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org (ISSN-2349-5162)

EVALUATION OF MECHANICAL
PROPERTIES OF Al-6061 REINFORCED WITH
GRAPHITE and FLY ASH OF SEED HUSK
PARTICULATE METAL MATRIX
COMPOSITE
1
Charles Edrard, 2Rajendrakumar J Boli, 3Pramod Kumar
1-3
Research Scholar, Department of Mechanical Engineering,
1,2
Chhatrapati Shahu Ji Maharaj University, Kanpur,Uttar Pradesh, India-208024.
3
PDA College of Engineering, Kalburgi, VTU, Belgaum, Karnataka.

Abstract: The aim of this work is to study the mechanical properties of Aluminium alloy Metal Matrix Composites (MMCs) as
they are gaining wide spread acceptance for automobile, industrial, and aerospace applications because of their low density, high
strength and good structural rigidity. In the present work an attempt has been made to synthesize Al-6061 with Graphite and fly
ash of seed husk (Hongge seeds) particulate metal matrix composites by using stir casting technique. The addition level of
reinforcement is being varied from 0, 4, 6, 8wt%. Preheated particle reinforcements are added to Al 6061 Alloy to improve
wettability and distribution. Microstructural analysis was carried out for the above prepared composites by taking specimens from
central portion of the casting to ensure homogeneous distribution of particles. Micro-hardness, tensile properties of the
composites were prepared as per the ASTM (E8M) standards. Microstructural characterization revealed fairly uniform
distribution in the matrix. The Micro-Vickers hardness of the composite was found to decrease with increase in filler content in
the composite. The tensile strength of the composites was found to increase confirming the dispersed graphite and fly-ash in Al-
6061 alloy contributed in enhancing the tensile strength and wear resistance too of the composites.

Index Terms: Al-6061 MMC’s, Graphite Particulates, Fly-Ash of Seed Husk, Stir-Casting, Mechanical Properties.

INTRODUCTION
Metal matrix composites (MMCs) are increasingly becoming an attractive materials in advanced aerospace applications
because of their properties, can be tailored through the addition of selected reinforcements [1]. Metal matrix composites have a
market potential for various applications, particularly in the automotive industry, where the pressure is to use light weight
materials & has increased because of environmental issues. Examples of components that have been manufactured using metal
matrix composites include pistons for diesel engines and connecting rods [2]. These materials have also been shown to possess
great potential for applications in the brake disks for railway brake equipment [3]. Aluminium-based Metal Matrix

Composites (MMCs) have received increasing attention in recent decades as engineering materials. The introduction of a
ceramic material into a metal matrix to produces a composite material that results in an attractive combination of physical and
mechanical properties which cannot be obtained with monolithic alloys [4]. The various reinforcements that have been tried out to
develop aluminium matrix composites(AMCs) such as graphite, silicon carbide, titanium carbide, tungsten, boron, Al203, fly-
ash, Zr, TiB2, etc. Addition of hard reinforcements such as silicon carbide, alumina, and titanium carbide improves hardness,
strength and wear resistance of the composites [1, 2-4]. Aluminium alloys are still the subjects of intense
studies, as their low density gives additional advantages in several applications. These alloys have started to replace cast iron and
bronze, to manufacture wear resistant parts. Previous studies have shown that mechanical properties of Al-matrix composites
would be enhanced with particulate reinforcement [5]. The particulate reinforced MMCs is mainly used due to easy availability of
particles and economic processing technique adopted for producing the particulate reinforced MMCs. Al alloy has been
commonly used as a base metal for MMCs reinforced with a variety of fibres, particles and whiskers [6-7]. Amongst different
kinds of the recently developed composites, particle-reinforced metal matrix composites and in particular aluminium base
materials have already emerged as candidates for industrial applications .

Investigation of mechanical behavior of aluminum alloys reinforced by micro hard particles such as Graphite, fly ash is
an interesting area of research. Therefore, the aim of this study is to investigate the effects of different factors such as: (i) weight
percentage of the particles (ii) Fabrication process on the microstructure, mechanical properties of the composites. Mechanical
properties were evaluated as per ASTM standards using computerized universal testing machine,pin on disk test.

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EXPERIMENTAL DETAILS

The following section highlights the materials used, their properties, method of composite preparation and evaluation of
microstructural and mechanical properties.

MATERIALS USED
The matrix material for present study is Al-6061. Table.1 gives the chemical composition of
6061Al. The reinforcing material selected was Graphite of particle size 125 μm. Table.2 gives the properties of Matrix and
Reinforcing materials used in the present study.

Table.1. Shows the Chemical Composition of Al 6061

Si Fe Cu Mn Ni Pb
0.43 0.7 0.24 0.139 1.05 0.24
Zn Ti Sn Mg Cr Al
0.25 0.15 0.001 0.802 0.25 Balance

Table.2. Shows the Properties of Matrix and Reinforcing Materials Used in the Study.
Material/ Density gm/cc Hardness Strength(Tensile/C Elastic
Properties (HB500) ompression) (MPa) Modulus(GPa)

Matrix Al 6061 2.7 30 115(T) 70-80

Reinforcement Gr. 2.25 1.7mohs scale 89.63(C) 8-15

Particle

PREPARATION OF COMPOSITES
The Aluminium 6061 alloy is used in this experiment as the matrix and graphite of 125 μm as reinforcement. The liquid
metallurgy route has been adopted to prepare the cast of composites Al-6061+Gr. Preheated Graphite powder of laboratory grade
purity of particle size 125 μm was introduced into the vortex of the molten alloy after effective degassing using solid
hexachloroethane (C2Cl6). Before introducing reinforcement particles into the melt they were preheated to a temperature of
2500C. The extent of incorporation of Graphite particles in the matrix alloy was achieved in steps of 3. i.e Total amount of
reinforcement required was calculated and is being introduced into melt 3 times rather than introducing all at once. At every stage
of before and after introduction of reinforcement particles, mechanical stirring of the molten alloy for a period of 10 min was
achieved by using Zirconia-coated steel impeller. The stirrer was immersed into the melt, located approximately to a depth of
2/3rd height of the molten metal from the bottom and run at a speed of 200 rpm. A pouring temperature of 750°C was adopted and
the molten composite was poured into cast iron mould. The extent of incorporation of graphite in the matrix alloy was varied from
0,4,6 & 8 wt%. Thus composites containing particles were obtained in the form of cylinders of diameter 12.5mm and length
125mm.

TESTING OF COMPOSITES
To study the microstructure of the specimens the central portion of the casting was cut by an automatic cutter device.
The specimen surfaces were prepared by grinding through 200, 400, 600, 800 and 1000 grit papers and then by polishing with 3
m diamond paste and then etched by Keller’s reagent to obtain better contrast. Microscopic examination of the composites was
carried out by optical microscopy. To investigate the mechanical behavior of the composites the tensile tests was carried out using
computerized uni-axial tensile testing machine as per ASTM standards. Fig.1(a) & (b). Shows the dimensions of the mould and
specimen used for tensile studies. For tensile results, test was repeated three times to obtain a precise average value.

Fig.1 (a) Permanent mould for Producing Composite

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Fig. (b) Dimensions of the Tensile Specimen

RESULTS AND DISCUSSIONS

MICROSTRUCTURAL STUDIES
Fabrication of metal–matrix composites with Graphite/FA particles by casting processes is usually difficult because
of the very low wettability of Graphite particles and agglomeration phenomena which results in non-uniform distribution and
weak mechanical properties. In the current work, 6061Al aluminum alloy matrix composites with micro size Graphite/FA
particles were produced by stir casting method. The magnitude of Graphite powder used in the composites were 0,4, 6 and
8wt%. The optical micrographs of the 6061Al alloy with 0, 4, 6, and 8wt. % Graphite/fly Ash particulates were shown in Fig
2(a-h). Fig. 2a-h shows microstructure of as cast 6061Al (Fig.2a-b) and 6061Al with 4 wt% (Fig. 2c-d) , 6wt% (Fig.2e-f) and
8wt% (Fig.2g-h) Graphite particulates. The stirring of melt before and after introducing particles has resulted in breaking of
dendrite shaped structure into equiaxed form, it improves the wettability and incorporation of particles within the melt and
also it causes to disperse the particles more uniformly in the matrix. Fig. 2c-h reveals the distribution of graphite particles in
different specimens and it can be observed that there is fairly uniform distribution of particles and also agglomeration of
particles at few places were observed in the composite reinforced with 0 wt.%,4wt%, 6wt% and 8wt% graphite. Further,
these figures reveal the homogeneity of the cast composites. The microphotograph also clearly reveals the increased filler
contents in the composites at 20 different locations.

Fig.2 (a) Fig.2(b) Fig.2 (c) Fig.2(d)

Fig.2(e) Fig.2(f) Fig.2(g) Fig.2(h)

Figs.2.1(a-h) Showing the Optical Microphotographs of 6061Al with and without Graphite Particulates (a-b) As cast (c)
with 0wt% of Graphite at 50X (d) with 4wt% of Graphite at 100X (e) with 6wt% of Graphite at 50X (f) with 6wt% of
Graphite at 100X (g) with 8wt% of Graphite at 50X (h) with 8wt% of Graphite at 100X

Fig 2.2: Microstructural observation of different wt% of FlyAsh (50X).

0% FA(i) 4% FA(j) 6%FA(k) 8%FA(l)

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Fig 2.3(i-l): Microstructural observation of different wt% of FlyAsh (50X).

0% FA(m) 4%FA(n) 6%FA(o) 8%FA(p)

Fig 2.4(m-p): Microstructural observation of different wt% of FlyAsh (100X).
TENSILE PROPERTIES
In any design work, it is important to consider practically realizable values of strength of the materials used in design.
The tensile test is one of the basic tests to determine these practical values. The range of values obtained from the tests forms the
basis for the size of the material in the products for the factor of safety. The tensile tests were carried out using computerized uni-
axial tensile testing machine as per ASTM standards. Three test specimens were used for each test and average value is reported.

Table.3. Showing the Tensile Test Results of Cast 6061Al, with Addition of 0, 4, 6 and 8wt% of Graphite Particulates to
6061Al with Graph below
Sl.No Weight Ultimate Yield
Percentage of Gr Tensile Strength
Particles(%) Strength (MPa)
(MPa)
1 0 141 125
2 4 183.42 145.66
3 6 192.33 157.22
4 8 196 163

250 200
Tensile Strength (MPa)

200 160
Yield Strength(MPa)

150 120
100
80
50
40
0
0 4 6 8 0
Gr. Weight % 0 4 6 8
Gr.Weight%

Fig 2.5. Graph of tensile strength Fig 2.6 Graph of yield strength

CONCLUSIONS:

The present work on synthesis and characterization of Al6061-Graphite composites led to the following conclusions. The
composites containing Al-6061 with 0, 4, 6 and 8wt% of Graphite particulates were successfully synthesized by melt stirring
method using three stages mixing combined with preheating of the reinforcing particles.The optical micrographs of composites
produced by stir casting method shows fairly uniform distribution of Graphite particulates in the Al-6061 metal matrix.The
experimental densities were found to be lower than theoretical densities due to the presence of porosities in all the composites.
The addition of Graphite has resulted in increase in tensile strength. The tensile strength is a function of volume fraction of
reinforcement. As volume fraction increases tensile strength of composite increases. However, addition of graphite has resulted
more improvement in tensile properties.

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