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Article history:
Received 21 February 2013
Accepted 10 May 2013
Available online 24 May 2013
a b s t r a c t
In this paper, a method of recycling aluminum and steel chip is presented by applying powder methodology. This method consists of the composite production, cold pressing, a new sintering method, denition of mechanical properties and fracture toughness. AISI 1040 steel chip was used as reinforcement
materials and AlMg1SiCu aluminum chip were used as matrix materials. AISI 1040 steel chip reinforcement was added into the matrix for 20%, 30% and 40% weight ratios. To determine the mechanical behaviors of composites, compressive strength, three point bending, hardness and fracture toughness, initial
notch depth method tests were performed at ambient condition. It was observed that steel chip reinforcement provided increased compressive strength and hardness, but the fracture toughness of composites decreased versus to increasing steel content. Considering analyses of microscopic micrographs of
composites (SEM), by increasing steel content causes an increase in the angular facets on fracture
surfaces.
2013 Elsevier Ltd. All rights reserved.
1. Introduction
Manufacturing sintered products by powder metallurgy method has been developed gradually in recent years. Especially, when
the recycling technologies for manufacturing have progressed, use
of waste products in metal industries comes into prominences [1].
In metal industries, waste and scrap metals that remain after
manufacturing processing are chip and discards. These waste
materials are reutilized by returning them to smelters. However,
during melting processes of materials for recycling, many metals
are lost due to occurring oxidation and costs of labor, energy and
environmental protection expenditures [2]. To overcome these disadvantages, there are different ways of recycling metal chip, consisting in the direct conversion of chip into compact metal. One
of them contains granulation which remains after cutting process,
then cold pressing and sintering processes. This type of recycling
can be applied to iron, copper, aluminum, to some extent to cast
metals and their alloys [3].
In the melting process for recycling aluminum waste and
scrap, approximately 10% of it is burst and approximately 10%
of it is lost on account of aluminum waste and scraps with the
slag removed from surface of the ladle [4]. The reason for the substantial losses of aluminum and aluminum alloys waste is due to
the rather long period of time in which it remains on the surface
Corresponding author. Tel.: +90 332 223 1907; fax: +90 332 241 01 56.
E-mail address: turandemirci@selcuk.edu.tr (M. Turan Demirci).
0261-3069/$ - see front matter 2013 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.matdes.2013.05.025
as molten aluminum and oxidizes intensively [2]. Therefore, powder methodology containing cold pressing and sintering processes
can be used to overcome all the disadvantages of recycling of aluminum waste chip. Aluminum chip especially are derived from
machining operations. For cold pressing and sintering, chip size
and irregular elongated spiral shapes make them unsuitable to
the cold pressing conditions. For obtaining optimum size and
shape of the chip, they must be broken into to small pieces by
milling processes.
Gronostajski et al. [5] investigated new methods for aluminum
and aluminum alloy chip recycling and compared conventional
and direct methods. Gronostajski et al. [6] in their study used the
direct recycling method which contains cold press molding and
hot extrusion. As aluminum alloys, they used Cu, Mg and W materials. As a result of their experiments, they determined that aluminum and its alloys can be recycled by a direct conversion method
which is characterized by low energy-consumption and large
material savings. Gronostajski et al. [4] investigated aluminum
chip composites and used the FeCr powder as a reinforcing phase.
The reinforcement of FeCr showed very good mechanical properties at room and elevated temperatures. Chmura et al. [7] studied
the recycling of aluminum and aluminumbronze chip in the use
of bearings. Bearing composites were produced by cold compaction
and hot extrusion. Mechanical and tribological properties were
determined for end of production processes of composite bearing
samples, and it was found aluminum-based with aluminum bronze
reinforcing phase have better frictional properties.
346
Table 1
Chemical composition of AlMg1SiCu aluminum and AISI 1040 steel chip.
AlMg1SiCu
AISI 1040
Si (%)
Fe (%)
Cu (%)
Mn (%)
Mg (%)
Al (%)
C (%)
P (%)
S (%)
0.67
0.2
0.74
98.6
0.123
0.138
0.65
1.26
96.7
0.4
0.04
0.2
Table 2
Mechanical properties of AlMg1SiCu and AISI 1040.
Materials
Elongation (%)
Elasticity (GPa)
AlMg1SiCu
AISI 1040
310
620
1416
25 (in 50 mm)
68.9
210
29
54
2. Experimental details
2.1. Raw materials
AlMg1SiCu aluminum chip was used as the matrix and AISI
1040 steel chip were used as reinforcing phase for the composite
materials. Chemical compositions, mechanical properties and fracture toughness were given in Tables 1 and 2 respectively. At the
beginning of the study, size reduction processes by using a cutting
device and sieve shaker were applied to aluminum and steel chip
which are remaining materials from sawing process. Then, the
sizes of the chip were reduced to grain sizes between 0.5 and
p
M)
Hardness (Brinell)
95
201
Table 3
Chip fraction used for this experiment.
Specimen
A
B
C
21
28
35
20
30
40
49
42
35
80
70
60
1 mm. Methyl alcohol was used to clean the chip from impurities
and cutting oils were used as lubricants and coolant. The cleaned
chips were dried at a temperature of 80 C in an oven for 2 h. Aluminum chip used as matrix material was mixed with 2040 wt%
ratios of reinforcing phase by mechanical stirrer for 15 min each
(Table 3) and so three different kinds of compositions were produced according to steel weight (%) contents.
347
Fig. 2. Microstructure photographs of the composite material surfaces after sintering process (15X).
p
K 1c r af a=W
where r is the stress, a is an initial notch depth, f (a/W) is a geometry factor. In addition, to calculate the geometry factor Eq. (2)
which given in ASTM were facilitated [13]. In this study, three different (a/W) notch depth ratios were applied to composites to
determine the changing fracture in terms of different a/W notch
depths (0.085, 0.095 and 0, 1) and the average fracture toughness
were found and discussed for all steel contents,
r 3PS=2BW 2
Fig. 3. Sintering tube for specimens.
348
(a) 80%Al20%AISI1040
(b) 70%Al30%AISI1040
(c) 60%Al40%AISI1040
Fig. 5. Instant photographs of failure of composite specimens.
349
80
70
60
15
20
25
30
35
40
45
Fig. 7. The graph showing the relation between hardness and steel chips content.
Fig. 10. Morphology of sintered surface of 20% AISI 1040 steel chip weight (%)
content of composite.
650
600
Fig. 11. Morphology of sintered surface of 30% AISI 1040 steel chip weight (%)
content of composite.
550
15
20
25
30
35
40
45
350
Wt.(%)
Atomic (%)
Fe
C
Mn
Al
Total
98.16
1.13
0.34
0.37
100
93.6
5.02
0.65
0.73
100
Table 9
EDS analysis results for region B of 40% AISI 1040 steel reinforced composites.
Fig. 12. Morphology of sintered surface of 40% AISI 1040 steel chip weight (%)
content of composite.
Element
Wt.(%)
Atomic (%)
Al
Mn
Cu
Si
Mg
Fe
Total
95.27
0.53
0.32
0.78
1.27
1.64
100
95.23
0.8
0.2
0.85
1.5
1.42
100
Table 4
EDS analysis results for region A of 20% AISI 1040 steel reinforced composites.
Element
Wt.(%)
Atomic (%)
Fe
C
Mn
Al
Total
96.35
2.15
0.29
1.21
100
90.1
7.01
0.55
2.34
100
Table 5
EDS analysis results for region B of 20% AISI 1040 steel reinforced composites.
Element
Wt.(%)
Atomic (%)
Al
Mn
Cu
Si
Mg
Fe
Total
96.6
0.65
0.82
0.78
0.32
0.85
100
93.73
1.19
1.02
0.84
1.35
1.87
100
Fig. 13. AlFe phase diagram computed for the AlAl3Fe equilibrium.
20
Table 6
EDS analysis results for region A of 30% AISI 1040 steel reinforced composites.
Wt.(%)
Atomic (%)
Fe
C
Mn
Al
Total
97.81
1.45
0.32
0.42
100
92.24
6.34
0.6
0.82
100
16
14
Stress, MPa
Element
20 %
30 %
40 %
18
12
10
8
6
Table 7
EDS analysis results for region B of 30% AISI 1040 steel reinforced composites.
Element
Wt.(%)
Atomic (%)
Al
Mn
Cu
Si
Mg
Fe
Total
96.26
0.65
0.78
0.79
0.3
1.08
100
95.23
0.7
0.82
0.64
1.83
0.78
100
decreases by increasing steel weight (%) content in region A. However, Fe weight (%) in region B increases by increasing steel weight
(%) content. It can comment that a simple role exchanged between
4
2
0
0.01
0.02
0.03
Strain (%)
Fig. 14. Flextural strengths of composites according to AISI 1040 steel chip weight
(%).
3/2
KIC (N/mm )
0.05
351
Fig. 16. Fracture surface of 20% AISI 1040 steel chip weight (%) content of
composite.
Fig. 17. Fracture surface of 30% AISI 1040 steel chip weight (%) content of
composite.
20 %
30 %
40 %
0.04
Fig. 18. Fracture surface of 30% AISI 1040 steel chip weight (%) content of
composite.
0.03
0.02
0.080
0.085
0.090
0.095
0.100
0.105
352
4. Conclusions
On the basis of presenting the investigation of manufacturing
recycled composites from granulated AlMg1SiCu aluminum and
AISI 1040 chips it has been concluded that
When steel chip content increased in composites, the hardness
of specimens increased to a maximum value of 121 BHN.
High temperatures under melting point for aluminum causes a
decrease in the porosities of specimens and high temperatures
cause better bonding between aluminum and steel chip, thus
this improves the mechanical properties of composites. Therefore determined 650 C sintering temperature increased the sintered density and mechanical properties.
Compressive strength enhanced with increasing steel chip
weight (%) contents. The maximum compressive strength is
approximately 640 MPa which contains 40 weight (%) content
steel chip.
According to the three-point bending tests, the fracture toughness of composites changed little with increasing notch depths.
In terms of AISI 1040 steel weight (%) contents, 20% steel reinforced composites have the highest fracture toughness values.
Moreover, we know that the steel reinforcement increases the
compressive strength. However, to improve mechanical properties
and decrease the porosity of composites, the cold pressing pressure
can be increased and the different sintering temperatures can be
used to investigate the effects of sintering temperatures for density, porosity and mechanical behaviors.
Acknowledgement
The present research was conducted as part of the Scientic Research Project funded by the Selcuk University in Turkey.
References
[1] Gronostajski JZ, Kaczmar JW, Marciniak H, Matuszak A. Production of
composites from Al and AlMg2 alloy chip. J Mater Process Technol
1998;77:3741.
[2] Gronostajski J, Chmura W, Gronostajski Z. Bearing materials obtained by
recycling of aluminium and aluminium bronze chip. J Mater Process Technol
2002;125:48390.