experimental analysis of mechanical properties … · of mmc’s by stir casting technique comprise...
TRANSCRIPT
http://www.iaeme.com/IJMET/index.asp 99 [email protected]
International Journal of Mechanical Engineering and Technology (IJMET) Volume 8, Issue 12, December 2017, pp. 99–107, Article ID: IJMET_08_12_011
Available online at http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=12
ISSN Print: 0976-6340 and ISSN Online: 0976-6359
© IAEME Publication Scopus Indexed
EXPERIMENTAL ANALYSIS OF MECHANICAL
PROPERTIES OF ALUMINIUM ALLOY WITH
SILICON CARBIDE
Raj Kumar
Research Scholar, MED, UIET, MDU, Rohtak.
Dr. Vineet Kumar
Professor, MED, UIET, MDU, Rohtak
ABSTRACT:
The objective of this research is to produce metal matrix composite (MMC) by stir
casting technique. The metal matrix composite are prepared by using aluminium (Al
6063) as a matrix and Sic particulates as reinforced with different percentage of
weight fraction ranging from 3.5, 6.5, 9.5, 12.5. The reinforced particles size of SIC
are 220 mesh, 400 mesh respectively. The steel prices are growing high day by day
those have an effect on manufacturing expense in automobile and domestic industries
, that why it is necessary to substitute steel with material having light weight and high
strong suit to weight proportion. The aluminium and its compounds have terrific
characteristics like light weight, wear and resistance to the corrosion that make
acceptable in copious industrial usage. This study analysis examines the micro-
structural and mechanical properties of al 6063 with SIC reinforced metal matrix
composites (MMC’s).
Keywords: MMC, SiC, Micro-structural, Tensile, Hardness, Mechanical properties.
Cite this Article: Raj Kumar and Dr. Vineet Kumar, Experimental Analysis of
Mechanical Properties of Aluminium Alloy With Silicon Carbide, International
Journal of Mechanical Engineering and Technology 8(12), 2017, pp. 99–107.
http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=12
1. INTRODUCTION:
The MMC’S will have desired characteristics of metal and ceramic are if they are fabricated
then designed properly. Metal matrix composites (MMC’S) have high strength , light weight ,
greater resistance to corrosion , wear and the ceramic brace have high stiffness and high
strength. The ductile metal matrix reinforced with the ceramic builds a fabric that has the
mechanical characteristics jointly ceramic reinforcement and metal matrix. [1] The fabrication
of MMC’S by stir casting technique comprise rising a molten solution of preferred metal
matrix followed by toting up of silicon carbide (sic) reinforcement into the molten solution.
[2]The next pace consists of solidification of aluminium alloy melt solution to attain the
Raj Kumar and Dr. Vineet Kumar
http://www.iaeme.com/IJMET/index.asp 100 [email protected]
required metal matrix composites (MMC’S) of the earthenware reinforcement. There are
copious factors that entail consideration observe for the manufacturing of mmc’s by means of
stir casting method. These factors embrace the consistent allocation of sic reinforcement,
wettability of the sic and aluminium alloy, defect free casting of mmc’s and the reaction takes
place among sic reinforcement and aluminium matrix composite (AMC) at superior temp. [3].
For obtaining most favorable properties of mmc’s the above said factors must be addressed
during manufacturing of mmc’s by means of stirring technique.
2. EVOLUTION OF ALUMINIUM MATRIX COMPOSITES (AMC’S)
These Aluminium matrix composites (AMC’S) combine the characteristics of metal matrix
along with the characteristics of SIC reinforcement which improve in superior mechanical,
thermal expansion and tribological characteristics. [4] The advancement of MMC may take in
basic issues such as selection and dividing the different phases, the properties of compound
and the potential modification of constituent. [dvivedi 2008, singhetal 2013] [5,1]. There are
plentiful fabrication techniques existing for the making of the AMC’S. Processing of AMC’S
can be divided on basis of matrix phases, as it is being appended with brace. The widespread
alliance for processing of AMC’S is as charts:
1. Solid state: powder blending, diffusion bonding.
2. Liquid state: stir casting, liquid metal infiltration, squeezes casting, spray deposition
3. Gas state: physical vapor discharge.
Generally technique for liquid phase is effective than solid and vapour phase.
3. STIR CASTING: The most basic and economical process used is vortex method or stirring the cast technique. It
involves the accession of preheated of 220 mesh and 400mesh Sic constituent part into the
vertex of melted alloy which is produced by rotating impeller. Microstructural in homogeneity
can cause addition of constituent part and sedimentation when it melts or solidify. Generally
stir casting technique is possible to integrate around 29-30 % Sic particle in range 5-100
micron in different – different molten aluminium alloys. This process is not beneficial for
integration of submicron size of Sic units. Another variety of stir casting is compo casting. In
this, SiC constituent part is integrated into mixture in the semi-solid state. [6]
4. EVOLUTION AND MANUFACTURE OF STIR CASTING SET UP
FOR GENERATION OF MMC’S:
The area comprises to yield the MMC’s by using the evolution and fabrication of stir cast.
The important designing concern for the fabrication of stir casting set up is to know the goals
of the study that are described as follow ( singh 2013, devivedi 2008)[1,5].
1. Casing of stirring system: Casing of the stir casting system is made by using
3cmx3cm, iron pipes. The altitude of the casing is 72cm from the ground surface and
its other dimensions being 72cm each i.e. length, width. The square pipes are
connected in middle at distance 20cm from both sides which is applied for adjusting
stirrer cum motor.
2. Stirrer Fabrication: Stirrer is composed of stainless steel (310grade). The
dimension of stirrer is 97cm and blades consist of zigzag pattern angle of 90 of each
side. The length of stirrer is 7cm each.
3. Motor – Dimmer: The motor is set up in middle of the frame having 220-1500
rpm for the stirrer working. And speed is adjusted by dimmer (0-240 volts).
Experimental Analysis of Mechanical Properties of Aluminium Alloy With Silicon Carbide
http://www.iaeme.com/IJMET/index.asp 101 [email protected]
4. Furnance description: Electrical muffle furnance is castoff for groundwork of
homogeneous metal matrix. The furnance inaugural dimension is 16cm x 16cm and
depth is 37cm .The electricity is used as a fuel in the fabrication of metal matrix
composite.
5. Raw Material Section: For the fabrication of metal matrix composite, silicon
carbide (220 meshes, 400 meshes) and aluminium alloy (Al 6063) are used as the raw
material. the aluminium matrix composite (AMC) having the wide application in
automotive and heavy good vehicle, beaking system, piston rods, frames, piston pin,
brake disc, axle tubes, reinforcement blades, gear box casting turbine blades , racing
car wheels and so on. The Various equipments are used in fabrication of metal matrix
composite (MMC) by stir casting technique as shown in figure 4.1, 4.2,4.3,4.4,4.5,4.6
below:
4.1 Crucibles 4.2. Casting mould 4.3 Tong
4.4. Stirrer with frame 4.5. Muffle furnance 4.6. Assembled stir casting
5. RESULT AND DISCUSSION:
Al/ Sic- MMC’s. The MMC’s were fabricated by differ weight fraction of sic (3.5%, 6.5%,
9.5%, 12.5%) with size of sic particles (220 mesh, 400 mesh). The fabricated MMC’s were
conducted various experiments to investigate properties of Al/ Sic – MMC’s.
5.1. Microstructure:
For microstructure testing, the fabricated MMC’s were polished in such a fine way that there
should be mirror like image on upper surface of samples. The mirror like surface finish of
samples were achieved by rubbing the sample on emery papers (100 to 2000 micron) and
velvet cloth with help of polishing machine and then surface of samples were washed by
killer’s etching reagent (Methanol, Hcl, Hno3, one drop of Hf). In the fabricated MMC’s the
difference of distribution of Sic particle to be seen by optical microstructure tester [range X50
to X 1500] Dewinter technologies Italy as shown in fig 5.1 (O).
Raj Kumar and Dr. Vineet Kumar
http://www.iaeme.com/IJMET/index.asp 102 [email protected]
Micrographs of Al/ Sic – MMC’s samples for different size and weight fraction of Sic
particles (220 mesh, 400 mesh) as in fig. 5.1.1 and fig. 5.1.2 for 220 mesh and 400 mesh
respectively.
Figure 5.1.1 Figure 5.1.2
5.2. Tensile Strength:
The tensile test was conducted at room temperature on on four column (UTM) universal
testing machine model no. Unitek -94100 Sr.no. 12/2016-316, max capacity load. Model no.
Unitek-94100 tensile testing machine was manufactured by Fuel Instruments & Engineering’s
Pvt. Ltd. as shown by figure no. 5.2 (O) The specimens of tensile test were prepared of Al/
Sic – MMC’s for various size (220 mesh, 400 mesh) and weight fraction (3.5%, 6.5%, 9.5%,
12.5%) of sic particles as per ASTM standard as shown in figure 5.2 (S).
Figure 5.2 (O)
Experimental Analysis of Mechanical Properties of Aluminium Alloy With Silicon Carbide
http://www.iaeme.com/IJMET/index.asp 103 [email protected]
Figure 5.2 (S)
The ten tensile specimens were prepared of Al/ Sic MMC’s various size of Sic (220 mesh,
400 mesh) and weight fraction (3.5%, 6.5%, 9.5%, 12.5%) of Sic.
Figure 5.2 (a) Standard specimens for Tensile Test of Sic 220 mesh and fraction weight of Sic.
Figure 5.2 (b) Standard specimens for Tensile Test of Sic 400 mesh and fraction weight of Sic
Figure 5.2 (C) Specimens after test on UTM of Sic 220 mesh
Figure 5.2 (D) Specimens after test on UTM of Sic 400 mesh
The results of tensile test of Al/ Sic –mmc’s of various sizes Sic and weight fraction of Sic
particles (3.5%, 6.5%, 9.5%, and 12.5%) are shown below.
Raj Kumar and Dr. Vineet Kumar
http://www.iaeme.com/IJMET/index.asp 104 [email protected]
Table 5.1 (A) Ultimate tensile strength in MPa & Weight % of Sic
Weight % of Sic 0% 3.5% 6.5% 9.5% 12.5%
220 mesh Sic 96 105 117 131 157
400 mesh Sic 98 109 123 140 169
Table 5.1 (B) Yield Strength in MPa & Weight % of Sic
Weight % of Sic 0% 3.5% 6.5% 9.5% 12.5%
220 mesh Sic 75.5 95.4 104.6 115.4 120.3
400 mesh Sic 77.9 97.4 107.6 120.4 131.5
Table 5.1 (C) % Elongation MPa & Weight % of Sic
Weight % of Sic 0% 3.5% 6.5% 9.5% 12.5%
220 mesh Sic 22 18.4 15.7 13.2 11.7
400 mesh Sic 20.4 17.8 14.8 12.9 11.2
5.3. Hardness:
Hardness test was performed on Micro Vickers Hardness Testing Machine at room
temperature. The testing machine was having model no. MVI-PC with microvicksys software
and machine Sr. No. 01/2017/1683. The hardness testing machine was manufactured by Fuel
Instruments & Engineers Pvt.Ltd. Model – PC is automatic Micro -Vickers hardness tester.
The hardness number with reference to scale HV were taken for specimens and shown by
table, graphs. The figure 5.3 (M) shown the hardness testing machine below.
Figure 5.3 (M)
Table 5.3 (A) Hardness & weight % Sic
Weight % of Sic 0 3.5 6.5 9.5 12.5
220 mesh 46 51.3 52.60 66.7 72.4
400 mesh 49.8 66.3 68.22 70.4 76.1
Experimental Analysis of Mechanical Properties of Aluminium Alloy With Silicon Carbide
http://www.iaeme.com/IJMET/index.asp 105 [email protected]
6. RESULT GRAPHS:
Graph between Ultimate Tensile Strength and Fraction weight of Sic
Figure 6.1 Graph between Yield Strength and faction weight of Sic
Figure 6.2 Graphs between Elongation and fraction weight of Sic
Figure 6.3 Graph between Vickers’s micro Hardness values and fraction weight of Sic
Figure 6.4
0
20
40
60
80
100
120
140
0% 3.50% 6.50% 9.50% 12.50%
Yie
ld s
tre
ngt
h in
Mp
a
Wt % of SiC
220 mesh
400 mesh
Raj Kumar and Dr. Vineet Kumar
http://www.iaeme.com/IJMET/index.asp 106 [email protected]
7. CONCLUSIONS
The Experimental Investigation provides the following Conclusions:
a) Microstructure: Optical micrographs showed homogeneous dispersion of SiC
particles in Al/SiC MMC’s in increasing trend in sample testing.
b) Tensile Strength: During the tensile test results, the tensile strength (MPa), yield
strength (MPa) increasing with the increase in reinforcement particulate size (220
mesh, 400 mesh) and weight fraction of Sic particles (3.5%, 6.5%, 9.5%, 12.5 %). The
increase in reinforced particulate size (220 mesh, 400 mesh ) and weight fraction (3.5
%, 6.5%, 9.5%, 12.5%) then % Elongation and % Reduction in area decrease
gradually.
c) Hardness (HV): During the hardness testing of Al/Sic –MMC’s samples, hardness
increases with increase in reinforcement particulate size (220 mesh, 400 mesh and
weight fraction (3.5%, 6.5%, 9.5%, 12.5%) of Sic particles.
REFERENCES:
[1] Singh S (2013) Primary and secondary processing of metal matrix composites. PhD.
Theses, Indian Institute of technology Roorkee, Roorkee [2] Singh I,Singh S,Singh A,(2013) conventional and unconventional hole making in metal
matrix composites. In: Machining and machine tools: research and development,
woodhead Publishing House,USA.ISBN:978-0-85709-154-3 (print),ISBN:978-0-85709-
219-9 (online)
[3] Su H,Gao W,Zhang H,Liu H,Lu J,Lu Z(2010) Optimisation of stirring parameters through
numerical simulations for preparation of aluminium matrix composite by stir casting
process.J Manuf Sci Eng 132:061007-1-7
[4] Hashim J,Looney L,Hashmi MSJ(1999) Metal matrix composites: production by stir
casting method.J Mater Process Technol 92-93:1-7
[5] Hashim J,Looney L,Hashmi MSJ(2002a) particle distribution in cast matal matrix
composites-part II.J Mater Process Technol 123(2):258-263
[6] Hashim J,Looney L,Hashmi MSJ(2002b) particle distribution in cast matal matrix
composites-part I.J Mater Process Technol 123(2):251-257
[7] Balasivanandha PS,Karunamoorthy L,Kathiresan S,Mohan B(2018) Influence of stirring
speed on distribution of particles in cast metal matrix composites.J Mater Process Technol
171:268-273
[8] Dvivedi A (2008) Electric discharge machining of Al6063-SiC MMC produced by stir
casting process.Ph.D.Theses,Indian Institute of technology Roorkee, India.
[9] Emany M,Razaghian A,Lashgari HR,Abbasi R,(2008) The effect of Al-5Ti-1B on
microstructure,hardness and tensile properties of Al2O3 and SiC- containing metal-matrix
composites.Mater Sci Eng,A 485:210-217
[10] Kalaiselvan k,Murugan N,Siva P(2011) production and characterization of AA6061-B4C
stir cast composite.Mater Des 32:4004-4009
[11] Lin G,Zhang H,Li H,Guan L,Huang L(2010) Effect ohfv Mg content on microstructure
and mechanical properties of SiCp/Al-Mg composites fabricated by semi solid stirring
technique.Trans nonferrous Soc China,1851-1855
[12] Sahin Y,Acilar M(2013) production and properties of SiC reinforced aluminium alloy
composites.Compos A 34:709-718
[13] Hashim J,Looney L,Hashmi MSJ(2001) The enhancement of wettability of SiC particles
in cast aluminium matrix composites.J Mater process Technol 119(1-3):329-335
Experimental Analysis of Mechanical Properties of Aluminium Alloy With Silicon Carbide
http://www.iaeme.com/IJMET/index.asp 107 [email protected]
[14] Hashim J,Looney L and Hashmi MSJ, particle distribution in metal matrix composites,
Part-1,journal of materials processing Technology,123:251-257.2002
[15] Nather,S,Brabazon,D and Looney,L, simulation of stir casting process, journal of
materials processing technology,143-144:567-571.2003
[16] Nai,S.M.L and Gupta M,, Synthesis and Characterization of free standing ,Bulk Al/Sicp
fuctionally gradient materials effects of different stirrer geometries. material research
bulletin,38:1573-1589.2003
[17] Hashim J,looney L and Hashmi MSJ ,Metal matrix composites: production by stir casting
method journal of materials processing technology,92-93:1-7.1999
[18] Allison,J.E and Cole ,G.S, Metal matrix compositesin automotive industry: Opportunities
and Challenges, journal of material science,19-24.1993
[19] Manna,A. Bhattacharyya,B, study of different tooling systems during turning for effective
machining of Al/SiC-MMC. The Institutiona of Engineering (India).journal
production,83:46-50.2003
[20] Surappa,M.K, Microstructure Evolution during Solidification of DRMMCs; State of the
art, journal of materials processing technology,63:325-333.3078.MANNA ET AL.1997
[21] Yang, J,Pickard, S.M,Ctedy, C.Evans, A.G and Mehrabian,t, The stress/strain behavior of
Aluminium matrix composites with discontinuous reinforcements, Acta Metalurgica
Materialia,39:1863-1870.1997
[22] Baljeet, Vineet Kumar Application of Acoustic Signal for Comparison of Fault of
Misalignment with No Defect Bearing International Journal of Engineering Business and
Enterprise Applications 4(2) (IJEBEA), March-May 2013, pp 146-150, ISSN 2279-0020.
[23] Sandeep Malik, Vineet Kumar An Approach To Optimization Of Process Parameters in
Wire Electrical Discharge Machining For EN24 Alloy Steel International Journal of
Research In Engineering And Applied Science, Vol 3, Issue 5, May 2013,pp 43-52, ISSN
2249-3905.
[24] Kaushik, Narinder & Singhaal, Sandeep. (2017). Mechanical and Metallurgical
Examinations of Stir Cast Aluminum Matrix Composites: A Review Study. International
Journal of Engineering and Technology. 9. 3203-3217.
10.21817/ijet/2017/v9i4/170904135.
[25] Kaushik, N., & Singhal, S. (2017). Examination of Wear Properties in Dry-Sliding States
of SIC Strengthened Al-Alloy Metal Matrix Composites by Using Taguchi Optimization
Approach. International Journal of Applied Engineering Research, 12(20), 9708-9716.
[26] Ranjith. R, Giridharan. P. K and Senthil Kumar. B, Predicting The Tensile Strength of
Friction Stir Welded Dissimilar Aluminum Alloy Using Ann, International Journal of
Civil Engineering and Technology, 8(9), 2017, pp. 345–353.
[27] Ragip Hadri and Ali Muriqi, Aluminum Alloys and Behavior under Cyclic Loading in
Joints of Truss Structures, International Journal of Civil Engineering and Technology,
8(11), 2017, pp. 746–752
[28] R. MuthuVaidyanathan, MahaboobPatel, N. SivaRaman, D. Tedwors, Effects of Process
Parameters On Friction Stir Welding Of 6063 Aluminum Alloy, International Journal of
Design And Manufacturing Technology (IJDMT), Volume 6, Issue 1, January - April
(2015), pp. 01-09