Presentation on

A Review on Mechanical and Tribological Behaviors of Stir cast Aluminum Matrix Composites.

GBPEC, Ghurdauri
Presented by: Himanshu Kala Sandeep Kumar M.tech 2nd yr Production engg. GBPEC Under guidance of: Dr. K.K.S. Mer Associate Proff. MED GBPEC

Contents
Introduction Composites Key terms Aluminum Matrix Composite Tribological properties Mechanical Properties Stir Casting Literature review Conclusion References

Introduction
Composite
A composite material is a material system composed of a suitably arranged mixture or combination of two or more nano, micro, or macro constituents with an interface separating them that differ in form and chemical composition and are essentially insoluble in each other. (Smith and Hashemi, 2008)

According to the chemical nature of the matrix phase, composite are classified as metal matrix(MMC), polymer matrix(PMC) and ceramic matrix composites(CMC).

In case of MMCs, aluminum matrix composite due their high strength to weight ratio, low cost and high wear resistance are widely manufactured and used in structural applications along with aerospace and automobile industry.

The disadvantage of producing AMCs usually lies in the relatively high cost of fabrication and of the reinforcement materials. Particulate-reinforced aluminum-metal matrix composites (AMCs) because of their isotropic properties and relatively low cost are attracting researchers. With the evolution of new processing techniques stir casting process has proved to be relatively economical and easy to use method.

Key terms
Aluminum Matrix Composite
In AMC the matrix phase is of pure aluminium or an alloy of it and the reinforcement used is a non-metallic ceramic such as SiC, Al2O3, SiO2, B4C, AlN etc

Tribological Properties
These are evaluated in terms of conditions. wear resistance of the material under lubricated and non-lubricated

Mechnical Properties
The mechanical properties of a composite depend on many factors such type of reinforcement, quantity of reinforcement, shape, size etc... These are eavluated in terms of tensile strength, hardness, compressive strength, fatigue stength.

Stir Casting
In a stir casting process, usually the particulate reinforcement is distributed into the aluminum melt by mechanical stirring. A recent development in stir casting process is a double stir casting or two-step mixing process [Wikipedia]. In this process, first the matrix material is heated to above its liquidus temperature. The melt is then cooled down to a temperature between the liquidus and solidus points to a semi-solid state. At this point the preheated reinforcement particles are added and mixed. Again the slurry is heated to a fully liquid state and mixed thoroughly. In double stir casting the resulting microstructure has been found to be more uniform as compared with conventional stirring. The potency of this two-step mixing method is mainly due to its ability to break the gas layer around the particle surface which otherwise impedes wetting between the particles and molten metal.

Su et al. (2012) designed a new three step stir casting method for fabrication of nano particle reinforced composite. First the reinforcement and Al particles are mixed using ball mills to break the initial clustering of nano particles. The composite powder is then incorporated into the melt with along with mechanical stirring. After adequate stirring the composite slurry is sonicated using an ultrasonic probe or transducer in order to improve the distribution of reinforced particles.

Kumar et al. (2013) used a 3 phase induction motor for electromagnetically stirring the aluminum melt and showed a improved particle matrix interface bonding with a small grain size structure.

Literature Review
S. Author No Material Properties Process Remarks Mechanical Properties 1. Kamat et al. (1989) Al(2024), Al2O3P Yield strength(YS) and Ultimate Tensile strength(UTS) YS, UTM and Ductility YS, UTS and Ductility Stir casting Yield strength in., UTM in.

2.

Azim et al.(1995) Tee et al.(1999)

Al(2024), Al2O3P Al, TiB2

Stir casting

YS in., UTS dec., Ductility dec. YS in., UTS in., Ductility dec.

Stir casting

Alaneme et al(2013)

Al, (SiC+ Bamboo ash) AlSi18Cu Ni, Al2O3f Al(2024), Al2O3p

UTS, Hardness, YS and Fracture toughness

Stir casting

UTS dec., Hardness dec., YS dec. and Fracture toughness in. UTS in., Hardness in., wear resistance in. Hardness in., UTS in.

Azim et al. (2002) Kok (2005)

Mechanical properties

Stir casting

Mechanical properties

Stir casting

Yar et al. (2009)

Al(A356), nano MgO

Hardness and Compressive strength(CS)

Stir Casting

Hardness in., CS in.

Amirkhanlou et al. (2010)

Al(356), SiCP

Hardness and Impact energy

Stir casting

Hardness in, impact energy in.

10

Sajjadi et al. (2011)

Al(A356), Al2O3p

Hardness and compressive strength

Stir Casting

Hardness in., CS in.

11

Su et al.(2012)

Al(2024), nano Al2O3

UTS

3 step Stir Casting

UTS in.

12

Kakaiselvan et Al(6061), B4C al. (2011)

Mechanical Properties

Stir Casting

Hardness in., UTS in.

13

Mazaheri et al (2013)

Al, (TiC +B4C), TiC, B4C

Hardness, Tensile test, Yield Strength, Elongation Mechanical properties

Stir Casting

YS(B4C), TS(B4C), Hardness(TiC +B4C), Elongation(TiC)

14

Kumar et al. (2013)

Al(359), Al2O3

Electromagnetc Hardness in., UTS stir casting in.

15

Jinfeng et al.(2008) Baradeswarn et al. (2013)

Al, (SiC+Gr)

Mechanical Properties

Stir Casting

Tensile strength in., elastic modulus in. UTS in., CS in., Hardness in.

16

Al(7075) , B4C

UTS, CS, Hardness

Stir Casting

17

Kumar et al. (2008)

Al-7Si , TiB2

Mechanical Properties

Stir Casting

Hardness in., UTS in., YS. in., Youngs modulus in. YS in., UTS in., Ductility in., hardness in. UTS in., YS in.

18

.Mazahery et al. (2009)

Al(356), nanoAl2O3

Mechanical properties

Stir Casting

19

Ling et al (2010)

Al, Al9(Co, Ni)2

UTS, YS

Stir casting

20

Prasad et al. (2011)

Kumar et al. (2012)

Al(356.2 ), Rice hush ash

Al(6061), AlN

Hardness and UTS

Stir casting

Hardness in., UTS in.

Hardness in.

21

Microhardness and Macrohardness

Stir casting

22

Atuanya et al(2012)

Al-Si-Fe, breadfruit seed hull ash

Tensile strength, Hardness, Impact Strength(IS)

Stir Casting

TS in., Hardness in., IS dec.

23

Selvam. J et al. (2013)

Al(6061), (SiC + Fly Ash)

Mechanical properties

Stir Casting

Hardness in., Tensile strength in.

24

Boopathi et. al (2013)

Al(2024), (fly ash+SiCP )

Mechanical properties

Stir casting

Hardness in., YS in., TS in.

25

Alaneme et al.(2013)

Al(A356), Rice husk ash(RHA)

Mechanical properties

Double Stir casting

Hardness dec., TS dec., Fracture toughness in.

Tribological Properties 27 Wilson et al. (1996) Al(356), SiCP, (Sic+Gr) Dry Sliding wear Stir casting Siezure resistance in.

28

Shipway et al. (1998)

Al, TiC

Dry Sliding wear

Stir casting

Wear rate dec.

29

Tee et al.(2000) Al , Tib

Dry Sliding wear

Stir casting

Wear losses dec.

30

Sahin et. al(2003)

Al, SiCp

Abrasive wear

Stir casting

Wear rate in.(load, dist., abrasive size) Wear losses in.(dist., abrasive size) and dec. (particle size, fraction) Wear rate dec. (fraction and size)

31

Kok (2006)

AL(2024), Al2O3

Abrasive wear

Double stir casting

32

Hosking et al. (1982)

Al(2024), Al2O3

Wear properties

Stir casting

33

Suresha et al. (2012)

Al, (Sic+Gr)

Dry sliding friction

Stir casting

COF in. (load, dist.)

34

Pramila Bai et al. (1992) Sivaprasad et al. (2008)

A(356), SiCp

Dry Sliding wear

Stir casting

Wear resistance in.

35

Al(6063), Tib2

Wear characteristics

Stir casting

Wear rate dec. (fraction) and

36

Hassan et al (2009) Ramachandra et al.(2007) Kumar et al (2013) Apasi et al. (2012)

Al, SiCp

friction and wear behaviour Wear and friction characteristics Tribological behaviour

Stir Casting

Wear resistance in. Wear resistance in.(fraction) and dec. (load, dist.) Wear resistance in.

37

Al, fly ash

Stir Casting

Al, (zircon sand +silicon carbide) Al-Si-Fe, coconut shell ash

Stir Casting

Dry sliding wear

Stir Casting

Wear rate in. (fraction) and dec.(load)

Prasad el al. (2012)

Venkat prasat et al. (2011)

Al(A356.2) , Rice husk ash(RHA)

Al, (Fly ash+graphite )

Tribological properties

Stir Casting

Wear rate dec., friction coefficient dec.

Wear Losses dec.

Dry sliding wear

Stir Casting

Conclusion
Stir casting method can be successively used to manufacture metal matrix composite with desired properties. Reinforcing Aluminum and its alloys with ceramics particles has shown an appreciable increase in its mechanical properties.

Addition of alumina, Sic, B4C etc particles in aluminum improves the hardness, yield strength, tensile strength while ductility is decreased.
Addition of graphite in aluminum increases the tensile strength and elastic modulus but hardness is decreased. Also it shows a decrease in friction coefficient in case of tribological behavior. Organic reinforcements like coconut ash, rice husk ash also improved the mechanical properties of the aluminum along with the tribological behavior of the composite. For Al MMCs with organic reinforcements, very limited work has been reported. Organic reinforcement additions to aluminum matrix systems have shown significant increase in the mechanical properties of resulting composites. However, substantial improvement in the tribological properties has not been achieved in the limited reported literature in this area. This provides scope for further investigations in the field. A few authors have reported about modified stir casting methods for improving the distribution of the reinforcement in the matrix. However, there is a lack of literature regarding availability of efficient techniques for nano level reinforcements. Hybrid ceramic reinforcement has increased the mechanical properties much but literature on tribological properties in case of hybrid reinforcement is scarce.

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