1.1 Introduction To The Project
1.1 Introduction To The Project
1.1 Introduction To The Project
INTRODUCTION
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1.2 OBJECTIVES
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CHAPTER 2
LITERATURE SURVEY
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Vehicle bodies
Tip truck bodies
Mine skips and cages
Pressure vessels
2.1.2 Weldability
When welding 5083 to itself or another alloy from the same sub-group,
the recommended filler metal is 5183. Other suitable fillers are 5356 and 5556
– Arc: Excellent
2.1.3 Fabrication
Machinability – Poor
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2.2.1 Preparation
2 B2O3 + 7 C → B4C + 6 CO
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2.4 STIR CASTING PROCESS
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one time. The SEM also has much higher resolution, so closely spaced
specimens can be magnified at much higher levels. Because the SEM uses
electromagnets rather than lenses, the researchers, as well as the actual
strikingly clear images, make the scanning electron microscope one the most
useful instruments in research today.
Often materials are subject to forces (loads) when they are used.
Mechanical engineers calculate those forces and materials scientists how
materials deform (elongate, compress and twist) or break as a function of
applied load, time, temperature, and other conditions. Materials scientists learn
about these mechanical properties by testing materials. Results from the test
depend on the size and shape of material to be tested (specimen), how it is held,
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and the way of performing the test. That is why we use common procedures, or
standards, which are published by the ASTM.
2.6.1 Hardness
δ = (L – L0) / L0
The stress is the ratio of the tensile load F applied to the specimen to its
original cross-sectional area S0:
σ = F / S0
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2.6.3 Compressive Strength
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2.7 THEORY OF WEAR
(1) Abrasive
(2) Fretting
(3) Corrosive
(4) Adhesive
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High stress abrasion is caused due to high stress which results in more
work hardening. Few examples are abrasion caused due to by rolling-contact
bearings, gears, pivots and cams. In low stress abrasion there is light rubbing
activity of the abrasive particles with the metal surface which causes scratches
and there is no work hardening. Gouging abrasion also results due to high stress
that forms grooves or gouges on the affected surface. Some examples where this
can occur are impact hammers in pulverisers, parts of crusher liners, etc. Factors
that can affect the resistance from abrasion are hardness, microstructure and for
steel carbon content is also a factor.
(a) Low Stress Abrasive Wear (b) High Stress Abrasive Wear
(c) Gouging
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2.8.2 Fretting Wear
This type of wear is caused between two metallic components which are
sliding against each other under an applied load and in an environment where
no abrasives are present. The name “adhesive” is given due to the forming of a
strong metallic bond between the asperities in the surface of the contacting
materials. Mild wear or oxidative wear occurs in the case of stainless steel
because the thin oxide layer on the surface prevents the formation of metallic
bond between the asperities. Wear rates are high for high load application on the
surface. This kind of wear is generally seen in sliding components in a valve,
conveyor belts, fasteners, etc. In case of martensitic steels very good wear
resistance is obtained for a minimum hardness of 53 HRC. In austenitic
stainless steels, the alloy additions increase the stability of oxide film and also
work hardened hardness. These factors enable the requirement of high load for
severe corrosion to occur.
This type of wear can occur in surface of materials which are cyclically
stressed. Therefore ball bearings, gears, etc. Normally experience the fatigue
wear. The extent of fatigue wear is determined by the factors like residual
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stress, surface finish, microstructure and hardness. Resistance to fatigue wear
can be improved by surface treatments like carburizing, nitriding and shot
peening because they increase surface hardness and improve residual stress
distribution
The wear test (dry sliding wear test) performed on the fabricated
composite (Gr – B4C reinforced Al5083 composites) is a type of Adhesive wear.
This type of wear is caused between two metallic components which are sliding
against each other under an applied load and in an environment where no
abrasives are present. Adhesive wear involves material transfer from one
surface to another due to direct contact and plastic deformation. Dry sliding
wear involves sliding of one surface over other under the application of a load
normal to the plane of motion. Dry wear tests will be carried out on the Pin on
disc wear- testing machine.
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2.10 PIN ON DISC METHOD
a) Pin-on-Disc Machine
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2.11 LITERATURE STUDY
There was 25% decrease in wear rate for Al−Gr−Si3N4 hybrid composites
when compared with Al−Si3N4 nanocomposite for the sliding distance of 1 km.
The wear rate of Al−Gr−Si3N4 hybrid composite was found to decrease by 65%
for the loads of 20 and 30 N. Al−Gr−Si3N4 hybrid composite exhibited around
15% reduction in coefficient of friction when compared with Al−Si3N4
nanocomposite, leading to less wear.
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to the increase in microspores and interspaces between the matrix and the
reinforcement.
Anthony Xavior.M et al. [3] focused on the role of Graphene in
reducing the wear and frictional coefficient of Al 2024- SiC - Graphene
reinforced hybrid composites. They carried out the dry frictional wear test using
pin-on-disc tribometer to evaluate the effect of Graphene and SiC content in the
composite under various normal load and disc speed conditions. Surface
roughness values (Ra) and microscopic studies on wear tracks were carried out.
Addition of SiC (0.0-12.0 Wt. %), Graphene (0.5 Wt. %) and
encapsulation enables significant improvement in both hardness and flexural
strength compared to base alloy. Combination of SiC & Graphene in the
nanocomposites has resulted in significant improvement on tribological
properties where, it gives the wear resistance by creating a solid lubricant layer
between the sliding surfaces. The results revealed that there is a decrease in
wear losses, surface roughness and coefficient of frictional values which are
observed to be due to Graphene and SiC content.
Navdeep Singh et al. [4] synthesized and analysed three different
compositions by varying the amount of solid lubricant, WS2 (0, 5, 9) wt.%. The
micro hardness value of every composition was obtained by using micro
hardness tester. The tribological properties were investigated under dry and
unidirectional sliding conditions on a pin on disk tribometer. Analysis of
variance (ANOVA) was used to investigate the percentage contribution of
various parameters on the wear and friction behavior.They concluded that the
impact of sliding distance on wear loss is high (80.81%) followed by speed,
content and load.
Shakir Gatea et al. [5] manufactured an aluminium 6092 alloy with
17.5% volume fraction silicon carbide (SiC) particles sheet by means of powder
metallurgical method, heat treated to T6 condition, is used to obtain a
fundamental understanding of the heat treatment effect on the fracture
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mechanism, the microstructural changes and the interface between the Al-
matrix and SiC particles. Tensile tests with different strain rates (8×10−5,
8×10−4, 8×10−3, 8×10−2 and 0.16 s−1) were carried out to study the toughness
and to find a correlation between the strain rate and heat treatment. The results
show that the 6092Al/SiCp composite with T6 treatment is not suitable for
direct application of high deformation processes due to the deleterious effect of
intermetallic compounds on the toughness. Therefore, heat treatment is required
to enhance the toughness of 6092Al/SiCp composite. The toughness and
ductility of the 6092Al/SiCp composite can be improved significantly using
heat treatment (O-condition annealing) with a low strain rate.
Kenneth Kanayo Alanemea et al. [6] investigated the the corrosion and
wear behaviour of Al–Mg–Si alloy matrix hybrid composites developed with
the use of rice husk ash (RHA) and silicon carbide (SiC) particulates as
reinforcements. RHA and SiC mixed in weight ratios 0:1, 1:3, 1:1, 3:1, and 1:0
were utilized to prepare 5, 7.5 and 10 wt% of the reinforcing phase with Al Mg
Si alloy as matrix using double stir casting process. The corrosion and wear
mechanisms were established with the aid of scanning electron microscopy. It
was evident that for most cases the use of hybrid reinforcement of RHA and SiC
resulted in improved corrosion resistance of the composites in 3.5% NaCl
solution. It was evident that for most cases the use of hybrid reinforcement of
RHA and SiC resulted in improved corrosion resistance of the composites in
3.5% NaCl solution. The coefficient of friction and consequently the wear
resistance of the hybrid composites were comparable to that of the Al–Mg–Si
alloy matrix reinforced with only SiC.
M. Abdul Wahab et al [7] examined the wear characteristics of
A356/melon shell ash particulate composites. Dry-sliding the stainless steel ball
against specimen disc revealed the abrasive wear behavior of the composites
under loads of 2 and 5N. The composite showed lower wear rate of 2.182×10 −4
mm3/Nm at 20 wt% reinforced materials under load of 5N. Results showed that
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wear rate decreased significantly with increasing weight percentage of melon
shell ash particles. Microstructural analyses of worn surfaces of the composites
reveal evidence of plastic deformation of matrix phase. The wear resistance of
A356 increased considerably with percentage reinforcement. Wear rate of the
base alloy on the other hand, is about 1.23 times higher than that for the alloy
reinforced with 20 wt% melon shell ash particles. Thus, composite with 20 wt%
reinforcement showed better wear resistance compared with all other
composites.
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base matrix. The composite was prepared by using Liquid Metallurgy Route
(Stir Casting Technique). For each composite, reinforcement particles were pre-
heated to a temperature of 200ºC and then dispersed in steps of 3 into the vortex
of molten Al6061 alloy to improve wettability and distribution. The hardness
and tensile properties of prepared composites were examined.
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The static and accelerated corrosion tests have been performed and the micro
hardness of the developed composites was also investigated. It is observed that
there is a significant improvement in micro hardness with addition of Graphite
(Gr) and Aluminium Oxide (Al2O3) particles in matrix alloy. There is a
significant reduction in the slurry erosive wear rate of the developed composites
with increased percentage weight of reinforcement. This can be attributed to the
higher hardness and excellent corrosion and wear resistance of the composite. It
is observed that increased content of reinforcement in the matrix alloy decreases
the mass loss during immersion test. The salt spray test shows the formation of
white and red rust formation; the red rust appears due to formation of pit in
aluminium matrix. Increased graphite particles reduce the corrosion rate under
identical test conditions.
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CHAPTER 3
METHODOLOGY
LITERATURE SURVEY
SELECTION OF
MATERIALS
SYNTHESIZE
SAMPLE PREPARATION
MICROSTRUCTURAL
ANALYSIS
MECHANICAL AND
TRIBOLOGICAL TESTS
MICROSRTUCTURAL
ANALYSIS
RESULTS AND
DISCUSSION
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CHAPTER 4
CONCLUSION
Thorough Literature survey has been carried out to identify the problem
and the objectives are finalized. Different synthesize, process is studied and also
basics of tribological properties and mechanical properties also been studied.
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REFERENCES
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9. Madeva Nagaral, V Auradi, Ravishankar M K. ‘Mechanical Behaviour of
Aluminium 6061 Alloy Reinforced with Al2O3 & Gr Particulate Hybrid
Metal Matrix Composites’.
10.V. N. Gaitonde, S. R. Karnik, M. S. Jayaprakash, “Some Studies on Wear
and Corrosion Properties of L5083/Al2o3/Graphite Hybrid Composites”
(2015).
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