bhavani sankar C

The main intentions of this experiment work is to lesson about the microstructures, mechanical properties and wear characteristics of Aluminum-zinc alloy (Al-7075) reinforced with silica carbide & Fly ash. Aluminum metal matrix composites are used in varies applications like aerospace, defense, automobile, sports equipment and electronics due to their complimentary properties viz. light weight, high strength and coefficient of thermal expansion. The commercial Al 7075 alloy is used broadly in the aerospace engineering for the invention of structural components. In this experiment work, Al 7075 Reinforced with 2, 4 & 6 (%) weight of Silica Carbide & 2 (%) weight of Fly Ash are manufactured using stir casting technique. Sample Specimens are prepared as per the international standards for tensile, hardness, impact, wear tests are conducted. It was concluded that Fly ash and cast iron powder up to 6% can be added to Aluminum successfully by stir casting method route to fabricate a hybrid composite. The hardness and tensile strength increased with the increase in concentration of silica carbide powder. The wear and frictional force decreased with the increase in concentration of cast iron powder in the aluminum matrix. Impact strength variation is marginal with the increase in wt% of Silica Carbide. Porosities were observed in microstructures and increased with increasing wt.
% of Silicon carbide (SiC) reinforcements in aluminum matrix composites. Pin-on-disc wear test indicated that reinforcing Al matrix with Silicon carbide (SiC) particles increased wear resistance.

Keywords- Metal Matrix Composite, Stir Casting, Hardness Test, Tensile Test, Impact Test, Wear

The intentions of this exertion is to lessons about the microstructures, mechanical properties and wear characteristics of as cast silicon carbide (SiC) non-breakable aluminum matrix composites (AMCs). AMCs of changeable Silicon carbide (SiC) substance (0, 7, 14 and 24 wt. %) were equipped by stir casting process. Microstructures, Vickers hardness, tensile strength and wear performance of the prepared composites were analyzed. The results show those introducing Silicon carbide (SiC) reinforcements in aluminum (Al) matrix increased hardness and tensile strength and 28 wt. % Silicon carbide (SiC) reinforced aluminum matrix composites showed maximum hardness and tensile strength. Microstructure observation exposed clustering and non-homogeneous distribution of Silicon carbide (SiC) particles in the Al matrix. Porosities were observed in microstructures and increased with increasing wt. % of Silicon carbide (SiC) reinforcements in aluminum matrix composites. Pin-on-disc wear test indicated that reinforcing Al matrix with Silicon carbide (SiC) particles increased wear resistance.

Abrasive Water Jet Machining (AWJM) is a versatile and fastest growing machining process primarily used to machine hard and difficult to machine materials. This machine is also used to machine soft, thick, light, thin and fragile materials. It compliments other technologies such as Milling, Laser, EDM etc…. It doesn't possess any mechanical stress to operator and environmental hazards. AWJM cut the material accurately unlike any other machining process. AWJM mainly adopted by aerospace industry for cutting high strength materials and other composites. It finds most of its applications in machining of gas turbines, rocket motors, space craft, nuclear power and pumps etc., very thin stream of about 0.004 to 0.010 dia. can be cut and material loss is also less due to cutting. Standoff distance between mixing tube and work part is typically 2 to 4mm important to keep to a minimum to get superior surface finish. The objective of this research is to analysis the effect of input process parameters and to optimize process parameters for achieving optimizing Processes responses such as Metal Removal Rate(MRR), Surface roughness (Ra), and Kerf width simultaneously while machining on the nickel-chromium based super alloy INCONEL 825 using AWJM process. It is a precipitation hardened material and has good creep-rupture strength. It shows good mechanical properties even at high temperatures. Applications are Intricate shapes can be easily obtained for Aerospace products.