mechanical and tribological behaviour of aluminium metal ... · pdf filemechanical and...

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Int. J. Mech. Eng. & Rob. Res. 2014 Bhaskar Raju S A et al., 2014

MECHANICAL AND TRIBOLOGICAL BEHAVIOUROF ALUMINIUM METAL MATRIX COMPOSITESUSING POWDER METALLURGY TECHNIQUE—

A REVIEW

Bhaskar Raju S A1*, A R K Swamy2 and A Ramesh3

*Corresponding Author: Bhaskar Raju S A,[email protected]

Aluminium metal matrix composites are widely used in engineering applications, speciallyautomobile, aerospace, marine and mineral processing industries owing to their improved wearproperties compared to conventional monolithic aluminium alloys. Presently hybrid compositesplays vital role in engineering application. The researchers who developed composites, weresubjected to many characterisations, specifically wear behaviour of these composites wereexplored to a maximum extent by number of researchers for the past 25 years. In this review anattempt has been made to consolidate some of the aspects of mechanical and wear behaviourof Al-MMCs and the prediction of the Mechanical and Tribological properties of Aluminium MMCsfabricated using Powder Metallurgy Technique.

Keywords: Al-MMCs, Density, Hardness, Mechanical properties, Wear, Powder metallurgy

INTRODUCTIONComposite materials are materials made fromtwo or more constituent materials withsignificantly different physical or chemicalproperties, that when combined, produce amaterial with characteristics different from theindividual components (Rajesh et al., 2012).The individual components remain separateand distinct within the finished structure. The

ISSN 2278 – 0149 www.ijmerr.comVol. 3, No. 4, October 2014

© 2014 IJMERR. All Rights Reserved

Int. J. Mech. Eng. & Rob. Res. 2014

1 Department of Mechanical Engineering, Sai Vidya Institute of Technology, Bangalore, India.2 Department Mechatronics Engineering, Acharya Institute of Technology, Bangalore, India.3 GATES Institute of Technology, Gooty, Andhra Pradesh, India.

new material may be preferred for manyreasons such as strength, light weight and lessexpensive when compared to traditionalmaterials (Izadi et al., 2013).

Aluminium alloys are the most widely usednonferrous materials in engineeringapplications owing to their attractive propertiessuch as high strength to weight ratio, goodductility, excellent corrosion resistance,

Review Article

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availability and low cost (ChinawadDhadsanadhep et al., 2008). Aluminium alloy-based Metal Matrix Composites (AMMCs)have been by now established themselves asa suitable wear resistant material especiallyfor sliding wear applications. However, inactual practice engineering componentsusually encounter combination of differenttypes of wear.

Aluminium Metal Matrix Composites(MMCs) have enhanced properties such aselastic modulus, hardness, tensile strength atroom and elevated temperatures andsignificant weight savings over unreinforcedalloys (Zulkoffli et al., 2009; and Ravichandranet al., 2014).

Hybrid Composites are relatively new andobtained by using two or more different kindsof reinforcement materials in a common matrix(Ramesh, 2014). Hybrids have a better all-around combination of properties thancomposites containing only a singlereinforcement phase (Dinesh Kumar Koliet al., 2013).

Powder metallurgy is the process ofblending fine powdered materials, pressingthem into a desired shape or form(compacting), and then heating thecompressed material in a controlledatmosphere to bond the material (sintering).The powder metallurgy process generallyconsists of four basic steps: powdermanufacture, powder blending, compacting,and sintering. Compacting is generallyperformed at room temperature and atelevated-temperature, the process of sinteringis usually conducted at atmospheric pressure(Saidatulakmar Shamsuddin et al., 2011; andYao Guini and Sun Kewei, 2011).

Rajesh Purohit et al. (2012) their work on“Fabrication of Al-SiCp composites throughPowder Metallurgy Process evolved itsProperties”. Al-SiCp composites with 5 to 30weight % of SiCp were fabricated usingpowder metallurgy process. Sintering of Al-SiCp composite parts was more energyefficient than for most other PM materials dueto the relatively low sintering temperatures.

Mechanical alloying of aluminum and siliconcarbide powders for 12 hours of milling resultsin fine homogeneous equiaxed compositepowder structure. SEM studies of ball milledpowders at intermediate stages reveal thatdue to impact of steel balls, the repeated coldwelding, fracturing and re-welding of powderparticles takes place and SiC particulates getembedded in the aluminum matrix.

Cold isostatic compaction at 600 MPafollowed by vacuum sintering at 600 °C hasbeen successfully used to produce Al-SiCpcomposites. Rockwell hardness, Density,porosity, compressive strength and tensilestrength of powder metal Al-SiCp compositesincreases with increase in reinforcementcontent from 5 to 30 weight percent of SiCp.Sintering of Al-SiCp composites result in de-densification due to higher compactionpressure used in the green stage and also dueto the removal of volatile materials duringsintering and thus improving the properties.

Mechanical alloying of powders result inimprovement in hardness, compressivestrength and indirect tensile strength of Al-SiCpcomposites with 5 to 30 weight percent of SiCparticulates.

Izadi et al. (2013) their work on “Friction stirprocessing of Al/SiC composites fabricated

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by powder metallurgy”. Friction StirProcessing (FSP) was applied to modify themicrostructure of sintered Al–SiC compositeswith particle concentrations ranging from 4 to16 vol%. Two SiC particle sizes (490 N and800 grades) were examined. The use of FSPhas been shown to improve the micro hardnessof Al-SiC composites produced by traditionalpowder metallurgy and sintering methods.However, when samples with 16 vol% SiC wereprocessed there were residual pores and lackof consolidation. This was likely due to theinitial low density (81.5-83.8% of theoretical)in the compacted materials, which could beattributed to the larger surface area of the fineparticles used.

An increase in hardness of all samples wasobserved after friction stir processing whichwas attributed to the improvement in particledistribution and elimination of porosity. Somerefinement of the initial SiC particles appearedto occur and it was shown that the influence ofreducing the initial SiC particle size onhardness values of the friction stir processedsamples was negligible. The increase in

hardness with SiC concentration in the frictionstir processed samples appeared to berelated to the mean inter-particle spacing. Inthis regard, a possible quantitative linearcorrelation has been proposed.

Chinawad Dhadsanadhep et al. (2008),“Fabrication of Al/Al2O3 Composite byPowder Metallurgy Method from Aluminiumand Rice Husk, and Ash rich in alumina”. Theirwork on Fabrication of Al-4wt.%Cu/Aluminacomposite was reported. The method offabrication was powder metallurgy by in-situreaction to form alumina during fabrication.Starting materials were mixture of aluminum,copper, and silica powders. Silica is in formof rice husk ash. The mixture was coldcompacted, and sintered at 650 °C for 1 h.Hot forging was carried out to furtherconsolidate the sintered billet, followed by 10-h heat treatment at temperatures between590 to 650 °C. This work suggests Sinteringof powder mixture was carried out at 650 °Cfor 1 h, followed by hot forging at 600 °C, andfinally heat treatment at 590 °C for 10 hrs.They observed that Chemical reaction

Figure 1: Microstructure of the Sinteredand Friction Stir Processed Alumix 431DAlloy, with a Comparison of (b) The as-Sintered and, (c) Friction Stir Processed

Microstructure

Figure 2: Microhardness Values of theSintered Al-SiC Composites Modified

by FSP

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between silica and aluminum powder tookplace during long time heating at temperatureabove 590 °C.

The investigation of microstructure showedreacted areas, consisting of gamma-aluminaand silicon. In some areas, silica powderremained amid the products of the reaction.Copper was found distributed in all areas, inform of Al2Cu compound.

Zulkoffli et al. (2009), “Fabrication OF AZ61/SIC Composites by Powder metallurgyprocess”. Mg-based Metal Matrix Composites(MMCs) with addition of SiC reinforcementwas fabricated by using a pre-alloyed AZ61powder compressed without binder agentunder compaction pressure of 200 MPa for20 minutes at different temperature intervalsof 200 °C, 250°C, 300 °C and 350 °C. Metalmatrix composite of AZ61 magnesium alloyreinforced by SiC particles was fabricatedfrom pre-alloyed powder using a hotcompaction and sintering techniques at

different temperature intervals, i.e., 200 °C,250 °C, 300 °C and 350 °C.

The microstructures and hardness of the as-hot compacted and sintered samples wereinvestigated. The as-hot compacted samplesshow the compaction at 350 °C alloweddiffusion element from SiC into the AZ61matrix. The sintering process allow recoveryof defects and releasing of internal stressesof compacted samples, and lead to thesoftening of the material, but for sample AZ61/SiC 350 °C sintered sample show increasingof hardness value owing to alloy elementsdiffusion and the growing of lamellarprecipitates on the sample during sintering.

Ravichandran et al. (2014), “Synthesisedaluminium-based hybrid powder metallurgiccomposites”. Aluminium-based metal matrixcomposites were synthesized from Al-TiO2-Grpowder mixtures using the powder metallurgytechnique and their forming characteristicswere studied during cold upsetting. Greencylindrical compacts of pure Al, Al-5wt%TiO2,Al-5wt%TiO2-2wt%Gr, and Al-5wt%TiO2-

Figure 3: SEM Image of Remaining SilicaShown as Bright Irregular Particle

Surrounded by Reacted Area (Al-4wt%Cu/15vol%Silica: Sintering 650 °C -1 h +

Hot Forging 600 °C + Heat Treating650 °C -10 hrs)

Figure 4: Hardness Comparison Betweenas-Hot Compacted and Sintered AZ61

Magnesium Alloy

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4wt%Gr were made using a 400-kN hydraulicpress equipped with suitable punch and dieand by sintering at (590 ± 10) °C for 3 h.Concluded that the apparent density, tapdensity and theoretical density increase withthe addition of TiO2 and Gr reinforcements tothe pure Al matrix. The reason for the densityincrease is the filling with fine powders of TiO2and Gr of the pores formed in the matrix bylarge irregular Al particles. The XRD patternsof the composite powders confirm thepresence of the matrix (Al) and reinforcements(TiO2 and Gr) phases, but no other intermetallicphases are found.

According to the SEM images, after 20 hof ball milling, the distribution of thereinforcement within the matrix material ishomogeneous and the addition ofreinforcements (TiO2 and Gr) to the soft

material influences the morphologicalcharacteristics of the MMCs.

The maximum value of true axial stress (z),true hoop stress () and true hydrostaticstress (m) were obtained for Al-5wt%TiO2composites having 4wt%Gr. The addition ofTiO2 and Gr with the Al matrix increases thestrength coefficient (K) and strain hardeningindex (n) of the composite. Addition of TiO2and Gr reinforcements to pure Al reduces thedensification and deformation characteristicsbecause of matrix work-hardening.

Wong Wai Leong Eugene and Manoj Gupta(2010), “Journal of Microwave Power andElectromagnetic Energy”, Characteristics ofAluminum and Magnesium BasedNanocomposites Processed Using HybridMicrowave Sintering. The sintering usually takesa few hours to realize density in excess of 90%.

Figure 5: SEM Images of as-Milled Al-5wt%TiO2 (a), Al-5wt%TiO2-2wt%Gr (b),and Al-5wt%TiO2-4wt%Gr (c) Composite Powders

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The present study highlights the use ofenergy efficient and environment friendlymicrowave sintering route to synthesize purealuminum, magnesium and magnesium basednanocomposites. Three reinforcements weretargeted: a) silicon carbide, a microwavesusceptor, b) alumina, a microwavetransparent material and c) copper, aconducting material.

Composites were prepared using blend –compact – microwave sintering – extrusionmethod. Process evaluation revealed thatmicrowave assisted sintering can lead to areduction of 86% in sintering time and energysavings of 96% when compared toconventional sintering.

Moreover, microwave assisted sintering ofmetal compacts in this study was carried outin air, in the absence of any protectiveatmosphere, without compromising themechanical properties of the materials. Resultsrevealed that Compared to conventionalsintering, hybrid microwave assisted rapidsintering can lead to reduction in processingtime up to 85% and energy savings of 96%.

Cost savings can also be achieved with theelimination of inert atmosphere duringmicrowave sintering.

Micro structural characterization revealedfiner microstructure for microwave sinteredmagnesium when compared to conventionallysintered magnesium. For monolithicmagnesium and aluminum samples, animprovement in hardness, 0.2%YS, UTS andwork of fracture was observed, whencompared with hybrid microwave sinteredsamples with conventionally sintered samples.In magnesium composite formulations, nano-size reinforcements formed a continuousnetwork along with the grain boundaries of thematrix. Mechanical characterization revealedan increase in hardness, 0.2%YS and UTS ofmagnesium with the addition of nano-sizereinforcements.

Asif et al. (2011), “Development ofAluminium Based Hybrid Metal MatrixComposites for Heavy Duty Applications”.Their study deals with the investigation of drysliding wear behaviour of aluminium alloybased composites, reinforced with siliconcarbide particles and solid lubricants such asgraphite/antimony tri sulphide (Sb2S3). Thefirst one of the composites (binary) consistsof Al with 20% Silicon Carbide particles(SiCp). The other composite has SiCp andsolid lubricants namely Graphite + Sb2S3(hybrid composite). Both composites arefabricated through P/M route using “Hotpowder pre forms forging technology”.

The density and hardness are measured byusual methods. The pin-on-disc dry wear teststo measure the tribological properties wereconducted for one hour at different parametersnamely loads: 30 N, 50 N and 80N and speed:

Figure 6: SEM Micrograph ShowingDistribution of Al2O3 in Mg/1.0Al2O3

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Figure 7: Effect of Load on Coefficient of Friction at Different Speeds: 5, 7 and 9 m/s

Figure 8: Comparison of Proposed Al Based Composites with Corresponding Valuesof Fe-Based Composites at Loads: 50 and 80 N for Sliding Speed: 9 m/s

5, 7 and 9m/s. Conclusions from this work wasdrawn that by Incorporation of graphiteparticles in the aluminium matrix as a secondreinforcement decreases the wear rates of thecomposite compared to SiCp reinforcedcomposite. Coefficient of friction is stabilizedwith incorporation of solid lubricants incomposite at solid state for various sliding

speeds and applied loads. Temperature risefor hybrid composite was more than that oftemperature rise for binary composite but it issignificantly lower than iron based composites.

Incorporating solid ingredients in aluminiumpowder play an important role in reducing thenoise level. Wear rate decreases as thesliding speed increases up to transition speed

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and load, due to work hardening of the surface,formation of Iron oxide, crushing of the SiCparticles and smearing of Graphite. Seizureoccurred for wrought aluminium based alloys,but no seizure occurred for Al/SiCp andGraphitic powder composites. Combination ofabrasion, delamination and adhesive natureof wear was observed. Proposed aluminiumbased composites with lower wear resistancehave better tribological characteristics thaniron based composites.

Ramesh (2014),”Characterization of AlBased Nano composites Using PowderMetallurgy Technique” by taking aluminium asthe matix and nano-materials such as carbonnanotube, graphene and nano-diamond asreinforcement to get the nanocomposites.

Uniform dispersion of the finereinforcements and a fine-grained matriximproved the mechanical properties of thecomposite. His work concludes that the carbonnanotubes reinforced aluminum matrixcomposite had been successfully developedthrough powder metallurgy.

The density values of AL + CNT + GR + NDcomposition were very near to the density valueof base metal. The density values of AL + CNT+ GR composition were less compared to thedensity values of AL + CNT + GR + NDcomposites. The hardness values were highfor AL + CNT + GR + ND composition than theAL + CNT + GR composition.

The wear resistance increases with theamount of reinforcements. It is evident from theexperiments that for AL+CNT+GR andAL+CNT+GR+ND composition composites,wear resistance was higher. Remarkablechange in compression strength values were

observed, which decreases with increasingpercentage of reinforcements.

Dolata-Grosz and Wieczorek (2007) theirwork on “Tribological properties of hybridcomposites containing two carbide phases”.The aim of the research conducted was toexamine the tribological properties, i.e., thefriction coefficient and wear, of hybridcomposites containing chromium and titaniumcarbides, shaped in the process of centrifugalcasting, as well as to assess the wear of theelement cooperating with it.

The scope of the research encompassed—the production of a composite with analuminium matrix and carbides, examinationof the structure and phase composition of acomposite formed by mechanical stirring, theuse of a composite suspension in centrifugalcasting and production of a sleeve withlayered arrangement of reinforcing phases,examination of the tribological properties,friction coefficient and wear of the frictioncouple: cast iron-composite, examination ofhardness.

The decreased wear of the composite witha lower fraction of reinforcing phases in the

Figure 9: Volume % of Reinforcementv/s Wear Rate

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tribological couple: cast iron – hetro phasecomposite, during which no negative effectsof increased wear of the cooperating materialwere observed.

RESULTS AND DISCUSSIONA small number of scientists were engaged inresearch of tribological and mechanicalcharacteristics of Hybrid Aluminiumcomposites using Powder MetallurgyTechnique. The research review is given below.

Sintering of Al-SiCp composite parts wasmore energy efficient than for most other PMmaterials due to the relatively low sinteringtemperatures. During isostatic compaction ofpowders, the quality of final product dependsupon the quality of initial manual compactionSintering of Al-SiCp composites result in de-

friction region results from the fact ofoccurrence, during its work, of twomechanisms of wear: adhesive and abrasive.

The combination of these mechanismsclearly intensifies the degree of wear, thusresulting in its almost triple growth comparedto the material with a larger fraction of hetrophase reinforcement. An increase in thereinforcing phase fraction allowed theelimination of the phenomena connected withadhesion wear. An increase in the reinforcingphase percentage fraction did not result inincrease in wear of the cast iron.

Therefore, it can be affirmed that a 10%fraction of a carbide reinforcing phase ensuresa uniform wear mechanism and has abeneficial influence on the operation of the

Figure 10: The Structure of Aluminium Cast Composite with Hybrid ReinforcementPhases a) Structure of Outside Layer, OM; b) Microstructure of Outside Layer, SEM

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densification due to higher compactionpressure used in the green stage and also dueto the removal of volatile materials duringsintering and thus improving retentionproperties.

Friction Stir Processing (FSP) was appliedto modify the microstructure of sintered Al-SiCcomposites. The use of FSP has been shownto improve the microhardness of Al-SiCcomposites produced by traditional powdermetallurgy and sintering methods. The materialflow in the stir zone during FSP was successfulin uniformly distributing the SiC particles. Theincrease in hardness with SiC concentrationin the friction stir processed samplesappeared to be related to the mean inter-particle spacing.

Starting materials were mixture of aluminum,copper, and silica powders. Silica was in formof rice husk ash. The mixture was coldcompacted, and sintered at 650 °C for 1 h.Chemical reaction between silica andaluminum powder took place during long timeheating at temperature above 590 °C. Theinvestigation of microstructure showed reactedareas, consisting of gamma-alumina andsilicon. In some areas, silica powder remainedamid the products of the reaction.

SiC reinforcement was fabricated by usinga pre-alloyed AZ61 powder compressedwithout binder agent under compactionpressure of 200 MPa for 20 minutes at differenttemperature intervals of 200 °C, 250°C, 300°C and 350 °C. The sintering process allowrecovery of defects and releasing of internalstresses of compacted samples, and lead tothe softening of the material, but for sampleAZ61/SiC 350 °C sintered sample showincreasing of hardness value owing to alloy

element diffusions and the growing of lamellarprecipitates on the sample during sintering.

Al-TiO2-Gr powder mixtures using thepowder metallurgy technique and their formingcharacteristics were studied during coldupsetting. Green cylindrical compacts of pureAl, Al-5wt%TiO2, Al-5wt%TiO2-2wt%Gr, andAl-5wt%TiO2-4wt%Gr were made using a 400-kN hydraulic press equipped with suitablepunch and die and by sintering at (590 ± 10)°C for 3 h. The reason for the density increaseis the filling with fine powders of TiO2 and Grof the pores formed in the matrix by largeirregular Al particles. The distribution of thereinforcement within the matrix material ishomogeneous and the addition ofreinforcements (TiO2 and Gr) to the softmaterial influences the morphologicalcharacteristics of the MMCs. Addition of TiO2and Gr reinforcements to pure Al reduces thedensification and deformation characteristicsbecause of matrix work-hardening.

Aluminum and Magnesium BasedNanocomposites Processed Using HybridMicrowave Sintering. The sintering usuallytakes a few hours to realize density in excessof 90%. The present study highlights the useof energy efficient and environment friendlymicrowave sintering route to synthesize purealuminum, magnesium and magnesium basednanocomposites. Compared to conventionalsintering, hybrid microwave assisted rapidsintering can lead to reduction in processingtime up to 85% and energy savings of 96%.

Cost savings can also be achieved with theelimination of inert atmosphere duringmicrowave sintering. Microstructuralcharacterization revealed finer microstructurefor microwave sintered magnesium when

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compared to conventionally sinteredmagnesium.

In the investigation of dry sliding wearbehaviour of aluminium alloy basedcomposites, reinforced with silicon carbideparticles and solid lubricants such as graphite/antimony tri sulphide (Sb2S3). The first one ofthe composites (binary) consists of Al with 20%Silicon Carbide particles (SiCp). The pin-on-disc dry wear tests to measure the tribologicalproperties were conducted for one hour atdifferent parameters namely loads: 30, 50 and80N and speed: 5, 7 and 9 m/s. Incorporationof graphite particles in the aluminium matrixas a second reinforcement decreases thewear rates of the composite compared toSiCp reinforced composite. Coefficient offriction was stabilized with incorporation ofsolid lubricants in composition of compositeat solid state for various sliding speeds andapplied loads. Combination of abrasion,delamination and adhesive nature of wear wasobserved. Proposed aluminium basedcomposites with lower wear resistance havebetter tribologocal characteristics than ironbased composites.

Aluminum as the matix and nanomaterialssuch as carbon nanotube, graphene and nano-diamond as reinforcement were used to formnano composites, using powder metallurgytechnique. The density values of AL + CNT +GR + ND composition were very near to thedensity value of base metal. The density valuesof AL + CNT + GR composition were lesscompared to the density values of AL + CNT +GR + ND composition composites. It isevident from the experiments that for AL + CNT+ GR and AL + CNT + GR + ND compositionwear resistance high for 2%. Less wear losswas observed.

CONCLUSIONSintering of Al composites is more energyefficient than for most other PM materials dueto the relatively low sintering temperatures.Cold isostatic compaction at 600 MPafollowed by vacuum sintering at 600 °C hasbeen successfully used to produce Alcomposites. Energy efficient and environmentfriendly microwave sintering route to synthesizepure aluminum composites can be used.Uniform dispersion of the fine reinforcementsand a fine-grained matrix improve themechanical properties of the composites. Anincrease in hardness of all samples wasobserved after friction stir processing whichwas attributed to the improvement in particledistribution and elimination of porosity. Theapparent density, tap density and theoreticaldensity increase with the additionreinforcements to the pure Al matrix. Thereason for the density increase was the fillingwith fine powders of reinforcements of thepores formed in the matrix by large irregularAl particles. Coefficient of friction wasstabilized with incorporation of solid lubricantsin composition of composite at solid state forvarious sliding speeds and applied loads.Incorporation of graphite particles in thealuminium matrix as a second reinforcementdecreases the wear rates of the compositecompared to SiCp reinforced composite.

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2. Chinawad Dhadsanadhep, TachaiLuangvaranunt, Junko Umeda andKatsuyoshi Kondoh (2008), “Fabricationof Al/Al2O3 Composite by PowderMetallurgy Method from Aluminum andRice Husk Ash”, Journal of Metals,Materials and Minerals, Vol. 18, No. 2,pp. 99-102.

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