24

CHAPTER 2

LITERATURE SURVEY

This survey investigates each improvement with its distinct courses

for implementing the mechanical behaviours of the AL SiC, Nano SiC
materials.

2.1 RESEARCH ARTICLES RELATED TO MMC

Meena et al. (2013) described the Metal Matrix Composites

(MMC‘s) have evoked a keen interest in recent times for potential
applications. Advance composite materials like Al/SiC metal matrix
composite is gradually becoming very important materials in
manufacturing industries e.g. aerospace, automotive and automobile
industries due to their superior properties such as light weight, low density,
high strength to weight ratio, high hardness, high temperature and thermal
shock resistance, superior wear and corrosive resistance, high specific
modulus, high fatigue strength etc. In this study aluminium (Al-6063)/SiC
Silicon carbide reinforced particles Metal-Matrix Composites (MMCs) are
fabricated by melt-stirring technique. The MMCs bars and circular plates are
prepared with varying the reinforced particles by weight fraction ranging from
5%, 10%, 15%, and 20%. The average reinforced particles size of SiC are 220
meshes, 300 meshes, 400 mesh respectively. The stirring process was carried
out at 200 rev/min rotating speed by graphite impeller for 15 min. The
microstructure and mechanical properties like Proportionality (MPa) limit,
Tensile strength upper yield point (MPa), Tensile strength lower yield
point (MPa), Ultimate tensile strength (MPa), Breaking strength(MPa), %
Elongation, % Reduction in area, Hardness (HRB), Density (gm/cc),
 25

Impact Strength (N.m) are investigated on prepared specimens of MMCs.

It was observed that the hardness of the composite is increased with
increasing of reinforced particle weight fraction. The tensile strength and
impact strength both are increased with rising of reinforced weight fraction.
Different mechanical tests were conducted and presented by varying the
particle size and weight fractions of SiC.

Dhayalana & Kalaiselvan (2014) said that Friction Stir Processing

(FSP) is a new technique used for the production of surface composite,
refinement of microstructure and enhancing the mechanical properties. In this
work, Surface Matrix Composite (SMC) was made-up on the surface of
aluminium alloy (6063) with ceramic reinforcement using friction stir
processing technique. SiC and Gr was used as reinforcement. The chosen FSP
parameters such as traverse speed of 30 mm/min, tool rotational speed of
1000 rpm and 10 KN of axial load. The FSP tool made of HcHCr with
cylindrical threaded profile pin having shoulder diameter of 18 mm, pin
length of 5.8 mm and pin diameter of 6 mm was used. The FSP was carried
out using friction stir welding machine. Three combinations of surface
composites (Al/0.8Vol.%SiC, Al/0.8Vol.%Gr and Al/0.4Vol.%SiC-
0.4Vol.%Gr) were fabricated. Optical Microscope (OM) and Scanning
Electron Microscope (SEM) was used to study the micro structural changes.
The recrystallized grain structure was observed in the FSP‘ed zone. The micro
hardness of friction stir processed plates was analyzed using a Vickers
hardness tester. Sic reinforced Al alloy surface composite resulted higher
micro hardness.

Manjunath C Melgi & Purohit (2013) studied, silicon carbide

particulate reinforced LM6 alloy matrix composites were produced by
gravity die casting process by varying the particulate addition by weight
 26

fraction on percentage basis. Mechanical properties such as tensile,

impact and wear test studies were conducted to determine the tensile
strength, ductility, toughness and wear characteristics of cast MMC‘s.
Micro structural properties of the as cast composites have also studied
by using optical microscope. The experimental result reveals that the
tensile property increases with increase in Sic, the toughness of
composite decreases as silicon carbide percentage increases and the
composite showed accountable increase in wear rate of cast MMC.

Mohammad M Ranjbaran (2010) developed Aluminium Matrix

Composite (AMC) is considered to be a promising material for low and high-
temperature applications. Fiber reinforced AMC materials have high specific
strength and modules of elasticity, together with excellent heat resistance.
This experimental investigation was initiated to study the low-toughness
fracture in Al 356-SiCp (silicon carbide particles) with respect to the role of
the various elements of the microstructure and their probable contribution.
The fracture in this composite is studied experimentally, in terms of fracture
toughness testing. The low-toughness fracture is believed to be an inherent
property of this composite and is caused mainly by the differential elastic and
thermal properties of the two constituents. These differentials degrade the
matrix alloy near the interface by its strain hardening capacity and by stress
intensification introduced by the SiC particle geometry. Consequently, the
matrix near the interface is subjected to high localized damage leading to
premature fracture. It is found that the matrix alloy controls both flow
properties and fracture in the materials investigated. It is concluded that a
higher toughness composite requires a proper choice of constituent properties
which dominate the stress state at the interface.
 27

Sandeep Kumar Ravesh & Garg (2012) explained the fabrication

of aluminium based metal matrix composite and then characterized their
mechanical properties such as hardness, toughness and tensile strength. In
the present study a modest attempt has been made to develop aluminium
based silicon carbide particulate MMCs with an objective to develop a
conventional low cast method of producing MMCs and to obtain
homogeneous dispersion of ceramic material. To achieve this objective stir
casting technique has been adopted. Aluminium 6061 (97.06% C.P) and
SiC, Fly Ash has been chosen as matrix and reinforcement material
respectively. Experiment has been conducted by varying weight fraction of
SiC (2.5%, 5%, 7.5%, 10%) while keeping all other parameters constant.
The result indicated that the developed method is quite successful and there is
an increase in the value of tensile strength, hardness and toughness with
increase in weight percentage of SiC.

Sucitharan et al. (2013) focused on the study of wear behavior of

Aluminium alloy (6063) –Zircon sand composite produced by the stir
casting technique by controlling various casting parameters. The pin on
disk apparatus is used to analyze the wear rate of the composite. Here the
combination of composites investigated is 0, 2, 4, 6, 8 wt% of ZrSiO4 with
the matrix and it is found that the increase in reinforcement increase the wear
resistant property.

Mahendra Boopathi (2013) Materials are frequently chosen for

structural applications because they have desirable combinations of
mechanical characteristics. Development of hybrid metal matrix composites
has become an important area of research interest in Materials Science. In
view of this, the present study focuses on the formation of aluminium-
Sic-fly ash hybrid metal matrix composites. The present study was
 28

aimed at evaluating the physical properties of Aluminium 2024 in the

presence of silicon carbide, fly ash and its combinations. Consequently
aluminium metal matrix composite combines the strength of the
reinforcement with the toughness of the matrix to achieve a combination
of desirable properties not available in any single conventional material.
The compositions were added up to the ultimate level and stir casting
method was used for the fabrication of aluminium metal matrix composites.
Structural characterization was carried out on metal matrix composites by
x-ray diffraction studies and optical microscopy was used for the micro
structural studies. The mechanical behaviors of metal matrix composites like
density, tensile strength, yield strength, elongation and hardness tests were
ascertained by performing carefully designed laboratory experiments that
replicate as nearly as possible the service conditions. In the presence of
silicon carbide and fly ash [SiC (5%) + fly ash (10%) and fly ash (10%) + SiC
(10%)] with aluminium, it was fairly observed that the density of the
composites was decreased and the hardness was increased.
Correspondingly, the increase in tensile strength was also observed but
elongation of the hybrid metal matrix composites in comparison with
unreinforced aluminium was decreased. The aluminium-SiC-fly ash hybrid
metal matrix composites significantly differed in all of the properties
measured. Aluminium in the presence of SiC (10%)-fly ash (10%) was
the hardest instead of aluminium-SiC and aluminium fly ash composites.
The study can be further extended by evaluating the wear and corrosion of the
resultant material.

Reddappa et al. (2011) In recent years, aluminium alloy based

metal matrix composites (MMC) are gaining importance in several aerospace
and automobile applications. Al6061 has been used as matrix material owing
to its excellent mechanical properties coupled with good formability and its
 29

wide applications in industrial sector. From literature survey it has been

observed that hardness and tensile strength of Aluminium alloy-beryl
composites increased significantly with increasing beryl content. The cast
matrix alloy and its composites have been subjected to solution zing treatment
at a temperature of 5300C for 18hr. followed by quenching in ice. Heat
treatment has profound effect on both hardness and tensile strength of
Al6061-beryl composites, among them composite with 10% beryl shows
maximum. Accordingly, the aims of the present study are (i) study the effect
quenching media and (ii) sliding distance on the wear properties of these
composites in both ‗as cast‘ and ‗heat treated‘ conditions. It was observed
that the quenching has significant effect on tensile, hardness and wear
behavior, exhibiting enhancement as compared to ‗as cast‘ composites.

Swamy et al. (2011) presented the comparative study of the

mechanical properties of Al6061-Tungsten carbide composites containing
Tungsten carbide (WC) particulate, and Al6061-graphite particulate
composites containing graphite particles. The reinforcing particulates in the
MMCs vary from 0% to 4% by weight. The ‗vortex method' of production
was employed to fabricate the composites, in which the reinforcements were
poured into the vortex created by stirring the molten metal by means of a
mechanical agitator. The composites were subjected to a series of tests. The
results of this study revealed that as the Tungsten carbide particle content was
increased, there were significant increases in the ultimate tensile
strength, hardness and Young's modulus, accompanied by a reduction in
its ductility. There was, however, only a very marginal increase in the
compressive strength, where as in graphite reinforced composites as the
graphite content was increased, there were significant reduction in
hardness and monotonic increases in the ductility, Ultimate Tensile
Strength (UTS), compressive strength and Young's modulus of the
 30

composite, An attempt is made in the paper to provide explanations for

these phenomena.

Kheder et al. (2010) The objective of this experimental

investigation is to produce a Metal Matrix Composite (MMC) using pure
aluminium as a base material reinforced with one of the following ceramic
additives each time (alumina Al2O3, silicon carbide SiC, and magnesium
oxide MgO) with different volume fractions. Liquid state mixing technique
was employed for the different constituent. Temperature was checked
frequently while mixing using a thermocouple. Degasser was added to the
content of the composite while mixing to minimize gas bubbles at the final
cast. After melting and mixing, melts were poured in metallic mould then we
got a cast from which specimens for various tests were prepared. Complete
mixing between the Al matrix and the additives was checked by taking
specimens from different parts from the cast (from the upper middle and the
upper edge, and from the middle, then from the lower middle and lower edge
then subjected to microscopic observation. Microstructure examination and
microanalysis were carried out using optical microscope and scanning
electron microscope equipped with energy dispersive x-ray analysis,
moreover tensile mechanical properties were determined in each case. The
addition of Sic, MgO & Al2O3 particulates into the matrix alloy increased the
yield strength, the ultimate tensile strength & the hardness, & decreased
elongation (ductility) of the composites in comparison with those of the
matrix. Increasing wt% of SiC, MgO & Al2O3 increased their strengthening
effect but SiC is the most effective strengthening particulates, for
higher strength, hardness & grain size reduction. On the other hand, it
decreases ductility & toughness.
 31

Ali Hubi Haleem Newel Muhammad Dawood developed

Aluminium Matrix Composite (AMCs) is considered to be a promising
material for low and high temperature applications. Particles reinforced
AMCs materials have high specific strength and modulus of elasticity,
together with excellent heat resistance .Silicon carbide particles reinforced
Aluminium Matrix Composite (AMCs) for hardness, impact strength, and
material toughness improvement were prepared. Stir-casting processing was
optimized. The hardness, impact strength, and material toughness were
evaluated. Under stir-casting, the silicon carbide particles were uniformly
distributed in the aluminium and well bonded with aluminium matrix. The
hardness and material toughness were increased 1.84 and2.16 times
respectively at particles weight fraction (10%) that of the of the unreinforced
aluminium based on the high hardness and deformation resistance of the
silicon carbide particles.

Rolling of wrought aluminium matrix composites with hard phase-

reinforcements such as SiC, is interesting to produce sheets for engineering
constructions due to their light weight combined with good strength and wear
resistance. In this work, the hot rolling behavior is studied for stir-cast
composites with matrix of Al 6061 and Al 6082 alloys and fine SiCp
particulates with size of 15 μm and 8 μm and weight fraction up to 30%. For
composite casting, optimum casting procedures and materials pre-treatment
has been applied for successful insertion of particles into the melt, better
particles/matrix wetting and particles distribution, minimized SiC/Al reaction.
From thermo mechanical simulation, step rolling is defined to be suitable at a
strain rate of 1 s−1 rate for each step, using intermediate heat treatment at
450 °C for a period of 10 s to 1 h. Generally, the quality of rolled product was
improved with improving casting quality. Successive hot rolling resulted in
decreasing void and the agglomeration clusters and hence enhanced
 32

mechanical properties are achieved. The flow behavior under rolling of Al-
particulate metal matrix composites, PMMCs, is analyzed and the product is
characterized for its mechanical properties.

Mohammad M Ranjbaran (2010) developed Aluminium Matrix

Composite (AMC) is considered to be a promising material for low and high-
temperature applications. Fiber reinforced AMC materials have high specific
strength and modules of elasticity, together with excellent heat resistance.
This experimental investigation was initiated to study the low-toughness
fracture in Al 356-SiCp (silicon carbide particles) with respect to the role of
the various elements of the microstructure and their probable contribution.
The fracture in this composite is studied experimentally, in terms of fracture
toughness testing. The low-toughness fracture is believed to be an inherent
property of this composite and is caused mainly by the differential elastic and
thermal properties of the two constituents. These differentials degrade the
matrix alloy near the interface by its strain hardening capacity and by stress
intensification introduced by the SiC particle geometry. Consequently, the
matrix near the interface is subjected to high localized damage leading to
premature fracture. It is found that the matrix alloy controls both flow
properties and fracture in the materials investigated. It is concluded that a
higher toughness composite requires a proper choice of constituent properties
which dominate the stress state at the interface.

Liaqat Ali et al. (2013) Ceramics contain a distinctive property

of completely absence of slip planes and have least probability of
deforming by the application of force. Among these ceramics, the silicon
carbide occupies a competent place to be used as a reinforcing agent for
aluminium or its alloys. It has the density close to aluminium and is best
for making composite having good strength and good heat conductivity.
 33

Stir casting has been used to synthesize Al/SiC MMCs by reinforcing

silicon carbide particles into aluminium matrix. The reason for using stir
casting is to develop technology for the development of MMCs at
affordable cost. The selection of SiC as reinforcement and Al as matrix is
because of their easy availability. The practical data acquired, analyzed
and optimized will be interpreted in the light of information available in
the literature and be shared with the relevant industries. The present work
was mainly carried out to characterize the SiC/Al composite which was
produced by reinforcing the various proportions of SiC (5, 10, 15, 25 and
30%) in aluminium matrix using stir casting technique. Mechanical
properties of test specimens made from stir-casted Aluminium-Silicon
Carbide composites have been studied using metallographic and mechanical
testing techniques. It was observed that as the volume fraction of SiC
in the composite is gradually increased, the hardness and toughness
increase. However, beyond a level of 25-30 percent SiC, the results are
not very consistent, and depend largely on the uniformity of distribution
of SiC in the aluminium matrix.

Sandeep Kumar Ravesh & Garg (2012) focused in the past few
years the global need for low cost, high performance and good quality
materials has caused a shift in research from monolithic to composite
materials. In case of MMC‘s, aluminium 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. Also a simple and cost effective method for
manufacturing of the composites is very essential for expanding their
application. Reinforcements like particulate alumina, silicon carbide, graphite,
fly ash etc can easily be incorporated in the melt using cheap and widely
available stir casting method. This paper presents a review on the mechanical
 34

and tribological properties of stir cast aluminium matrix composites

containing single and multiple reinforcement. Addition of alumina to
aluminium has shown an increase in its mechanical and tribological
properties. Organic reinforcement like fly ash, coconut ash also improved the
tensile and yield strength. Self-lubricating property of graphite improved the
machinability of aluminium. Many authors have also reported about modified
stir casting route.

Baghchesara et al. (2007) The objective of the present

investigation was to evaluate the mechanical properties of Al/ZrO2 composite
prepared via vortex or direct incorporation method. An Al-356 alloy and ZrO2
particles with average size of 1 micron as the reinforcing material were used
as the raw materials. The results showed that addition of ZrO2 particles to
the matrix increases significantly the mechanical properties of aluminium.
The UTS of a sample having 15 vol. percent ZrO2 prepared in 750oC,
increased from 145 to 232 MPa and the hardness of the sample increased
from 45 to 64 brinell. The Al-356/ZrO2 composite specimens fail in a
macroscopically brittle manner with little or no necking observed around the
fracture site and with a relatively flat fracture surface.

Tzamtzis et al. (2011) Particulate Metal Matrix Composites

(PMMCs) have attracted interest for application in numerous fields. The
current processing methods often produce agglomerated particles in the
ductile matrix and as a result these composites exhibit extremely low
ductility. The key idea to solve the current problem is to adopt a novel Rheon-
process allowing the application of sufficient shear stress (τ) on particulate
clusters embedded in liquid metal to overcome the average cohesive force or
the tensile strength of the cluster. In this study, cast A356/SiCp composites
were produced using a conventional stir casting technique and a novel Rheon-
 35

process. The microstructure and properties were evaluated. The adopted

Rheon-process significantly improved the distribution of the reinforcement in
the matrix. A good combination of improved Ultimate Tensile Strength (UTS)
and tensile elongation (ε) is obtained.

Ashok Kr Mishra (2012) Tribological behavior of aluminium alloy

Al-6061 reinforced with silicon carbide particles (10% & 15%weight
percentage of SiCp) fabricated by stir casting process was investigated.
The wear and frictional properties of the metal matrix composites was
studied by performing dry sliding wear test using a pin-on-disc wear tester.
Experiments were conducted based on the plan of experiments generated
through Taguchi ‟ s technique. A L9 Orthogonal array was selected for
analysis of the data. Investigation to find the effect of applied load,
sliding speed and sliding distance on wear rate, as well as the coefficient
of friction during wearing process was carried out using ANOVA and
regression equation for each response were developed for both 10% &
15% SiC reinforced Al-6061MMCs. Objective of the model was chosen
as „smaller the better‟ characteristics to analyze the dry sliding wear
resistance. Results show that sliding distance has the highest effect followed
by load and sliding speed. Finally, confirmation tests were carried out to
verify the experimental results & Scanning Electron Microscope were
done on wear surfaces.

Muzakkir Ahmed Khan (2014) explained about the Aluminium

alloys are widely used in aerospace and automobile industries due to their low
density and good mechanical properties, better corrosion resistance and wear
resistance, low thermal coefficient of expansion as compared to conventional
metals and alloys. The excellent mechanical properties of these materials and
relatively low production cost males them a very attractive candidate for a
 36

variety of applications both from scientific and technological viewpoints. In

this paper an attempt has been made to provide a literature review on the
overall performance of reinforced composites fabricated by stir casting
method and effect of process parameters on properties of Aluminium based
MMC. The literature review framework in this paper provides a clear
overview that the process parameters play important role for optimum
properties of Aluminium based Metal Matrix Composites.

Youhei Asaka & Masashi Miyazaki (2004) described to evaluate

the filler compositions of recently available light-cure resins. The composition
of each resin paste was evaluated using an energy dispersive X-ray
fluorescence spectrometer. Scanning electron microscopic observation of the
polymerized resin pastes was also conducted. The main component of each
resin composite was Si, while the other elements detected were Al, Ba, Sr, Zr,
and K. These elementary compositions differed among the resin pastes used.
Three different types of filler morphology were observed; splintered, prepay
merited and splintered, and spherical. The results of this study have thus
characterized recently developed resin composites based on their filler
elements and morphology.

Kenneth Kanayo Alanemea & Peter Apata Olubambia (2013) said

that the corrosion and wear behavior Al–Mg–Si alloy matrix hybrid
composites developed with the use of Rice Husk Ash (RHA) and alumina as
reinforcements has been investigated. Alumina added with 2, 3, and 4wt.%
RHA were utilized to prepare 10wt.% of the reinforcing phase with Al–Mg–
Si alloy as matrix using double stir casting process. Open Circuit corrosion
Potential (OCP) and potential dynamic polarization measurements were used
to study the corrosion behavior while coefficient of friction was used to assess
the wear behavior of the composites. The corrosion and wear mechanisms
 37

were established with the aid of scanning electron microscopy. The results
show that the corrosion resistance of the single reinforced Al–Mg–Si/10wt .%
Al2O3 composite was superior to that of the hybrid composites in 3.5% NaCl
solution, and the corrosion rates increased with increase in wt.% RHA. The
increase in the population of matrix/reinforcement interface with increase in
wt.% RHA in the hybrid composites was identified as the likely reason for the
increase in corrosion rates observed with increase in wt.% RHA. The
coefficient of friction and consequently, the wear rate of the composites were
observed to increase with increase in RHA wt.%. The wear mechanism of the
composites was observed to transform from predominantly abrasive wear to a
combination of both adhesive and abrasive wear with increase in RHA wt.%.

David Raja Selvam et al. (2013) Stir casting is one of the simplest
ways of producing Aluminium Matrix Composites (AMCs). This work
focuses on the fabrication of AMCs reinforced with various weight
percentages of SiC particulates and a constant weight percentage of Fly Ash
by modified stir casting route. The wet ability of SiC and Fly ash particles in
the matrix was improved by adding magnesium into the melt. The
microstructure and mechanical properties of the fabricated AMCs were
analyzed. (Jenix Rino et al. 2013) The present study deals with the
investigation of the mechanical behavior of Aluminium 6063 alloy
composites reinforced by Zircon sand (ZrSiO4) and Alumina (Al2O3) particles
with a total reinforcement in Wt% is 8, and in this hybrid reinforcement the
variations (0+8)%, (2+6)%, (4+4)%, (6+2)%, (8+0)% were taken in to
account for investigating the properties such as density tensile strength
and hardness of the composites synthesized by Stir casting technique. The
mechanical properties evaluation reveals variations in hardness and the tensile
strength values with the composite combinations. From the experimental
studies, the optimum volume fraction of hybrid reinforcement in Al
 38

6063 alloy on the basis of microstructure and mechanical properties it

is found that the (4+4) wt% combination.

The SEM micrographs revealed that the addition of Fly Ash helped
to prevent SiCp dissolution and the formation of Al4C3. The mechanical
properties like hardness and tensile strength were improved with the increase
in weight percentage of SiC particulates with constant weight percentage of
Fly Ash in the aluminium matrix.

2.2 RESEARCH ARTICLES RELATED TO SIC WITH AL

Auradia & Kori (2014) In the present work, 11wt% B4C particulate
reinforced 6061 Al matrix composites were produced by conventional melt
stirring method. Processing of composite is carried out at a temperature of
7500C involving two stage additions. Preheated B4C particles along with
K2TiF6 halide salt (with ratio of 0.3) was introduced in steps of two rather
than adding all at once. Characterization of the prepared composites is done
using SEM/EDX and X-RD studies. Fairly uniform distribution of B4C
particulates without clustering in 6061Al matrix was evident from SEM
studies. The prepared composite consists of D-Al, B4C and minor phases like
Al3Ti, AlB2 and Al3BC are confirmed by XRD studies. The addition of B4C
particulates to 6061Al matrix has resulted in improvements in mechanical
properties of the base alloy.

Haizhi Ye (2003) explained the development of Al-Si alloy and its

based material for engine application is reported in this paper, focusing on
improving the material‘s fatigue limit and wear resistance, which are two
important properties for engine block materials. The paper begins with a
description of the microstructure (primary and eutectic phases, intermetallics
and casting defects) of Al-Si alloy and its effects on this material‘s fatigue
 39

and wear behaviors. Then, some recent techniques to enhance these two
properties are discussed such as alloying, composite production, and casting.

Michael Oluwatosin Bodunrina et al. (2015) studied the

Aluminium hybrid composites are a new generation of metal matrix
composites that have the potentials of satisfying the recent demands of
advanced engineering applications. These demands are met due to
improved mechanical properties, amenability to conventional processing
technique and possibility of reducing production cost of aluminium
hybrid com-posits. The performance of these materials is mostly
dependent on selecting the right combination of reinforcing materials
since some of the processing parameters are associated with the
reinforcing particulates. A few combinations of reinforcing particulates
have been conceptualized in the design of aluminium hybrid composites.
This paper attempts to review the different combination of reinforcing
materials used in the processing of hybrid aluminium matrix composites
and how it affects the mechanical, corrosion and wear performance of
the materials. The major techniques for fabricating these materials are
briefly discussed and research areas for further improvement on
aluminium hybrid composites are suggested.

Tarek A Khalifa & Tamer S Mahmoud (2009) Mechanical

properties at elevated temperatures of as-cast and extruded AA6063
aluminium alloy reinforced with SiC particles (SiCp) were studied. Hot
extrusion was carried out with reduction in area of 25% on the as cast
composites which were prepared by the vortex method. Tensile tests carried
out at room temperature showed that for the as-cast composites, the addition
of SiCp up to 10% by weight improves the strength but reduces ductility.
Further addition of SiCp reduces both the strength and the ductility of the
 40

composites. At 150 and 300 oC the matrix alloy exhibits higher strength than
the composites, but the extruded composites have better strength than as-cast
composites? Time rupture creep tests carried out at 300 oC showed that the
composites exhibits higher creep resistance as compared to the matrix alloy
except at relatively low stresses where the matrix has a better creep resistance.

Hemalatha et al. (2013) Aluminium-Alumina composites have

increasingly widened their use due to merits of processing, high specific
strength and modulus of elasticity while carrying good deformability and
conductivity comparable to metals. In addition to its use in structural
components for high performance application, such as aerospace vehicles
and racing automobiles, hence this composite requires a good processing
method so that the quality of the Al6063/Al2O3 composite is not affected.
Hence stir casting method of casting is adopted and Al 6063 plate is casted
with varying mass of Al2O3 (3%, 6%, 9%). Also the distribution of Alumina
and Aluminium is examined by microstructure analysis, hardness distribution
and the material is tested for its mechanical Properties such as tensile strength
and Hardness.

Sandeep Kumar Ravesh & Garg (2012) deals with the fabrication
of aluminium based metal matrix composite and then characterized their
mechanical properties such as hardness, toughness and tensile strength. In
the present study a modest attempt has been made to develop aluminium
based silicon carbide particulate MMCs with an objective to develop a
conventional low cast method of producing MMCs and to obtain
homogeneous dispersion of ceramic material. To achieve this objective stir
casting technique has been adopted. Aluminium 6061 (97.06% C.P) and
SiC, Fly Ash has been chosen as matrix and reinforcement material
respectively. Experiment has been conducted by varying weight fraction of
 41

SiC (2.5%, 5%, 7.5%, 10%) while keeping all other parameters constant.
The result indicated that the developed method is quite successful and there is
an increase in the value of tensile strength, hardness and toughness with
increase in weight percentage of SiC.

Mahendra Boopathi (2013) Materials are frequently chosen for

structural applications because they have desirable combinations of
mechanical characteristics. Development of hybrid metal matrix composites
has become an important area of research interest in Materials Science. In
view of this, the present study focuses on the formation of aluminium-
Sic-fly ash hybrid metal matrix composites. The present study was
aimed at evaluating the physical properties of Aluminium 2024 in the
presence of silicon carbide, fly ash and its combinations. Consequently
aluminium metal matrix composite combines the strength of the
reinforcement with the toughness of the matrix to achieve a combination
of desirable properties not available in any single conventional material.
The compositions were added up to the ultimate level and stir casting method
was used for the fabrication of aluminium metal matrix composites. Structural
characterization was carried out on metal matrix composites by x-ray
diffraction studies and optical microscopy was used for the micro
structural studies. The mechanical behaviors of metal matrix composites like
density, tensile strength, yield strength, elongation and hardness tests were
ascertained by performing carefully designed laboratory experiments that
replicate as nearly as possible the service conditions. In the presence of
silicon carbide and fly ash [SiC (5%) + fly ash (10%) and fly ash (10%) + SiC
(10%)] with aluminium, it was fairly observed that the density of the
composites was decreased and the hardness was increased.
Correspondingly, the increase in tensile strength was also observed but
elongation of the hybrid metal matrix composites in comparison with
 42

unreinforced aluminium was decreased. The aluminium-SiC-fly ash hybrid

metal matrix composites significantly differed in all of the properties
measured. Aluminium in the presence of SiC (10%)-fly ash (10%) was
the hardest instead of aluminium-SiC and aluminium-fly ash composites.
The study can be further extended by evaluating the wear and corrosion of the
resultant material.

Rajmohan & Palanikumar (2010) presented, a neural network

based on Back-Propagation (BP) algorithm with hidden layers are used for the
modeling of Thrust force in drilling of hybrid metal matrix composites.
Materials used for the present investigation are Al 356- aluminium alloy
reinforced with silicon carbide of size 25 microns and mica of size 45 microns
which are produced through stir casting route. Experiments are conducted on
a vertical CNC machining centre using Tin coated carbide drill of 6 mm
diameter. The parameters considered for the drilling experiments are spindle
speed, feed rate and wt % SiC. The data for training and testing have been
taken from experiments conducted as per Design of experiments. An
empirical model has been developed for predicting the Thrust force of Al
356/Sicp-mica composites. The result shows that the well trained neural
network model can precisely predict the thrust force in drilling of Al 356/SiC-
Mica composites. Validation results reveal that the neural network model is
suitable for predicting the thrust force in drilling hybrid composites. It was
found that the maximum error obtained in training of ANN system when
comparing the experimental results is less than 5.0%. The efficiency of the
system can be improved by using more number of data point.

Basavarajappa et al. (2004) investigated the Mechanical properties

of as cast aluminium alloy composite reinforcing with SiCp and graphite
particles. The result reveals that as the reinforcement content increases the
 43

mechanical properties such as ultimate tensile strength, yield strength,

hardness and compressive strength of the composite increases predominantly
but the density of the composite will decrease. The increased strength of
aluminium 2024/SiCp-Gr composite is attributed to synergistic effect of the
dislocation density generated due the differences in coefficient of thermal
expansion between the constituents of the composite.

Ali Hubi Haleem & Newal Muhammad Dawood (2003) The

developed Aluminium Matrix Composite (AMCs) is considered to be a
promising material for low and high temperature applications. Particles
reinforced AMCs materials have high specific strength and modulus of
elasticity, together with excellent heat resistance. Silicon carbide particles
reinforced Aluminium Matrix Composite (AMCs) for hardness ,impact
strength, and material toughness improvement were prepared. Stir-casting
processing was optimized. The hardness, impact strength, and material
toughness were evaluated. Under stir-casting, the silicon carbide particles
were uniformly distributed in the aluminium and well bonded with aluminium
matrix. The hardness and material toughness were increased 1.84 and2.16
times respectively at particles weight fraction (10%) that of the unreinforced
aluminium based on the high hardness and deformation resistance of the
silicon carbide particles.

Donga et al. (2009) discussed The processing and mechanical

behavior of Al2O3 composites with 1–20wt.% Nano-/micro-sized SiC
particles was investigated. The composites were desired by hot-pressing. The
mechanical properties of Nano-/micro-sized SiC/Al2O3 composites including
hardness, fracture toughness and flexural strength were investigated. It was
found that the fracture strength and fracture toughness of the Nano-/micro-
sized SiC/Al2O3 composites were significantly improved in comparison with
 44

the monolithic Al2O3. 7.6MPam1/2was the highest fracture toughness and

was found in the composite with 5% SiC, while the 20% SiC composite
exhibited the highest flexural strength. The toughening and strengthening
mechanisms of the ceramic composites were discussed.

Kenneth K Alaneme & Ayotunde Aluko (2012) The production

quality and age-hardening behavior of Al 6063/SiC particulate composites
developed using borax additive and a two-step stir casting was investigated.
This was aimed at establishing optimum processing and thermal ageing
conditions required for the development of Al 6063/SiCp composites. Al
6063/SiCp composites containing 6, 9, and 12 volume percent of SiC were
produced; and samples representative of each composition were subjected to
age-hardening treatment at 180oC, 190oC, and 200oC for holding times
ranging from 30 to 180 minutes. Micro-structural characterization and density
measurements were used as a basis of evaluating the porosity and general
casting quality of the composites; while hardness measurements were used to
study the age hardening behavior. Experimental results show that Al
6063/SiCp composites having low porosity levels (≤ 1.6 % porosity) and a
good uniform distribution of the SiC particulates in the matrix of the Al 6063
were produced. Compared with the monolithic alloys, the aging response of
the 6 and 9 volume percent (vol. %) SiC composites were generally poor,
while the 12vol.% SiC composites showed appreciable age-hardening
response at temperatures of 180-190oC (at 200oC, the ageing response was
poor). Also, the transformation sequence of the composites appeared to be
different from that of the monolithic alloy judging from the nature of the
hardness profiles.

Balamurugan Adhithan et al. (2012) Aluminium (1100) is found

wide application for rail coaches, aircraft industry, bearing materials, piston
 45

material, transmission lines etc. But due to their low melting point and low
hardness they will wear and deformed easily. The metal Aluminium cannot
meet al.l the required properties suitable for various engineering applications.
So it is necessary to develop the Aluminium based materials that could
have all combinational properties satisfying all our engineering
requirements. SiC can be considered as ideal reinforcements due to their high
strength, high aspect ratio and thermo mechanic properties. However, until
now, the main obstacle is to obtain a homogenous dispersion of the SiCs in
the desired matrix. Quite a few methods have studied to help improving the
dispersion of SiCs in a polymer matrix. The objective of this work is to
reinforce light Aluminium with SiC by melt stirring method. Different wt%
of SiC was added to Aluminium [1100] separately to make Aluminium
composites and its mechanical and thermal properties have been investigated
using test like tensile, hardness, coefficient of thermal expansion. The
improvement of mechanical and thermal properties for both the cases has
been compared with pure Aluminium.

Sharanabasappa (2013) The results of an experimental

investigation of the mechanical properties of fly ash and Alumina
reinforced aluminium alloy (LM25) composites samples, processed by
stir casting route are reported in this paper. Three sets of composites
with constant weight fraction of fly ash (particle size of 3-100 μm)
and Al2O3(particle size of 150 μm) with different wt% were used. Composite
samples have the reinforcement weight fractions of constant 3% fly Ash and
varying %wt of 5, 10 and 15% Al2O3. The main mechanical properties studied
were the tensile strength, ductility impact strength & hardness. Unreinforced
LM25 samples were also tested for the same properties. It was found that the
tensile strength & hardness of the aluminium alloy (Lm25) composites
increases with the increase in %wt of Al2O3 up to certain limit. in
 46

addition of more amount of reinforcement the Tensile strength

decrease due to poor wet ability of the reinforced material with metal
aluminium matrix .And the chirpy test shows decrease in impact load
absorption with increase in %weight reinforcement. The Microstructure
study of the samples indicated near uniform distribution of the fly ash and
Al2O3 particles in the matrix. LM25 alloy is mainly used where good
mechanical properties are required in castings of a shape or dimensions
requiring an alloy of excellent cast ability in order to achieve the desired
standard of soundness. The alloy is also used where resistance to
corrosion is an important consideration particularly where high strength is
also required.

Liaqat Ali et al. (2013) Ceramics contain a distinctive property

of completely absence of slip planes and have least probability of
deforming by the application of force. Among these ceramics, the silicon
carbide occupies a competent place to be used as a reinforcing agent for
aluminium or its alloys. It has the density close to aluminium and is best
for making composite having good strength and good heat conductivity.
Stir casting has been used to synthesize Al/SiC MMCs by reinforcing
silicon carbide particles into aluminium matrix. The reason for using stir
casting is to develop technology for the development of MMCs at
affordable cost. The selection of SiC as reinforcement and Al as matrix is
because of their easy availability. The practical data acquired, analyzed
and optimized will be interpreted in the light of information available in
the literature and be shared with the relevant industries. The present work
was mainly carried out to characterize the SiC/Al composite which was
produced by reinforcing the various proportions of SiC (5, 10, 15, 25 and
30%) in aluminium matrix using stir casting technique. Mechanical
properties of test specimens made from stir-casted Aluminium-Silicon
 47

Carbide composites have been studied using metallographic and mechanical

testing techniques. It was observed that as the volume fraction of SiC
in the composite is gradually increased, the hardness and toughness
increase. However, beyond a level of 25-30 percent SiC, the results are
not very consistent, and depend largely on the uniformity of distribution
of SiC in the aluminium matrix.

Zuhair M Gasem & Amro M AI-Qutubl (2002) The

electrochemical behavior of aluminium alloy 6061/A1103 metal matrix
composite was investigated in 3.5% NaCl aqueous solution. Two composite
compositions were examined containing 10% and30% (by volume) of sub-
micron alumina particulates as the reinforcement phase. The composites were
fabricated via powder metallurgy processing. Cyclic polarization tests were
carried out to determine pitting potentials and repassivation potentials in
darted 3.5% NaCl solution. The pitting potential was 50 m V nobler for the
higher-content reinforcement composite, while the repassivation potentials
were essentially identical. The scanning electron microscope was used to
reveal pits morphologies generated potential statically at a potential 150 m V
nobler than the open circuit potentials for two hours immersion in quiescent
chloride solution. Excessive pitting of the matrix alloy was observed in both
composites. Pits forming in the 6061/A1203/30p composite were more
numerous and more uniformly dispersed compared to pits on the lower-
content reinforcement composite which were deeper and more localized.
Preliminary results suggest that pit initiation sites correlate with regions
exhibiting agglomeration of the reinforcement particles.

Chennakesava Reddy & Essa Zitoun (2010) The material selection

criteria involve the requirement of high strength and good corrosion resistance
aluminium alloys for the matrix materials. The mechanical properties have
 48

been determined for different metal matrix composites produced from Al

6061, Al 6063 and Al 7072 matrix alloys reinforced with silicon carbide
particulates. The yield strength, ultimate strength, and ductility of Al/SiC
metal matrix composites are in the descending order of Al 6061, Al6063 and
Al 7072 matrix alloys. Mg has improved the wet ability between Al and SiC
particles by reducing the SiO2 layer on the surface of the SiC. The fracture
mode is ductile in nature.

Sunday Aribo et al. (2011) The effect of high temperature on

mechanical properties of silicon carbide particulate reinforced cast aluminium
alloy composite has been investigated. 15% weight fraction silicon carbide
aluminium alloy (6063) composite was cast by stir casting technique. The
samples were machined to tensile, impact and hardness test samples and were
tested at room temperature and elevated temperatures of 100°C, 250°C and
400°C. The results showed that the ultimate tensile strength, yield strength
and hardness of the composite are enhanced at the elevated temperature.
However the impact energy was observed to decrease with increase in
temperature.

Jagatheesh Kumar et al. (2014) This paper presents the wear

behavior of Al6063 discontinuously reinforced with graphite and Aluminium
oxide composite. Graphite is chosen because it has self-lubricating property
which can reduce friction and also reduce wear. Al 6063-6% Al2O3,
Al 6063-6% Al2O3-1% Gr composites were produced by stir casting
method and then the samples strength and wear behavior were carried out
by hardness test and pin-on-disc wear test apparatus. The obtained result
showed that Al 6063-6% Al2O3-1%Gr hybrid composite exhibited more wear
resistance when compared to Al 6063-6% Al2O3 mono-reinforced composite.
It was expected that the addition of 1 wt.% Gr particulates might pin
 49

downed the wear. In order to judge the densification behavior, the samples
were multi-axially forged and the strength of the samples was compared. The
results showed that the multi-axially forged samples exhibited more strength
than as-casted samples due to presence of pores in as-casted condition.

Meena et al. (2013) Metal Matrix Composites (MMC‘s) have

evoked a keen interest in recent times for potential applications.
Advance composite materials like Al/SiC metal matrix composite is
gradually becoming very important materials in manufacturing industries
e.g. aerospace, automotive and automobile industries due to their superior
properties such as light weight, low density, high strength to weight ratio,
high hardness, high temperature and thermal shock resistance, superior wear
and corrosive resistance, high specific modulus, high fatigue strength etc. In
this study aluminium (Al-6063)/SiC Silicon carbide reinforced particles
metal-matrix composites (MMCs) are fabricated by melt-stirring technique.
The MMCs bars and circular plates are prepared with varying the reinforced
particles by weight fraction ranging from 5%, 10%, 15%, and 20%. The
average reinforced particles size of SiC are 220 mesh , 300 mesh, 400 mesh
respectively. The stirring process was carried out at 200 rev/min rotating
speed by graphite impeller for 15 min. The microstructure and mechanical
properties like Proportionality (MPa) limit, Tensile strength upper yield
point (MPa), Tensile strength lower yield point (MPa), Ultimate tensile
strength (MPa), Breaking strength(MPa), % Elongation, % Reduction in
area, Hardness (HRB), Density (gm/cc), Impact Strength (N.m) are
investigated on prepared specimens of MMCs. It was observed that the
hardness of the composite is increased with increasing of reinforced
particle weight fraction. The tensile strength and impact strength both are
increased with rising of reinforced weight fraction. Different mechanical tests
 50

were conducted and presented by varying the particle size and weight
fractions of SiC.

2.3 RESEARCH ARTICLES RELATED TO NANO SIC WITH

AL AND OTHER MATERIALS

Ali Mazahery & Mohsen Ostad Shabani (2012) The

microstructure and mechanical properties of nano composites processed via
stir casting were studied. The composites were based on the A356 aluminium
alloy reinforced with nano SiC particles. The density measurements show that
the samples contain little porosity and the amount of porosity in the
composites increases with increasing weight fraction of SiC. The
microstructures of the composites were examined using optical microscope
and transmission electron microscope. Microscopic observations of the
microstructures reveal that the dispersion of the particles is uniform. The yield
strength, ultimate tensile strength and the elastic modulus are improved with
the addition of nano particles although some reduction in ductility is
observed. The highest yield strength and ultimate tensile strength are obtained
with the addition of 3.5% SiC nano-particles. A relatively ductile fracture in
tensile fractured samples was observed by fractography examination.

Babu Rao et al. (2011) focused an attempt has been made to

modify the micro sized Silicon carbide powder into nano structured Silicon
carbide powder using High Energy Ball Mill. Ball milling was carried out for
the total duration of 50 hours. The sample was taken out after every 5 hours of
milling and it was characterized for its crystallite size, lattice strain, and
percentage of crystalline by using X-Ray Diffract meter. It was found that for
the 50 hrs, milling the crystallite size was reduced from 120 nm to 26 nm and
the percentage of crystalline got reduced from 74% to 49%. The size, shape
and texture of the fresh as well as nano structured Silicon carbide powder
 51

were studied using Scanning Electron Microscopy (SEM). The fresh Silicon
carbide powder particles were mostly angular in shape. The shape of the 50h
milled particles is irregular and the surface morphology is rough.

Cecilia Borgonovo (2010) Conventional manufacturing methods

are sub-optimal for nano-composites fabrication. Inhomogeneous dispersion
of the secondary phase and scalability issues are the main issues. This
work focuses on an innovative method where the reinforcement is formed in-
situ in the melt. It involves the reaction of the molten aluminium with a
nitrogen-bearing gas injected through the melt at around 1273 K. AlN
particles are expected to form through this in situ reaction. A model has
been developed to predict the amount of reinforced phase. Experiments
have been carried out to confirm the feasibility of the process and the
mechanism of AlN formation discussed. The detrimental effect of oxygen in
the melt which hinders the metrication reaction has been proved. The effect of
process times and the addition of alloying elements (Mg and Si) have also
been investigated.

Suneel Donthamsetty & Nageswara Rao ( 2010) paper presented

the mechanical properties of A356 matrix nano composites fabricated by
reinforcing nano silicon carbide (SiC) particles at 0.1 to 0.5 weight percent
with the aid of ultrasonic cavitations. SiC Nano particles synthesized by
bottom-up and top-down approach are used in this work as reinforcements
and change in mechanical properties are observed. For comparison, A356
matrix composite reinforced with micro particles at 0.5 wt% by stir casting
also prepared. Till now, SiC nano particles produced by bottom up approach
were used as reinforcements in A356 alloy by so many researchers to improve
mechanical properties. But in this work, Nano particles produced by high
energy ball milling (Top-down approach) are also used as reinforcements. It
 52

is observed that there is reduction in tensile properties for the composites

prepared using nano particles via top down approach than that of bottom up
approach. But significant increase compared to the composites prepared by
reinforcing same amount of micro particles by stir casting. The reasons may
be due to the non-uniformity in size of particles and contamination while
milling nano particles. However, the change in properties is less and use of
nano particles via top down approach is admissible when compared to the cost
of nano particles synthesized from bottom up approach or chemical routes.

Dinesh Kumar Koli et al. (2014) Nanotechnology is spreading

vastly in the various demanding fields of engineering and medicines like
aerospace, defense, automobiles, electronics, materials, chemistry, energy,
environment, information & communication, consumer goods and bio-
technology. It created a high impact on development of new generation Nano
materials with advanced features and wide range of their applications.
Reinforcement of submicron or Nano-sized particles with aluminium matrix
yields superior mechanical and physical properties and changes morphology
and interfacial characteristics of Nano-composites. A wide range of research
has been done on the processing methods and material properties of Al-Al2O3
Nano-composites. Recently, ultrasonic assisted casting, Nano-sintering,
powder metallurgy, high energy ball milling, friction stir process are being
applied for the production of Al-Al2O3 Nano-composites in which
agglomeration of the reinforcing particles causes grain growth resulting
changes in the microstructure. Control of the grain size by minimizing
agglomeration of Nano particles and retaining the enhanced microstructure
during these processes has become a challenging task. This area is further
looked-for research work to control the microstructures under various
processing conditions.
 53

Yousef Mazaheri et al. (2010) In this study ball milling of Al356

and Al2O3 powder mixture was carried out in order to produce Al356-Al2O3
nano-composite containing 20 vol.% Al2O3. The structural evolution and
morphological changes of powder particles during ball milling were studied
by X-ray diffractometery and scanning electron microscopy analysis. As a
result of ball milling Al2O3 particles were uniformly dispersed in Al356
matrix. Furthermore the crystallite size of the Al356 decreased to 25 nm after
ball milling for 10 h. Morphological studies of powder particles indicated that
the powder particle size co-tenuously decreases with increasing milling time.
Hardness and elastic modulus values of powder particles were measured by
nano indentation method. It was found that the hardness and elastic modulus
of Al356-20 vol.% Al2O3 nano-composite were about 216 Hv and 86 GPa,
respectively which is higher than 75 Hv and 74 GPa for as-received Al356.

In this work, we describe the fatigue behavior of silicon carbide

(SiCP)-reinforced A359 aluminium alloy matrix composite considering its
microstructure and thermo-mechanical properties. A variety of heat
treatments have been performed for the 20 vol. % SiCp composite, which
resulted in different strength and elongation behavior of the material. The
fatigue behavior was monitored, and the corresponding S–N curves were
experimentally derived for all heat treatments. The fatigue strength was found
to depend strongly on the heat treatment. In addition, the fatigue behavior was
monitored non-destructively via the use of lock-in thermography. The heat
wave, generated by the thermo-mechanical coupling and the intrinsic
dissipated energy during mechanical loading of the sample, is detected by a
thermal camera.
 54

2.4 RESEARCH ARTICLES RELATED TO SEM ANALYSIS

Karantzalis et al. (2010) Novel metal matrix composites have been

produced by cast production route. TiC and WC ceramic rein forcing particles
have been successfully introduced into Al 6060, Al 319, Al 356, Al–7Si–
5Mg, Al–20Cu and Al2007 alloys. Refined grain structure and various inter
metallic phase formation have been observed. Particle–melt and particle–
solidification front interactions, solidification sequence and particle–matrix
interfacial characteristics have been examined by means of metallographic,
SEM examination and EDX analysis. Particle distribution, inter metallic
phase formation and location and grain structure are discussed in terms of
ceramic-melt wetting characteristics, alloying element interfacial segregation
and particle– solidification front thermal behavior.

Danimir et al. (2012) Composite cements are widely used in

dentistry, due to their positive characteristics (bond strength, color, low
solubility etc.). However, removal of the cement presents one of the
drawbacks of their use, since incomplete removal might cause bacterial
adhesion, gingival irritation and subsequent inflammation. The aim of this
study was to investigate surface characteristics of composite cements after
different ways of excess removal, by means of profilometric and SEM
analysis. Thirty Lucite reinforced ceramic specimens were divided into three
groups, based on the way of cement excess removal: Group 1 (polished) -
excess was fully polymerized for 40 s, then removed; Group 2 (cleaned) -
excess was removed with a cotton roll, after which cement was fully
polymerized for 40 s; Group 3 (pre-polymerized) - excess was light cured for
5 s, after which cement excess was broken with an instrument and then fully
polymerized for 40 s. Surface roughness was measured using a surface
profilometer. Subsequently, the specimens were inspected by a scanning
electron microscope. The data were statistically analyzed. The examination of
 55

variants of average values proved the statistically significant difference in the

height of average values per group, p < 0.0001; the statistically significantly
highest values were found for the pre polymerized group, whereas the
statistically significantly lowest values were found for the polished group.
The results of this study show that utmost attention has to be paid to the
excess removal procedure, since surface roughness parameters directly
depend on the choice of the applied technique.

Colombo et al. (2009) Dealing with composites in polymeric

matrix, the pultruded ones are among the more suitable for large production
rates and volumes. For this reason, their use is increasing also in structural
applications in civil and mechanical engineering. However, their use is still
limited by the partial knowledge of their fatigue behavior; in many
applications it is, indeed, required duration of many millions of cycles, while
most of the data that can be found in literature refer to a maximum number of
cycles equal to 3 millions. In this paper a pultruded composite used for
manufacturing structural beams is considered and its mechanical behavior
characterized by means of static and high-cycle fatigue tests. The results
allowed to determine the S-N curve of the material and to assess the existence
of a fatigue limit. Observations at the scanning electronic microscope (SEM)
allowed evaluating the damage mechanisms involved in the static and
fatiguing failure of the material.

Serajul Haque (2013) The high cost of fabrication hindered the

actual application of Metal Matrix Composite (MMC) despite of their high
stiffness, strength, corrosion resistance, wear resistance, non-reactivity with
chemicals and so many other tailored quality which are never obtained in
alloy of metals. In this study, a modest attempt has been made to find out the
process parameters at which best mechanical properties of Al6061, 4%Cu and
 56

reinforced 5% Sic ceramic MMC can be obtained. Addition of 4% Cu in

Al6061 is more or less comparable to the composition of duralumin, which is
widely used in aerospace applications. Sic is hard and having linear thermal
expansion at high temperature. With reinforcement of SiCp in Al-Cu alloy, it
can be postulated that hardness of MMC retains at high temperature
applications. An analysis of Variance (ANOVA) was used for analysis of
data with the help of SPSS (Version-17.0) software. Independent parameters
are three levels of pouring rates (1.5cm/s, 2.5 cm/s and 3.5 cm/s), material
type (Al6061+4%Cu alloy and Al+4%Cu, reinforced 5%SiCp MMC
processed using stir casting technique) and dependent parameters are hardness
and impact strength, which is found that at different pouring rates material
hardness and impact strength are highly significant. At pouring rate of 2.5
cm/s and 700±5˚C pouring temperature, optimum values of hardness and
impact strength are observed as compared to other values of pouring rates (1.5
cm/s and 3.5 cm/s). With reinforcement of 5% SiC trend of mechanical
properties is same, but hardness and impact strength of MMCs are increased
by 25% and 20% respectively. Also it is observed from scanning electron
microscopy (SEM) that at pouring rate 2.5 cm/s a better homogeneity can be
obtained.

Sajjadia et al. (2011) Aluminium/alumina composites are used

in automotive and aerospace industries due t their low density and good
mechanical strength. In this study, compo casting was used to fabricate
aluminium–matrix composite reinforced with micro and Nano-alumina
particles. Different weight fractions of micro (3, 5and 7.5 wt.%) and Nano
(1, 2, 3 and 4 wt.%) alumina particles were injected by argon gas into the
semi-solid state A356 aluminium alloy and stirred by a mechanical stirrer
with different speeds of 200, 300and 450 rpm. The microstructure of the
composite samples was investigated by Optical and Scanning Electron
 57

Microscopy. Also, density and hardness variation of micro and Nano

composites were measured. The microstructure study results revealed that
application of compo casting process led to a transformation of a
dendrite to a non dendrite structure of the matrix alloy. The SEM
micrographs revealed that Al2O3 Nano particles were surrounded by
silicon eutectic and inclined to move toward inter-dendritic regions.
They were dispersed uniformly in the matrix when 1, 2 and 3 wt.%
Nano Al2O3 or 3 and 5 wt.% micro Al2O3 was added, while, further
increase in Al2O3 (4 wt.% Nano Al2O3 and 7.5 wt.% micro Al2O3)led to
agglomeration. The density measurements showed that the amount of porosity
in the composites increased with increasing weight fraction and speed of
stirring and decreasing particle size. The hard-ness results indicated that the
hardness of the composites increased with decreasing size and increasing
weight fraction of particles.

Veeresh Kumar (2010) The aluminium based composites are

increasingly being used in the transport, aerospace, marine, automobile and
mineral processing industries, owing to their improved strength, stiffness and
wear resistance properties. The widely used reinforcing materials for these
composites are silicon carbide, aluminium oxide and graphite in the form of
particles or whiskers. The ceramic particles reinforced aluminium composites
are termed as new generation material and these can be tailored and
engineered with specific required properties for specific application
requirements. Particle reinforced composites have a better plastic forming
capability than that of the whisker or fiber reinforced ones, and thus they have
emerged as most sought after material with cost advantage and they are also
known for excellent heat and wear resistance applications. In this paper it is
aimed to present the experimental results of the studies conducted regarding
hardness, tensile strength and wear resistance properties of Al6061-SiC and
 58

Al7075-Al2O3 composites. The composites are prepared using the liquid

metallurgy technique, in which 2-6 wt. %‘age of particulates was dispersed in
the base matrix in steps of 2. The obtained cast composites of Al6061-SiC and
Al7075- Al2O3 and the castings of the base alloys were carefully machined to
prepare the test specimens for density, hardness, mechanical, tribological tests
and as well as for micro structural studies as per ASTM standards. The SiC
and Al2O3 resulted in improving the hardness and density of their respective
composites. Further, the increased %‘age of these reinforcements contributed
in increased hardness and density of the composites. The experimental density
values were agreed with that of the theoretical density values of the
composites obtained using the rule of mixture for composites. The dispersed
SiC in Al6061 alloy and Al2O3 in Al7075 alloy contributed in enhancing the
tensile strength of the composites. The wear factor K obtained using
computerized pin on disc wear tester with counter surface as EN31 steel disc
(HRC60) and the composite pin as specimens, demonstrated the superior wear
resistance property of the composites.

Venkatesh et al. (2009) Aluminium Silicon Carbide (A356-Sic)

Metal Matrix Composite (MMC) materials have a set of mechanical and
physical properties that are ideally suited for application in Aerospace and
Automobile industries and not widely used because of its poor machinability.
To overcome this barrier, our investigation is to study on machinability
analysis of A356 -SiC(20p) (MMC) with Poly Crystalline Diamond (PCD)
insert of grade 1300. Base matrix material is Aluminium A356 reinforced
with 20 % weight by volume of Silicon carbide particles of mean diameter 55
µm to 80 µm is used. The main focus of investigation is to determine
minimum power consumed by main spindle, good surface finish and
minimum tool wear. The worn out insert is also analyzed under Scanning
Electron Microscope (SEM) and the results would be discussed.
 59

2.5 RESEARCH ARTICLES RELATED WEAR PROPERTIES

Jayakumar Lakshmipathy & Balamurugan Kulendran (2014) In the

present study, the reciprocating wear behavior of 7075Al/SiC composites and
6061Al/Al2O3 composites that are prepared through liquid metallurgy route is
analyzed to and out the effects of weight percentage of re-enforcement and
load at the fixed number of strokes on a reciprocating wear testing machine.
The Metal Matrix Composite (MMC) pins are prepared with different weight
percentages (10, 15 and 20%) of SiC and Al2O3 particles with size of 36 μm.
Hardness of these composites increases with increase in wt.% of
reinforcement. However, the impact strength decreases with increase in
reinforcement content. The experimental result shows that the volume loss of
MMC specimens is less than that of the matrix alloy. However, the volume
loss is greater in6061Al/Al2O3 composites when compared to 7075Al/SiC
composites. The temperature rise near the contact sur-face of the MMC
specimens increases with increase in wt.% of reinforcement and applied load.
The coefficient of friction decreases with increase in load in both cases.

Amal Nassar & Eman Nassar (2013) studied the effect of NanoSiC
particles on the mechanical properties for the polymer composite material.
We using the epoxy resin (EPOBOND Epoxy) supplied from epobond for
chemicals and electrical components in Egypt as matrix reinforced with
silicon carbide nano particles with different weight percentage (5, 10, 15 and
20). The tensile tests were made by using LLOYD" Universal Tensile Testing
Machine System at room temperature, the wear tests were made by Pin-on-
Disc machine and A Chirpy impact test machine was used for measuring the
impact toughness during impact testing . It is found that the addition of Nano
SiC particles on epoxy resin can improve the wear resistance however the
strength decrease with further increase in weight percentage of
reinforcement.
 60

Gowrishankar (2014) discussed about the strength of Al6061 alloy

can be improved by precipitation hardening, during the precipitation of
metastable phases formed by supersaturated solid solution. The experimental
study is focused on artificial ageing of solution zed Al6061 alloy at 100o
150oand 200o C. The peak hardness is obtained at different aging temperature
by plotting hardness v/s time. The peak aging duration is observed to vary
between 3 to 10 hours depending on aging temperature. As the aging
temperature decreases the precipitation of secondary solute rich phases takes
place in the more number of intermediate stages. The intermediate phases
strain the lattice during their precipitation to enhance the mechanical
properties, so better mechanical property is observed at lower aging
temperature. In this paper, mechanical properties such as micro hardness,
tensile strength, and wear resistance have been studied to determine the
effect of artificial ageing on Al6061 alloy. However, under identical
heat treatment conditions, the precipitation hardened alloy exhibited
better mechanical properties in comparison with as-cast alloy.

Suresh et al. (2003) Beryl/Al–Si–Mg composites containing 2.0–

10.0% of beryl particles have been fabricated by squeeze casting. Pressure of
80MPa was maintained during solidification in a specially designed die and
punch maintained at 400 ◦C. The tensile and wear properties have been
evaluated and compared with gravity cast beryl–aluminium composites. The
squeeze cast composites show peak strength of 216MPa showing an increase
of 11.6% in tensile strength. The new composites also have improved wear
resistance when compared to gravity cast composites. Squeeze cast
composites with 6wt.% of beryl particles showed almost 1.2 times reduced
adhesive wear rate at 2400m sliding distance when compared to that at 600m.
 61

Rajan et al. (2007) The roles of the melt and the mould material on
the cooling curve parameters and the heat transfer at the casting/mould
interface during solidification of Al(356) alloy and its composites reinforced
with silicon carbide and graphite particles are investigated. A dimensionless
thermal parameter is used to model the effect of thermo physical properties of
the alloy and the composite systems, the mould materials and the heat content
on the cooling rate.

The reduction in the effective thermal diffusivity of the composite

system at high weight fractions of insulating dispersoids plays a dominant
role in reducing the cooling rates, although the heat content of the matrix
alloys lower. Addition of Mg improves the casting/mould interfacial heat
transfer of the alloys and the composites studied, thus proving its
multifunctional role, apart from its well-known function as a wetting
promoter of ceramic reinforcements with the aluminium alloy matrix. The
graphite mould yields higher heat flux transients compared to steel and the
sand moulds.

Muthukrishnan & Paulo Davim (2011) described the study of the

tool wear mechanism in machining the metal matrix composites (MMC)
and its dependence on the percentage of reinforcing with MMC.
Aluminium alloy (A356 - Sic) silicon carbide metal matrix composite of two
samples, were prepared in-house by using stir casting method. Samples
having 10 and 20% silicon carbide particles (grain size ranging from 55 to 85
mm) by weight are fabricated in the form of cylindrical bars.

Experiments were conducted in the medium duty lathe by using

Polycrystalline Diamond (PCD) insert. Optimum parameters were obtained
by analyzing the power consumed on an average surface roughness (Ra) of
the machined component. By setting these optimum parameters at a
 62

constant machining condition, tool wear study was carried out for a time
duration of 100 min. The result showed that the tool flank wears was
maximum while machining 20% of the SiC reinforcing MMC when
compared with 10% of the SiC reinforcing MMC. The result proved that
the effect of SiC particles‘ weight percentage was a dependent parameter on
tool wear. The main mechanism of tool wear in machining Al-SiC MMC
includes two-body abrasion and three-body abrasion. However, the tool
wear images were captured by optical microscope and SEM, which
supported the result.

Jaspreet Singh et al. (2013) illustrated the studies of Mechanical

and Tribological behavior [ i.e. dry sliding behavior] of Al matrix composites
reinforced with Sic and Gr particulate up to 10%, to study the effect of
reinforcement, Load, Sliding speed and Sliding distance on stir cast Al-Sic
and Al-Gr Metal matrix composites.

Parametric studies indicate that the hardness, tensile strength of Al-

Sic composite is greater than that of Al-Gr composite because of high
hardness of SiC particulates. As graphite has a solid lubricant property but
due to increased percentage of graphite as a reinforcement [i.e 10%], its wear
characteristics also reduces. The corresponding values of composites, clearly
indicating that the Al-SiC composite exhibits better hardness and wear
characteristics, Increase of either Load or Sliding distance or both increases
wear.

2.6 SUMMARY

In this chapter, survey analysis of mechanical and tribological

properties of aluminium matrix composites with different weight fractions
and different size ranges of Research articles related to SiC and Nano SiC
 63

AMCs are illustrated. Based upon the survey the precedence of this work will
be used to prepare MMC using Silicon carbide as micro and nano size range
as an reinforcement in aluminium (A6063) matrix and to study its mechanical
and wear characteristics. Studies were also to be carried on the effect of
particle size on mechanical properties and wear behaviour of aluminium SiC
composites.