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Aluminum alloys are widely used in aerospace and automobile industries due to their low
density and good mechanical properties, better corrosion resistance and wear, low thermal
coefficient of expansion as compared to conventional metals and alloys. The excellent
mechanical properties of these materials and relatively low production cost make them a very
attractive candidate for a variety of applications both from scientific and technological
viewpoints metals and reinforcements. Present work is focused on the study of behavior of
Aluminum Alloy 6082 with silicon carbide composite produced by the stir casting technique.
Different % age of reinforcement is used. Tensile test, Hardness Test, Microstructure performed
on the samples obtained by the stir casting process.
A new class of materials, called “Composite Materials” has answered to this research to
great extent. Composite materials are those which are created artificially by combining two or
more materials which usually have dissimilar characteristics.
Metal Matrix Composites (MMC’s) consist of either pure metal or an alloy as the matrix
material, while the reinforcement generally a ceramic material. The key features of MMC’s are
specific strength and stiffness, excellent wear resistance, high electrical and thermal
conductivity.
The purpose of this research is to investigate the mechanical properties of Al 6082 metal matrix
composites reinforced with silicon carbide The test specimens are prepared as per ASTM
(American society for testing and materials) standard size by stir casting process. These
specimens are tested for hardness as per ASTM standards at different loads using “Brinell
hardness testing machine”. The tensile strength of the specimen is tested by using “Universal
Testing Machine”.
From the studies in overall it can be concluded that Al 6082 metal matrix composite exhibits
superior mechanical properties when reinforced with silicon carbide than other aluminum
composites.
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Department of Mechanical Engineering
CHAPTER-1
INTRODUCTION
The length-to-diameter (l/d) ratio is known as the aspect ratio and can vary greatly. The
continuous phase is the matrix, which is a polymer, metal, or ceramic. Polymers have low
strength and stiffness, metals have intermediate strength and stiffness but high ductility, and
ceramics have high strength and stiffness but are brittle. The matrix (continuous phase) performs
several critical functions, including maintaining the fibers in the proper orientation and spacing
and protecting them from abrasion and the environment. In polymer and metal matrix composites
that form a strong bond between the fiber and the matrix, the matrix transmits loads from the
matrix to the fibers through shear loading at the interface. In ceramic matrix composites, the
objective is often to increase the toughness rather than the strength and stiffness; therefore, a low
interfacial strength bond is desirable.
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1.1.1. TYPES OF COMPOSITE MATRIX MATERIALS
There are three main types of composite matrix materials
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1.1.2. CHARACTERISTICS OF THE COMPOSITES
The shape of the discontinuous phase (which may by spherical, cylindrical, or rectangular
cross-sanctioned prisms or platelets), the size and size distribution (which controls the texture of
the material) and volume fraction determine the interfacial area, which plays an important role in
determining the extent of the interaction between the reinforcement and the matrix.
Metal matrix composites (MMCs) are composite materials that contain at least two constituent
parts, a metal and another material or a different metal. The metal matrix is reinforced with the
other material to improve strength and wear
Metal matrix composites possess some attractive properties, when compared with organic
matrices. These include (i) strength retention at higher temperatures, (ii) higher transverse
strength, (iii) better electrical conductivity, (iv) superior thermal conductivity, (v) higher erosion
resistance etc. The main advantage of metal matrix compositeare they have Low transverse
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strength, Good corrosion resistance, Low operational temperature limits, Low thermal
conductivities, Low electrical conductivities.
Good elastic modulus properties can be achieved by the unidirectional incorporation of fibers or
whiskers in the metal matrix even though the bonding between them may be poor. But, strong
metallic matrices rather than weak metal or polymer matrices are essential for good transverse
modulus and shear strength. Carbon/graphite fibers have been used with metal matrices on a
laboratory / experimental scale only, because most basic fabrication techniques involve high
temperatures which have detrimental effects on the fiber. However, research on these lines is
continuing in view of the potential of the composites.
This is the widest group of Metal Matrix Composites. Matrices of Aluminum Matrix
Composites are usually based on aluminum-silicon (Al-Si) alloys and on the alloys of 2xxx and
6xxx series.
Powder metallurgy(sintering)
Stir casting
Infiltration
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The following properties are typical for Aluminum Matrix Composites:
Aluminum Matrix Composites (AMC) are used for manufacturing automotive parts
(pistons, pushrods, brake components), brake rotors for high speed trains, bicycles, golf clubs,
electronic substrates, cores for high voltage electrical cables.
Magnesium Matrix Composites are reinforced mainly by silicon carbide (SiC) particles
(particulate composites)
Low density
High stiffness (modulus of elasticity)
High wear resistance
Good strength even at elevated temperatures
Good creep resistance
Magnesium Matrix Composites are used for manufacturing components for racing cars,
lightweight automotive brake system, aircraft parts for: gearboxes, transmissions, compressors
and engine.
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The following properties are typical for Titanium Matrix Composites:
High strength
High stiffness (modulus of elasticity)
High creep resistance
High thermal stability
High wear resistance
Titanium Matrix Composites are used for manufacturing structural components of the
jet’s landing gear, turbine engine components (fan blades, actuator pistons, synchronization
rings, connecting links, shafts, discs), automotive engine components, drive train parts, general
machine components.
Copper Matrix Composites are reinforced by: Continuous fibers of carbon (**C**),
silicon carbon (SiC), tungsten (W), stainless steel 304 (long-fiber reinforced composites); Silicon
carbide particles (particulate composites). Powder metallurgy (sintering) and infiltration
technique are used for fabrication Copper Matrix Composites.
Copper Matrix Composites are used for manufacturing hybride modules, electronic
relays, electrically conducting springs and other electrical and electronic components.
Hybrid composites are a new generation of metal matrix composites that havethe
potentials of satisfying the recent demands of advanced engineering applications. Thesedemands
are met due to improved mechanical properties, amenability to conventionalprocessing technique
and possibility of reducing production cost of aluminum hybrid composites.So, we are using
hybrid metal matrix composite in our project.
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Department of Mechanical Engineering
1.3. Fabrication Methods of Metal Matrix composites
In recent years, the potential of metal-matrix composite (MMC) materials for significant
improvement in performance over conventional alloys has been recognized widely. However,
their manufacturing costs are still relatively high. There are several fabrication techniques
available to manufacture the MMC materials: there is no unique route in this respect. Due to the
choice of material and reinforcement and of the types of reinforcement, the fabrication
techniques can vary considerably. The processing methods
Which include Rheocasting and Spray Atomization Normally the liquid-phase fabrication
method is more efficient than the solid-phase fabrication method because solid-phase processing
requires a longer time. The matrix metal is used in various forms in different fabrication
methods. Generally, powder is used in pneumatic impaction and the powder metallurgy
technique, and a liquid matrix is used in liquid-metal infiltration, plasma spray, spray casting,
squeeze casting, pressure casting, gravity casting, stir casting, investment casting, etc. A
molecular form of the matrix is used in electroforming; vapor deposition and metal foils are used
in diffusion bonding, rolling, extrusion, etc.
Most of the MMCs are produced by this technique. In this technique, the ceramic particles are
incorporated into liquid metal using various processes. The liquid composite slurry is
subsequently cast into various shapes by conventional casting techniques or cast into ingots for
secondary processing. The process has major advantage that the production costs of MMCs are
very low. The major difficulty in such processes is the non-wettability of the particles by liquid
aluminum and the consequent rejection of the particles from the melt, non-uniform distribution
of particles due to their preferential segregation and extensive interfacial reaction. Liquid-metal
infiltration, squeeze casting, compo casting, pressure casting, spray codeposition, stir casting etc.
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Stir Casting
The final distribution of the particles in the solid depends on material properties and
process parameters such as the wetting condition of the particles with the melt, strength of
mixing, relative density, and rate of solidification. The distribution of the particles in the molten
matrix depends on the geometry of the mechanical stirrer, stirring parameters, placement of the
mechanical stirrer in the melt, melting temperature, and the characteristics of the particles added.
An interesting recent development in stir casting is a two-step mixing process. In this process,
the matrix material is heated to above its liquids temperature so that the metal is totally melted.
The melt is then cooled down to a temperature between the liquids and solidus points and kept in
a semi-solid state. At this stage, the preheated particles are added and mixed. The slurry is again
heated to a fully liquid state and mixed thoroughly. This two-step mixing process has been used
in the fabrication of aluminum.
Squeeze Casting
Squeeze casting is also known as liquid metal forging is a combination of casting and
forging process. the molten metal is poured in the bottom half of the pre-heater die. As the
metal starts solidifying the upper half closes the die and applies pressure durimg the
solidification process. The amount of pressure thus applied I significantly less than used in
forging, and part of the grade detail can be produced. Coring can be used with this process
o form holes and recesses. The porosity iss low and mechanical properties are improved.
Both the ferrous and non-ferrous materials can be produced using this method.
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1.3.2. Solid phase fabrication methods
There are several ways to fabricate MMC using solid-phase materials but among them diffusion
bonding and the powder metallurgy route are used widely. Diffusion bonding, hot rolling,
extrusion, drawing, explosive welding, Powder metallurgy route, pneumatic impaction, etc.
Powder Metallurgy
Powder metallurgy is a term covering a wide range of ways in which the materials are
components are made from metal powders. Powder metallurgy process can avoid are
greatly reduce the need to use metal removal processes, thereby drastically reducing a
yield loss in manufacturing and often resulting in lower cost. Powder metallurgy is also
used to make undue materials impossible to melt or form in others ways.
The role of the reinforcement in a composite material is fundamentally one of increasing the
mechanical properties of the neat resin system. All of the different fibers used in composites
have different properties and so affect the properties of the composite in different ways. For most
of the applications, the fibers need to be arranged into some form of sheet, known as a fabric, to
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make handling possible. Different ways for assembling fibers into sheets and the variety of fiber
orientations possible to achieve different characteristics.
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1.4.5. Silver Nano Particles
Metal Nano particles are commonly used for surface modifications in fiber
reinforced polymer composites because of their large specific surface area and electronic,
magnetic, other related properties. Nano particles of silver of between 1nm and 100 nm in
size, while frequently described as being silver some are composed of a large percentage
of silver oxides due to their large ration of surface-to-bulk silver atoms.
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CHAPTER-2
LITERATURE SURVEY
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chosen stainless steel as the main crucible and stirrer material. The machine consisted of a
four 45º flat bladed stirrer and a crucible in a resistance heated furnace chamber. Stirring
speed was varied from 200 to 500 rpm.
4. Bai & Zhao (2010) studied the contribution, and “The effect of the micro-
structuralcharacteristics on tensile properties and fracture behavior of partially-
squeeze Al7075 alloy die casting in the as-cast and T6 heat-treated conditions”. The
results show that inferior tensile properties of the casting partially- squeezed part were
caused by the -Al cells with fragment, rosette, angular and globular shapes, while finer
dendrites with smaller secondary dendrite arm spacing and more rounded silicon particles
corresponded to higher tensile properties. After T6 treatment, tensile properties increased
significantly due to the spheroidization of silicon particle and consequently the reduction
of stress concentration at silicon/eutectic matrix interface.
5. Gopalakrishnan &Murugan (2012) attributed the “primary attraction of
practitioners and researchers to Metal matrix composite (MMC) to improved
specific strength, high temperature and wear resistance application”. Aluminum
matrix reinforced with titanium carbide (Al-TiC) was reported by the authors to have a
good potential. In composite fabrication, the main challenge, as noted by the authors is to
produce this composite in a cost-effective way to meet the above requirements. In the
study, Al-TiC castings with different volume fraction of TiC were produced in an argon
atmosphere by an enhanced stir-casting method.
7. H.B. Bhaskar and Abdul Sharief, “Tribological properties of Aluminum 2024 Alloy-
Beryl Particulate MMC’s”, Bonfring International Journal of Industrial Engineering and
Management Science, Vol. 4, No. 4, pp. 143-147, 2012.
8. Jayashree P .K , Gowri Shankar M.C , Achutha Kini, Sharma S.S and Raviraj
Shetty, “Review on Effect of Silicon Carbide (SiC) on Stir Cast Aluminum Metal
Matrix Composites” . The importance of composites as engineering materials is reflected
by the fact that out of over 1600 engineering materials available in the market today more
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than 200 are composites. These composites initially replaced Cast Iron and Bronze alloys
but owing to their poor wear and seizure resistance, they were subjected to many
experiments and the wear behavior of these composites were explored to a maximum
extent and were reported by number of research scholars for the past 25 years. In the
present study, based on the literature review, the effect of Silicon carbide on Stir cast
Aluminum Metal Matrix Composites is discussed. Aluminum Metal Matrix Composites
with Silicon carbide particle reinforcements are finding increased applications in
aerospace, automobile, space, underwater, and transportation applications. This is mainly
due to improved mechanical and tribological properties like strong, stiff, abrasion and
impact resistant, and is not easily corroded. In the present scenario, a review of different
researchers has been made to consolidate some of the aspects of mechanical and wear
behavior of Aluminum Metal Matrix Composites reinforced with Silicon carbide particles
in both untreated and precipitation hardened condition Vol.3, No.3 2013.
10. Dipti Kanta Das, Purna Chandra Mishra,Saranjit and Swati Pattanaik, “ Fabrication
and Heat Treatment Of Ceramicreinforced Aluminum Matrix Composites ”.
Ceramic-reinforced aluminum matrix composites have attracted considerable attention in
engineering applications as a result of their relatively low costs and characteristic isotropic
properties. Reinforcement materials include carbides, nitrides and oxides. In an effort to
achieve optimality in structure and properties of ceramic-reinforced metal matrix
composites (MMCs), various fabrication and heat treatment techniques have evolved over
the last 20 years. In this paper, the status of the research and development in fabrication
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and heat treatment techniques of ceramic-reinforced aluminum matrix composites is
reviewed, with a major focus on material systems in terms of chemical compositions,
weight or volume fraction, particle size of reinforcement, fabrication methods and heat
treatment procedures. Various optical measurement techniques used by the researchers are
highlighted. Also, limitations and needs of the technique in composite fabrication are
presented in the literature. The full potential of various methods for fabricating ceramic-
reinforced aluminum matrix composites is yet to be explored.
11. Bala G Narasimha, Vamsi M Krishna and Dr. Anthony M Xavior, “A Review on
Processing of Particulate Metal Matrix Composites and its Properties”. In the past,
materials are confined only to monolithic type, but for the better physical, chemical and
triboloigical properties comparing to the monolithic materials composite materials are
have been evolved. Metal matrix composites have evoked a keen interest in recent times
for potential applications, because the characteristics of MMCs can be designed into the
material, custom-made, dependent on the application. From this potential, metal matrix
composites fulfill all the desired conceptions of the designer. Out of these Al/Al alloy
based MMC’s are gaining wider acceptance in many industries e.g. aerospace, automotive
and automobile industries due to their superior properties such as light weight, low
density, high strength to weight ratio, low cost, high quality and high performance etc. in
structural materials. The aim of this paper is to review the current research and
development of Al matrix based MMC and discusses the various existing and emerging
processing techniques for the fabrication of Aluminum matrix composites. The vortex (or
mixing) method continues to be the most popular processing method in use because of its
operation, total production cost, and suitability, while the infiltration, casting, and spray
atomization and co-deposition techniques receive less attention.
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CHAPTER-3
MATERIALS AND METHODS
3.1 ALUMINUM 6082
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