Advances in Materials and Processing Technologies

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Prediction of tensile strength in squeeze casted

hybrid aluminium matrix composites using
conventional statistical approach

M. Arulraj, J.P. Davim & M.S.J. Hashmi

To cite this article: M. Arulraj, J.P. Davim & M.S.J. Hashmi (2021): Prediction of tensile strength
in squeeze casted hybrid aluminium matrix composites using conventional statistical approach,
Advances in Materials and Processing Technologies, DOI: 10.1080/2374068X.2021.1896865

To link to this article: https://doi.org/10.1080/2374068X.2021.1896865

Published online: 14 Mar 2021.

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ADVANCES IN MATERIALS AND PROCESSING TECHNOLOGIES
https://doi.org/10.1080/2374068X.2021.1896865

RESEARCH ARTICLE

Prediction of tensile strength in squeeze casted hybrid

aluminium matrix composites using conventional statistical
approach
a
M. Arulraj , J.P. Davimb and M.S.J. Hashmic
a
Department of Mechanical Engineering, Coimbatore Institute of Engineering and Technology, Coimbatore,
India; bDepartment of Mechanical Engineering, University of Aveiro, Aveiro, Portugal; cDepartment of
Mechanical and Manufacturing Engineering, School of Mechanical and Manufacturing Engineering, Dublin
City University, Ireland

ABSTRACT ARTICLE HISTORY

Among non-ferrous materials, aluminium and its alloys are one of Accepted 14 February 2021
the challenging materials having high structural characteristic,
KEYWORDS
superior tribological and mechanical properties and used for the LM24 aluminium alloy;
typical applications like carburettor, cylinder, cylinder lid, absorber, silicon carbide; fly ash;
engine gear box, side cover, etc. Squeeze casting is one of the squeeze casting; taguchi
simplest processes of manufacturing of composite materials and it method
attains better advantages of low material processing cost, easy
handling of material, size, design and good stability of matrix
structure. This work was aimed to develop new hybrid aluminium
composites with enhanced tensile strength to support the indus­
tries. In this present work, LM24-SiCp-fly ash composite was pro­
cessed through squeeze casting process. Test coupons were cast
with 3 levels and 4 parameters based on Taguchi’s L9 (34) orthogo­
nal array. Influence of process factors on the tensile strength of
fabricated component was evaluated and observed that reinforce­
ment percentage and squeeze pressure were the major process
parameters affecting the tensile strength. Optimum parametric
settings were arrived at by statistical tool for producing the com­
posites with enhanced strength up to 25%. From microstructural
study, applying high level of squeeze pressure improved the uni­
form dispersion, good bonding between the matrix and
reinforcement.

1. Introduction
The process of selection of an appropriate choice of a material for typical engineering
applications is of paramount importance and is a tedious action to accomplish because of
the day-to-day innovations in materials development. Reinforced composite materials
have become a trendy feasible solution for meeting the essential needs of many engineer­
ing applications and thus many researchers are working effortlessly around the world for
the development of new composites to overcome the limitation of materials. Composite
materials, especially Metal Matrix Composites (MMCs) are highly capable of replacing

CONTACT M. Arulraj arulraj96@gmail.com Department of Mechanical Engineering, Coimbatore Institute of

Engineering and Technology, Coimbatore, India.
© 2021 Informa UK Limited, trading as Taylor & Francis Group
2 M. ARULRAJ ET AL.

current monolithic materials for the specific engineering fields including aviation, auto­
mobile, and marine fields. The frequently used metal matrix materials are of aluminium,
magnesium, copper and their alloys due to their excellent wear resistance, superior
corrosion resistance, improved tensile strength, toughness, and impact strength etc. In
particular, aluminium based MMCs; called Aluminium Matrix Composites (AMCs) are
believed to be a significant contributor among other matrix materials because of the
reasons of its ability to be compatible with hard as well as soft reinforcements [1–4].
Metal Matrix composites (MMCs) are usually processed using both solid state as well
as liquid state processes. Squeeze casting is one of a proven casting route liquid state
process of metal forming process for the production of light weight near-net shaped
metal alloy components [5,6]. Appreciable contributions are have been made by several
researchers for the fabrication of crucial components. One of these studies reveals that
the applied pressure is found to be a significant factor because of the reason that this
activates the multidirectional feeding mechanisms throughout the die cavity during
solidification of the melt and slows down the formation of porosities caused by both
gases as well as shrinkage [7]. Also, these parameters are strongly involved in grain
refinement of many squeeze cast aluminium alloys including AC8A, LM24, LM13 and
A356 [8–10]. Yue [5] observed, while processing AA7010 wrought aluminium alloy
through squeeze casting that, factors such as high pouring temperature and high pressure
also need to be considered with care because these factors affect the tensile strength of the
composites. Though several research works reported the improvement of mechanical
properties through squeeze casting method, tuning for the appropriate settings of process
variables is a proven way of obtaining the quality castings [5,11–15]. The optimum
squeeze casting condition usually exhibits a significant enhancement in mechanical
properties of many aluminium alloys [16–20].
Reinforcements of agro waste materials are trendy now and offer a great deal to
achieve attractive benefits such as economically sound and pollution-free environment
[21,22]. Therefore, utilisation of naturally available agro-waste particulates as reinforce­
ment has become a supportive measure. Many researchers started working with several
agro waste reinforcement and reported their extensive studies for improving mechanical
properties of AMC’s [23,24]. Groundnut shell ash, coconut shell ash, cow horn ash, corn
cob ash,, fly ash and bagasse are reported to be the familiar reinforcements and in fact
producing some considerable advancements. Though many matrix composites were
reported with these ash reinforcements, no attempts were made to fabricate a LM24
reinforced with fly ash particulates. Generally, fly ash is one of readily available reinfor­
cements and possesses excellent capability to enhance the wear resistance property.
Hence, these reinforcements would lead to improve the properties of certain applications
especially the piston, cylinder, connecting rod, etc. where wear and tensile properties are
essentially open for the enhancement. Therefore, the present study is undertaken to
produce an LM24 based AMC reinforced with fly ash especially for improving mechan­
ical properties [25–27].
Tensile strength of the composite material decreases with increased percent of reinfor­
cement material. Following observations are made from the above literature that, a) LM24
alloy has wide range of applications but its usage is limited due to poor hardness and wear
resistance. b) Aluminium alloys reinforced with individually with silicon carbide and fly ash
particles possess excellent properties and also reduce cost. c) Study and analysis of impact
 ADVANCES IN MATERIALS AND PROCESSING TECHNOLOGIES 3

Table 1. Chemical elements of LM24 alloy.

Element Si Fe Cu Mn Mg Cr Ni Zn Al
JIS (wt %) 10–13 ≤1 ≤0.5 ≤ 0.5 ≤ 0.3 ≤ 0.5 ≤0.5 ≤ 0.5 Bal.
Ingot (wt%) 10.62 0.686 0.12 0.48 0.21 0.030 0.026 0.125 87.71

Figure 1. Morphology of SiC particles (a) lower magnification, (b) higher magnification.

strength of composite materials are not fully explained in literature. d) Stir casting the most
commonly preferred processing route for preparing MMCs. e) Squeeze casting route limits
most of the disadvantages of stir casting and offers excellent casting properties. f) Taguchi
method not only reduce experimental trials but also limits the casting defects by defining
appropriate set of parameters and levels.
This paper highlights the fabrication of LM24-SiCp-fly ash composites using squeeze
casting process and presents the effects of selected squeeze casting process parameters on
the tensile strength of the produced composite with the help of Taguchi method. The chemical
composition of LM24 base matrix material is presented in Table 1. Also, the microstructural
studies on fabricated LM24-SiCp-fly ash composite while attempting for the improvement of
tensile strength is performed. Results exhibit a significant contribution of fly ash in the
enhancement of tensile strength of the aluminium composites. Taguchi method is used to
plan experiments, study, analyse and optimise the parameters (i.e. percent reinforcement of
SiC and FA, pouring temperature, squeeze pressure and mould temperature) for higher tensile
strengths of the composite parts. Figure 1 shows the morphological structure of SiC particles.

2. Optimisation techniques
Taguchi method is a powerful statistical tool widely applied for improving the perfor­
mance of metal matrix composites by conducting experiments at reduced material and
processing cost, efforts and time [18,19]. Selection of squeeze casting factors (squeeze
pressure, reinforcement material, mould temperature and pouring temperature) and
their operating levels influencing the composite properties are done by conducting
pilot experiments and consulting literature [20,21]. Three operating levels are considered
4 M. ARULRAJ ET AL.

for each parameter to study their effects. Taguchi L9 orthogonal array experiments were
used to conduct experiments and collect response (impact strength) data.

3. Experiments and tests

3.1. Squeeze casting experimental setup
The Squeeze casting setup used for preparing the samples is shown in Figure 2. The major
elements of the setup were electric furnace, preheaters, split die set, punch and hydraulic
circuits. The electric furnace used for melting the metal of bottom pouring type and the
heating capacity is of 1200°C. A stainless steel crucible having a capacity of 5 kg was used
for holding the material. The pathway provided for transferring the molten metal from
the furnace to die was facilitated with the heating coils capable of maintaining 500°C to
have better fluidity by avoiding the possibility of solidification in-between. A split die set
made using H13 die steel was used to produce the hollow cylindrical sample with the
dimensions of 50 mm and 200 mm diameter and height, respectively. The die setup was
provided with the temperature-controlled preheating coils to heat and maintain the
temperature of the die in the range of 500 ± 10°C. The heating coils around the die set
were mounted such that the temperature was maintained uniform throughout the die. To
avoid the sticking of molten metal on the inner walls of crucible and the die were coated

Figure 2. Squeeze casting setup.

 ADVANCES IN MATERIALS AND PROCESSING TECHNOLOGIES 5

Table 2. Process parameters and their levels.

Operating Levels
Process Parameters Notation 1 2 3
Reinforcement (wt. %) A 2.5% FA +7.5% SiCp 5% FA+5% SiCp 7.5% FA+2.5% SiCp
Pouring temperature (°C) B 675 700 725
Squeeze pressure (MPa) C 75 100 125
Mould temperature (°C) D 200 250 300

with graphite. A 40-ton hydraulic press with a punch was used to apply the load on the
molten metal to produce the squeezed samples.
As received LM24 Ingots were sliced to small pieces and were charged in to the
crucible furnace for preparing melt. The temperature of the furnace was raised to
600°C, to prepare the molten metal of LM24 alloy. Hexachloroethane (C2Cl6) in
tablet form was used to remove the dissolved hydrogen and sodium in the molten
metal. Mechanical stirrer enabled to create vortex in the molten metal. During
stirring process, the preheated (i.e. 400 °C) reinforcement materials (i.e. SiC and
FA particles) were added to the prepared molten metal. Later, the molten metal was
stirred continuously for about 5 minutes to obtain uniform distribution of reinfor­
cement in the aluminium matrix. After ensuring the required pouring temperature
the molten metal was then started to transfer through hot path way. The molten
metal was pressurised by applying squeeze pressure with the help of hydraulic press.
The casting was ejected from the die-half upon solidification.
The reinforcement greater than 7.5 wt% led to agglomerations in the casting
part. Therefore, the proportion of reinforcement material was set between the
ranges of 2.5–7.5 wt% for experimentation, analysis and optimisation [27]. The
melt mixture was then transferred to the preheated die temperature (i.e. 200°C) for
pressurisation. The die assembly was designed to withstand the maximum squeeze
pressure of 125MPa. Micro-pores in the prepared metal matrix composites were
observed when the squeeze pressure maintained below 75MPa. Therefore, the
squeeze pressure was set between the ranges of 75 to 125 MPa. The pressure
maintained beyond 60 s did not show significant improvement in the impact
strength. Contrary, less than 15 s of pressure duration may not be sufficient
enough to ensure complete solidification of casting samples. The upper and
lower bounds of stir-squeeze casting parameters considered for experimentation
is presented in Table 2. Taguchi L9 orthogonal array experiments were considered
for five influencing factors operating at four respective levels. The universal testing
machine KUT-40 model was employed for performing the tensile test on the
specimens. The tensile test specimens were prepared for each experimental con­
dition as per the E8M-04ASTM standard and it is shown in Figure 3. The samples
of prepared casting samples are shown in Figure 4.

4. Results and discussion

This section discusses the results of experimental data and analysis of factors on tensile
strength. Micro-structure analyses at different casting conditions are discussed to
6 M. ARULRAJ ET AL.

Figure 3. Squeeze casting samples.

Figure 4. Tensile test specimens.

explain the significance of squeeze pressure on the strength. The set of factors respon­
sible for higher tensile strength is determined and validated by conducting practical
experiment.

4.1. Taguchi method

Taguchi method is an off-line cost-effective control method applied to improve the
tensile strength of the composite samples by determining the set of optimal squeeze
casting condition. L9 orthogonal array for collecting experimental data, S/N ratio com­
putation, analysis of variance (ANOVA) were employed for the said purpose.

4.1.1. S/N ratio response

S/N ratio corresponds to higher-the-better (HB) quality characteristics are used for the
response, tensile strength. The experimental values of impact strength are transformed to
corresponding values of S/N ratio using the Eq. 1.
 ADVANCES IN MATERIALS AND PROCESSING TECHNOLOGIES 7

Table 3. Experimental observations and S/N ratio for tensile strength.

Parameters and their levels Tensile Strength (MPa)
Ex. No. A B C D R1 R2 R3 R4 Ravg S/N Ratio (dB)
1 1 1 1 1 321 342 339 326 332 50.4227
2 1 2 2 2 341 350 351 342 346 50.7815
3 1 3 3 3 385 385 382 388 385 51.7766
4 2 1 2 3 340 350 354 356 350 50.8813
5 2 2 3 1 360 361 364 363 362 51.1741
6 2 3 1 2 318 328 324 326 324 50.2109
7 3 1 3 2 344 352 350 362 352 50.9308
8 3 2 1 3 308 310 309 313 310 49.8272
9 3 3 2 1 316 316 320 320 318 50.0485
Y 50.6726

!
1X n
1
S=NðdBÞ ¼ 10log10 (1)
n i¼1 R2i

Term, i = 1, 2, . . ., n (here n = 4) and Ri is ith response value of an experimental

condition. The computation of mean value (YÞ � of S/N ratios is done using Eq. 2. The
calculated S/N ratio of each experimental condition is presented in Table 3.
!
1 X N
Mean; Y�¼ Yj (2)
N j¼1

Term, j = 1, 2 . . . N (here N = 9) and Yj is S/N ratio for jth parametric set.

The collected experimental input-output data were used to determine the factor
significance and their optimal levels for high tensile strength. The S/N ratio values of
tensile strength were used for this purpose. The affecting factors were determined based
on the average signal-to-noise ratio values which correspond to each level of the factors
estimated and the resulted details are presented in Table 4. The highest S/N ratio value
corresponded to level 1 to level 3 of each factor determines the optimal level. It is
noteworthy that the optimal parameter and levels determined for squeeze casting con­
dition is found as A1B3C3D3 (i.e. percent of reinforcement: 7.5% SiC + 2.5% FA, pouring
temperature: 725°C, squeeze pressure: 125 MPa, mould temperature: 300°C).

4.1.2. Analysis of variance (ANOVA)

To determine the factor significance and their percent contribution towards tensile
strength the ANOVA was performed. The essential terms used to construct the
ANOVA table and their computation is performed using the equation 3–11and their
values are given in Table 5.

Table 4. Factor effects on tensile strength (S/N ratio).

A B C D
Level1 50.9936 50.7449 50.1536 50.5484
Level2 50.7554 50.5942 50.5704 50.6411
level3 50.2688 50.6786 51.2938 50.8284
Max-Min 0.7248 0.1507 1.1402 0.280
Rank 2 4 1 3
Optimum A1 B3 C3 D3
8 M. ARULRAJ ET AL.

Table 5. ANOVA table.

Source Pool SS DOF MSS F ratio PSS PC (%)
A 0.8194 2 0.4097 10.42 0.7801 33.19
B Yes 0.0043 2 0.00215
C 1.9796 2 0.9981 25.39 1.9797 58.89
D Yes 0.1529 2 0.07645
Pooled Error 0.1572 4 0.0393 0.2144 7.92
TSS 2.9742 2.9742 100

�2
SSm ¼ NY (3)

2 2 2
SSA ¼ nA1 � A1 þ nA2 � A2 þ nA3 � A3 SSm (4)

Total sum of squares,

TSS ¼ SSA þ SSB þ SSC þ SSD þ SSE (5)

DOFparameter = Number of parameter levels – 1 (6)

Degree of freedom for pooled error,

DOFpooled error ¼ DOFB þ DOFC (7)

SSA
MSSA ¼ (8)
DOFA

F ratio for parameter A,

MSSA
FA ¼ (9)
MSSpoolederror

Pure sum of squares due to parameter A,

PSSA ¼ MSSA DOFA � MSSpoolederror (10)

Percentage contribution of parameter A,

PSSA
PCA ¼ � 100 (11)
TSS
Figure 5 shows the mean S/N ratio tensile strength values of individual factors of squeeze
casting process. The variations correspond to pouring temperature and mould tempera­
ture are comparatively less compared to that of obtained for reinforcement and squeeze
pressure (refer Table 5 and Figure 5). Therefore, ANOVA tests are to be performed to
know the factor contribution or effects by estimating the Fischer test values based on
experimental data.
The percentage of contribution of all the influencing process parameters and pooled
error is shown in Figure 6. By applying Taguchi method the optimum parametric setting
from the above, the set levels were determined.
 ADVANCES IN MATERIALS AND PROCESSING TECHNOLOGIES 9

51.40 Reinforcement
(wt. %)
51.20 Pouring
temperature (°C)
51.00 Squeeze pressure

Average S/N Ratio

(MPa)

50.80 Mould
temperature (°C)

50.60

50.40

50.20

50.00
1 2 3
Levels

Figure 5. Main Effect plot for the tensile strength.

8%

33% Reinforcement
59% Squeeze Pressure
Pooled Error

Figure 6. Percent contribution of squeeze casting process.

4.2. Confirmation experiments

Confirmatory experiments were conducted for the optimal condition (A1B3C3D3) to validate
with the initial settings. Important to note that, the optimal factor levels are one among the
combinatorial set of L9 orthogonal array. The tensile strength obtained for different squeeze
casting conditions. The tensile strength obtained for the optimal squeeze casting condition
was found to be equal to 385 MPa. However, tensile strengths corresponding to squeeze
casting condition of LM24 alloy and the initial parameter setting condition (percent of
reinforcement: 2.5% SiC +7.5% FA, pouring temperature: 650°C, stir squeeze pressure: 75
MPa, mould temperature: 200°C) were found to be equal to 320 and 332 MPa, respectively.
This shows that there is a significant improvement of 3.75% with the percentage reinforce­
ment to LM24 alloy. Furthermore, Taguchi method determined optimal squeeze casting
condition (A1B3C3D3) resulted in 20.31% increase in tensile strength compared to that
obtained for initial parametric condition (A1B1C1D1). Therefore, Taguchi method is an
efficient tool which can be applied by any novice user to improve the casting properties for
reduced time, efforts, energy and cost.
10 M. ARULRAJ ET AL.

4.3. Microstructural analysis

The samples with different casting conditions are required to be used for micro­
structure examination was made ready and polished followed by cleaning with
Keller’s reagent. This sample was prepared based on the results of optimal squeeze
casting parametric condition and the uniform distribution of reinforcement par­
ticles in the matrix phase and good wettability was also confirmed. The quality
indicators such as porosity, agglomeration of reinforcement, shrinkage were ana­
lysed appropriately using visual inspection. Further, the heat transfer rate within
the casting was found to be high because of the application of higher level of
squeeze load. The developed strong interface-transfer the applied load from the
matrix to reinforcement that could help to refine the microstructure. In addition,
increased application of squeeze pressure forces the metal mixture close to die-
surface walls that helps in better heat transfer resulting in improvement of
solidification rate and grain structure. The refined grain structure generally
increases the number of barriers to the movement of dislocations resulting in
higher tensile strength.
The microstructures of the material due to varying the squeeze pressure in the range of
75 MPa, 100 and 125 MPa are shown in Figure 7. (a-c). From the observation of
microstructural study, the increased squeeze pressure reduced the porosities; cluster
eliminates these porosities and gives better grain refinement in the microstructure
(Figure 7. c). This might be due to faster cooling rate as a result of improved heat-
transfer at the metal-mould interface.

5. Conclusions
The following are the conclusions drawn for improving the tensile strength of squeeze
cast hybrid aluminium matrix composite.

(i) Taguchi method determines the percentage of reinforcement and squeeze pres­
sure which were found to be significant factors for tensile strength. The pouring
temperature and mould temperature showed negligible contribution and their
effects are treated as insignificant.
(ii) From the ANOVA, percentage of reinforcement, squeeze pressure and squeeze
time were identified as significant process control parameters in this study.
(iii) The optimum casting conditions were found for reinforcement percentage: 90%
LM24 + 7.5 wt. %SiCp, + 2.5 wt. %FA, pouring temperature: 725°C, squeeze
pressure: 125 MPa and mould temperature: 300°C. At optimum condition, the
casting has tensile strength of 385 MPa. Also, validated the optimum casting
conditions through the confirmation experiments.
(iv) Increase in squeeze pressure showed better distribution of reinforcement material
in an aluminium matrix with refined dendritic structure.
(v) From the microstructural analysis, the optimum casting conditions showed better
grain refinement and attained uniform dispersion of reinforcement’s particles in
the microstructure.
 ADVANCES IN MATERIALS AND PROCESSING TECHNOLOGIES 11

Porosity

a) Squeeze pressure 75 MPa

Cluster formation

b) Squeeze pressure 100 MPa

SiC particles

Fly ash particles

c) Squeeze pressure 125 MPa

Figure 7. (a-c) Microstructure of HAMCs at different casting conditions

12 M. ARULRAJ ET AL.

(vi) The optimum casting condition may also be used when hybrid aluminium matrix
composite is processed for the typical applications like carburettor, cylinder,
cylinder lid, absorber, engine gear box, side cover, gear box, crank case lid,
upper lid and lower lid of gas adjuster, etc.

Nomenclature
SS Sum of squares
MSS Mean sum square
PC Percentage contribution
TSS: Total sum of squares
PSS: Pure sum of squares
DOF: Degree of freedom
FA: Fly Ash
SiCp: Silicon Carbide particle
MMCs: Metal Matrix Composites

Disclosure statement
No potential conflict of interest was reported by the authors.

ORCID
M. Arulraj http://orcid.org/0000-0002-0930-169X

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