], proper selection and controlling of processing variables could achieve good quality of composites. S.M.Seyed Reihani [6] reported the effect of SiC particles on the aging behavior, mechanical properties and wear resistance of Al (6061) alloy made by squeeze casting method. D.P.Mondal [7] opinion was that the applied load affects the wear rate of alloy and composites significantly and is the most dominating factor controlling the wear behavior. The cumulative volume loss increases with increasing applied normal load and the contact surface temperature increases as the applied load increases. Kowk and Lim [8] suggested that massive wear occurs if the particles are smaller than the threshold value at higher speeds. A. Daoud et.al [9] reported that addition of magnesium alloy to composite during production ensures good bonding between the matrix and the reinforcement. A.Wang and H.J.Rack [10] reported that the steady state wear rate of 7091Al matrix composite is generally independent of reinforcement geometry (particulate versus whisker) and orientation (perpendicular versus parallel) with the exception of wear at 3.6m/s where the parallelly oriented SiC composite was found to be superior. C. Subramanian [11] and Chen .M, Perrry. T, Alpas. A.T [12] suggested the incorporation of silicon in Al-alloy and the results concluded that the higher wt.% of Si improves the hardness of the composites and increased particle size improves the load carrying capability of the composites. Peter J, Blau [13] defined wear as the progressive loss of material due to relative motion between the surface and the contacting substance or substances. According to U.Sanchez-Santana, C.Rubio-Gonzalez, G.Gomez-Rosas, J.L.Ocana, C.Molpeceres and J.Porro, M.Morales [14] the wear damage may be in the form of micro-cracks or localized plastic deformation. Abdulhaqq A.Hamid, P.K.Ghosh, S.C.Jain, Subrata Ray [15] found that the wear rate varies with normal load, which is an indicative of Archards law and is significantly low in the case of composites.

2. Experimental Procedure and Materials


2.1. Material and Sample Details Dry sliding wear tests were performed on SiC and B4C particulates reinforced Al (6061) alloy (Al-MgSi) matrix composite. Table1 shows the nominal composition weight percentage of matrix materials and Table 2 shows the Rockwell Hardness and density of material in tempered condition. The hardness measurements were made by applying a load of 100kg and the average is calculated from 10 different values of the experiments. The density measurements were all set according to the ASTM standard C1270-88. The particulate morphology study results such as size and shape details are given in Table 3 and plate1 and plate2 shows SEM morphologies of SiC and B4C particulate reinforcements respectively. The wear samples were in the form of circular rod (10mm diameter and 30mm height)

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fabricated by stir cast techniques. The average weight percentage of SiC and B4C particulates in the composites were determined by quantities metallographic digital image analyzer.
Table 1:
Material Percentage

Nominal composition weight percent of matrix material.


Si 0.43 Fe 0.7 Cu 0.24 Mn 0.139 Ni 0.05 Pb 0.24 Zn 0.25 Ti 0.15 Sn 0.001 Mg 0.802 Cr 0.25 Al Balance

Table 2:

Matrix material hardness and density.


Matrix Material 6061 Al Rockwell hardness (HRC) 72.25 Density (g/m3) 2.70

Table 3:
Particulate SiC B4C

Particulates morphology details.


Size Range (m) 30-70 5-20 Shape Angular irregular Angular - irregular

Plate 1: SEM morphologies of Silicon Carbide.

Plate 2: SEM morphologies of Boron carbide.

2.2. Processing Methodology Metal matrix composites are generally produced either by Liquid Metallurgy Route (LMR) or Powder Metallurgy Technique (PMT). In LMR the particulate phases are mechanically dispersed in the liquid phase before solidification of the melt. Stir casting technique is one of popular LMR method and also known as a very promising route for manufacturing near net shape hybrid metal matrix composite components at a normal cost.

Tribological Characterization of Stir-Cast Hybrid Composite Aluminium 6061 Reinforced with SiC and B4C Particulates

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The execution of stir casting technique yields relatively homogenous and fine microstructure which improves the addition of reinforcement material in the molten metal. In addition, the porosity level of composite should be minimized and the chemical reaction between reinforcement and matrix should be avoided. The proper selection of process parameter such as pouring temperature, stirring speed, pre-heat temperature of reinforcement can produce good quality composites. In this present work, stir casting technique was used to fabricate 6061 Aluminum alloy with varying weight percentages of SiC (5, 10, and 15) and a constant weight percentage of B4C (3) reinforcements. The experimental set up were as shown in plate 3 and plate 4. The stir casting furnace is mounted on the floor and the temperature of the furnace is precisely measured and controlled in order to achieve sound quality composite.Two thermocouple and one PID controller were used for this purpose. Because of mild steel materials having high temperature stability, it is selected as stirrer rod and impeller. This stirrer was connected to 1HP DC Motor through flexible link and was used to stir the molten metal in semi solid state. The screw operator lift is used to bring the stirrer in contact with the composite material. The melt was maintained at a temperature between 750 to 800 oC for one hour. Vortex was created by using a mechanical stirrer. Weighed quantity of SiC (5,10 and 15wt.%) along with 3 weight percentage of B4C particulate, preheated at 600C were added to the melt with constant stirring for about 10min at 500 to 650rpm for all samples.
Plate 3: Stir cast unit with control system.

Plate 4: Stir cast unit with mechanical stir setup.

2.3. Pin-On-Disc Wear Test The composite specimen of a pin were rubbed against a hardened steel at various load conditions such as 10N, 20N and 40N (1kgf, 2kgf and 4kgf) and different velocities such as 1.571m/s, 3.142m/s and 4.712m/s. Dry sliding wear tests were carried out using pin -on- disc type wear tester at different sliding velocity such as 1.57m/s, 3.142 m/s and 4.712 m/s within a load range of 10 to 40N (1kgf to 4kgf). Plate 5 and plate 6 shows the complete pin-on-disc wear test experimental setup. The slider disc is made up of 0.95 to 1.20% carbon (EN31) hardened steel disc with hardness of 62 HRC having

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diameter 165mm. The pin test sample dimensions were 10 mm diameter and 30 mm height. Care should be taken to note that the test samples end surfaces were flat and polished metallographically prior to testing. Conventional aluminium alloy polishing techniques were used to get ready the contact surfaces of the monolithic composite aluminium specimen for wear test.The procedure involves grinding of composite aluminium surfaces manually by 240, 320, 400, and 600 grit silicon carbide papers and then polishing them with 5, 1, & 0.5m alumina using low speed polishing machine. This preparation technique created considerable surface relief between hard and soft aluminium matrix. The polished surfaces were cleaned ultrasonically with acetone and methanol solutions. The counter face materials were also polished and cleaned ultrasonically in acetone and methanol solutions before each wear test. The steel slider was polished using the above described procedure and all the tests were conducted at room temperature. At a given load level, weight loss from the worn surfaces were found to increase linearly with sliding distance, except during the transient period at the beginning of the test. The wear rates were calculated from the slope of weight loss versus sliding distance curves determined at several applied load levels within the range of 10 to 40N. The wear rates measured in weight units were then converted to volumetric wear rates. The micro structural investigation and semi quantitative chemical analysis on the worn surfaces were performed by SEM. 2.4. Hardness Test The resistance indentation or scratch is termed as hardness. Hardness test was carried out at room temperature using Rockwell hardness tester with at least six indentations of each sample and then the average values were utilized to calculate hardness number. The hardness of MMCs increases with the volume fraction of particulate in the alloy matrix. The added amount of SiC and B4C particles enhances hardness, as these particles are harder than Al alloy, which render their inherent property of hardness to soft matrix as shown in figure 1. The hardness graph shows that the sample with less than 5 wt% of SiC and 3 wt% B4C particulate behaves almost the same as unreinforced. But the sample with 15 wt% SiC and 3 wt% B4C showed slightly high hardness and low toughness as compare to 10wt% SiC and 3 wt% B4C. Higher the percentage of particulates in the matrix lesser is the toughness. Composites with higher hardness could be achieved by this technique which may be due to the fact that silicon carbide and boron carbide particles act as obstacles to the motion of dislocation. Therefore, from this study it is evidently indicated that 10 wt% SiC and 3 wt% boron carbide composite sample have high hardness and good toughness. Hence this may be considered as the optimum weight percentage of the particulate to achieve better hybrid composite properties for heavy vehicle applications.
Figure 1: Hardness of unreinforced alloy and composites at different volume fraction

Tribological Characterization of Stir-Cast Hybrid Composite Aluminium 6061 Reinforced with SiC and B4C Particulates

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3. Results and Discussion


3.1. Microscopic Examination The Optical Microscopy illustrates the microstructures of Al (6061) alloy and Al (6061) composite with different volume fraction of SiC and a common volume fraction of B4C. Plates 7, 8, 9 & 10 show the optical microscopic images at 100X magnification for both unreinforced and reinforced samples. However, a very few reinforcement particles were found to be of irregular shape resulting in random dispersion throughout matrix.
Plate 7: Optical Microscope image of unreinforced Al (6061) alloy at 100X magnification.

Plate 8:

Optical Microscope image of 5% SiC + 3% B4C particulate reinforced Al (6061) composite at 100X magnification.

Plate 9:

Optical Microscope image of 10% SiC + 3% B4C particulate reinforced Al (6061) composite at 100X magnification.

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Plate 10:

V. C. Uvaraja and N. Natarajan


Optical Microscope image of 15% SiC + 3% B4C particulate reinforced Al (6061) composite at 100X magnification.

3.2. Wear Characteristics 3.2.1. Effect of Sliding Distance on Co-Efficient of Friction Figure 2(a), 2(b) & 2(c) clearly elucidates the relationship between co-efficient of friction and sliding distance under different load condition. In all the samples, the co-efficient of friction decreases with increase in sliding distance under different load conditions. The friction co-efficient is higher at the commencement of the test due to the elevated friction force between the disc and the pin surface. Friction co-efficient of test specimen was obtained from the frictional force during sliding condition. The variation of co-efficient of friction against sliding distance was studied for three different applied loads like 10N, 20N, & 40N for unreinforced alloy and three different composite specimens with varying volume percentage particle reinforcement (5, 10 & 15% of SiC). From this test its shows the co-efficient of friction of composite is low with high 15%SiC for all loads, but considering the different loads condition then under high load 40N (figure 3) the composite shows opposite results that is high coefficient of friction.
Figure 2(a): Co-efficient of friction of unreinforced alloy and composites at applied load of 10N with a function of sliding distance

10N 0 .4 0 Co-efficient of friction


5 % S iC + 3 % B 4 C 1 0 % S iC + 3 % B 4 C 1 5 % S iC + 3 % B 4 C Al 6061

0 .3 5

0 .3 0

0 .2 5 1000 2000 3000 4000

S lid in g d is ta n c e (m )

Tribological Characterization of Stir-Cast Hybrid Composite Aluminium 6061 Reinforced with SiC and B4C Particulates

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Figure 2(b): Co-efficient of friction of unreinforced alloy and composites at applied load of 20N with a function of sliding distance
0.5 20N
5%SiC+3%B4C 10%SiC+3%B4C 15%SiC+3%B4C Al 6061

Co-efficient of friction

0.4

0.3 1000 2000 3000 4000

Sliding distance (m)

Figure 2(c): Co-efficient of friction of unreinforced alloy and composites at applied load of 40N with a function of sliding distance
40N Co-efficient of friction 0.5
5%SiC+3%B4C 10%SiC+3%B4C 15%SiC+3%B4C Al 6061

0.4

0.3 1000 2000 3000 4000

Sliding distance (m)

Figure 3: Co-efficient of friction of unreinforced alloy and composites at different loads

Co-efficient of friction

0.5
5%SiC+3%B4C 10%SiC+3%B4C 15%SiC+3%B4C Al 6061

0.4

0.3 10 20 Load (N) 30 40

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V. C. Uvaraja and N. Natarajan

1.2.2. Effect of Sliding Distance on Wear Rate Figure 4(a), 4(b) & 4(c) clearly explains the correlation between wear rate and sliding distance. The wear rate decreases and attains a lower steady value with the increase in sliding distance, in all the samples. Test specimens wear rate was obtained from the ratio between volume loss and sliding distance. The variation of wear rate against sliding distance was calculated for three different applied loads like 10N, 20N, & 40N for unreinforced alloy and three different composite specimens with varying volume percentage particle reinforcement (5, 10 & 15% of SiC) and is depicted in figures 4(a,b&c).
Figure 4(a): Wear rate of unreinforced alloy and composite at applied loads of 10N as a function of sliding distance
2.0

10N
1.8 m /m) 1.6 1.4 1.2 1.0 0.8 1000 2000 3000 4000
5%SiC+3%B4C 10%SiC+3%B4C 15%SiC+3%B4C Al 6061

Wear rate (10

-12

Sliding Distance (m)

Figure 4(b): Wear rate of unreinforced alloy and composite at applied loads of 20N as a function of sliding distance.

3.0 m /m) 2.5 2.0 1.5 1.0 1000


5%SiC+3%B4C 10%SiC+3%B4C 15%SiC+3%B4C Al 6061

20N

Wear rate (10

-12

2000

3000

4000

Sliding Distance (m)

Tribological Characterization of Stir-Cast Hybrid Composite Aluminium 6061 Reinforced with SiC and B4C Particulates

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Figure 4(c): Wear rate of unreinforced alloy and composite at applied loads of 40N as a function of sliding distance
5

40N
5%SiC+3%B4C 10%SiC+3%B4C 15%SiC+3%B4C Al 6061

-12

m /m) Wear rate (10

1 1000 2000 3000 4000

Sliding Distance (m)

The following observations were made from figures 4(a,b&c), 1. At a constant sliding distance, the wear rate for the unreinforced alloy was found to be larger than the reinforced composite material in all the cases. 2. The reinforced composite with higher concentration of SiC (15%) shows better decrease in wear rate. 3. At the maximum load of 40N, wear rate is high at the range of 30 to 40 % as compared to other load condition. 4. Thus the wear rate is low at low applied load and high sliding distance. 3.2.3. Effect of Applied Load on Wear Rate Figure 5(a), 5(b) & 5(c) shows the effect of applied load of the 6061 Al with 5 to 15% SiC and 3% B4C composite worn against hardened steel. The wear rates of the composite do not increase monotonically through the entire applied load range. Wear rate depends on the presence of carbide phase in matrix. Plate 11show the SEM worn surface micrographs of both unreinforced and reinforced sample. The pure Al 6061 worn surface as shown in plate 11 which has a smooth surface nature and more tribolayers are formed hence the wear rate is more in the unreinforced sample. The examination of hybrid composite sample worn surfaces as shown in plates 11 (b), (c) and (d) showed that rough surface nature and less tribolayers due to silicon carbides and boron carbide embedded in matrix as compared to the unreinforced alloy.
Figure 5(a): Wear rate of unreinforced alloy and composite at speed of 150rpm as a function of load

6 m /m)

5%SiC+3%B 4C 10%SiC+3%B 4C 15%SiC+3%B 4C Al 6061

-12

Wear rate (10

150rpm
10 20 Load (N) 30 40

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Figure 5(b): Wear rate of unreinforced alloy and composite at speed of 300rpm as a function of load
4
5%SiC+3%B4C 10%SiC+3%B4C 15%SiC+3%B4C Al 6061

m /m) Wear rate (10

-12

1 10 20 Load (N) 30

300rpm
40

Figure 5(c): Wear rate of unreinforced alloy and composite at speed of 400rpm as a function of load

6 m /m)
3

5%SiC+3%B4C 10%SiC+3%B4C 15%SiC+3%B4C Al 6061

-12

Wear rate (10

0 10 20 Load (N) 30

400rpm
40

(a)

(b)

Tribological Characterization of Stir-Cast Hybrid Composite Aluminium 6061 Reinforced with SiC and B4C Particulates

550

Figure 5(c): Wear rate of unreinforced alloy and composite at speed of 400rpm as a function of load - continued

(c)

(d)

Plate 11 shows the SEM photographs of the worn surface of (a) the unreinforced Al alloy and composites with (b) 5%, (c) 10% and (d) 15% reinforcement under an applied load of 40N.

3.2.4. Effect of Volume Fraction of Reinforcement Particulate on Wear Rate Figures 6(a), 6(b) & 6(c) illustrate the effect of varying volume fraction of reinforcement particulate on the wear rate. The wear rate of three Al 6061 alloy containing 5, 10, 15 percent SiC particles and 3% of B4C are compared. Increase in the volume fraction of the particle shows low wear rate. Figures 6(a,b&c) shows wear rate relationship with particulate percentage reinforcement. The reinforced Al MMC shows low wear rate as compared to unreinforced Al 6061 alloy due the presence of hard phase particulate in matrix.
Figure 6(a): Wear rate of unreinforced alloy and composite at applied load of 10N as a function of volume fraction
1 50rp m 6 m /m) 10 N 2 0N 4 0N 4
3 -12

Wear rate (10

10

15

V o lu m e fractio n o f S iC (% )

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V. C. Uvaraja and N. Natarajan

Figure 6(b): Wear rate of unreinforced alloy and composite at applied load of 20N as a function of volume fraction
5 150rpm 4 10N 20N 40N

m /m) Wear rate (10

3 -12

1 0 5 10 15

Volume fraction of SiC (%)

Figure 6(c): Wear rate of unreinforced alloy and composite at applied load of 40N as a function of volume fraction
5 300rpm 4 10N 20N 40N

m /m) Wear rate (10

3 -12

1 0 5 10 15

Volume fraction of SiC (%)

4. Conclusion
The objective of this study is to investigate the tribological behavior of different percentage of silicon carbide with boron carbide particulates in aluminum 6061 matrix hybrid composite. Hardness test, Pinon-disk test, SEM analysis and Metallographic examination were performed and the following results were obtained: 1. The fabricate 6061 Al alloy and composites with 5, 10, and 15 wt, % SiC reinforcements were found using stir caster technique. 2. The uniform distribution of the particles was obtained in the 6061Al/10 wt. % SiC cast at stirring speed of 650 rpm exhibits as compared to the other two composites. From optical microscope is observed in the 6061 Al alloy matrix and 10 wt. % SiC reinforcements act as a good bonding. 3. Hybrid composites showed high hardness as compared to unreinforced alloy due to hard phase silicon carbide and boron carbide particulates embedded uniformly in aluminum 6061 based matrix. 4. Hybrid composite sample with 10wt. % SiC and 3wt% B4C composition have better tribological properties. The reinforcement of Al 6061 alloy with SiC and B4C particulates up to a volume fraction of 5 to 15 wt. % has marked effect on wear rate. The wear rate and coefficient of friction decrease with increasing volume fraction of reinforcements.

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Acknowledgements
The authors would like to express their deep sense of gratitude to Mr. P. Suresh Kumar, Assistant professor in BIT, Sathyamagalam, for his valuable support and guidance. They also extend their gratefulness to Mr.S.Sudhakar, Asst. Manager, BEML Ltd, Mysore, for his constant guidance and discussion throughout the research work. The authors also would like to thank their M.E Students for all their supports. The authors would like to extend their gratitude to the everlasting blessings showered by Almighty Bannari Amman and Bannari Amman Institute of Technology for providing infrastructural support.

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