ITSEC International Journal of Engineering Sciences, Vol. 1, No. 1, January 2020, Greater Noida pp.
4-11
Fabrication and Characterization ofAluminum Metal Matrix
Composite
1 2
Abhishek Kumar Vivek Kumar
Assistant Professor Assistant Professor
Mechanical Engineering Department Mechanical Engineering Department
IILM Academy of Higher Learning,Greater I.T.S. Engineering College, Greater Noida,
Noida, Uttar Pradesh, Uttar Pradesh, India.
India.2003.abhi@gmail.com Vivekkumar.me@its.edu.in
ABSTRACT higher cost of fabrication for high-
Metal matrix composite materials performance MMCs, lower ductility and
increasingly replace traditional materials toughness. Presently, MMCs tend to cluster
used in building engineering, aeronautics, around two extreme types. One consists of
mechanical engineering and in many other very high performance composites
domains. It is related to a possibility of reinforced with expensive continuous fibers
obtaining practically any combination of and requiring expensive processing
beneficial properties of the material, e.g. methods. The other consists of relatively
high vibration damping coefficient, high low-cost and low-performance composites
abrasion resistance, and high value of the reinforced with relatively inexpensive
Young’s modulus, low specific gravity and particulate or fibers. The cost of the first
low coefficient of thermal expansion. In type is too high for any but military or
the present investigation, Al 6351/Al2O3 space applications, whereas the cost/benefit
metal matrix composite was fabricated by advantages of the second type over
stir casting technique. Microstructure unreinforced metal alloys remain in
characteristics wereobserved on doubt.The application of response surface
metallurgical microscope to observe the methodology (RSM) and central composite
distribution of reinforcement in matrix design (CCD) for modeling, optimization,
alloy. Uniform distribution was observed and an analysis of the influences of
in all samples. dominant machining parameters on thrust
force, surface roughness and burr height in
KEYWORDS: Aluminium alloy the drilling of hybrid metal matrix
(6351), Alumina (Al2O3). composites produced through stir casting
route[1]. Many factors which influence the
1. INTRODUCTION effect of viscosity during Al–SiC MMC
production. Processing periods (up to 65
Metal matrix composites (MMCs) usually min), stirring speeds (50–500 rpm), and
consist of a low-density metal, such as reinforcement sizes (13–100 µm) for two
aluminum or magnesium, reinforced with different viscosity levels (1 and 300 mPa-s)
particulate or fibers of a ceramic material, were investigated [2]. Particulate metal
such as silicon carbide or graphite. matrix composites (PMMCs) have attracted
Compared with unreinforced metals, interest for application in numerous fields
MMCs offer higher specific strength and [3]. The wear rate of spray formed
stiffness, higher operating temperature, and composites is significantly lower than the
greater wear resistance, as well as the base alloy and stir cast composite under
opportunity to tailor these properties for a same sliding condition [4] .Comparing with
particular application. However, MMCs the Newtonian case, the couple stress
also have some disadvantages compared effects of fluids containing suspensions
with metals. Chief among these are the
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ITSEC International Journal of Engineering Sciences, Vol. 1, No. 1, January 2020, Greater Noida pp. 4-11
provide an enhancement in the load [8]. Rheological properties of aqueous
capacity, as well as a reduction in the concentrated aluminium nitride (AlN)
attitude angle and the friction parameter. suspensions have been investigated in the
AA6063 aluminium matrix composite presence of a sintering aid, deffloculant,
billets reinforced with SiC particles binder and plasticizers, in order to screen
(Al/SiCp) were prepared by stir casting the most suitable experimental conditions
method for extrusion process. The results to obtain a good rheological behavior for
show that the die wear is affected tape casting thick and non-cracked tapes
differently by the SiC particle with good flexibility[9].The wear rate of all
size[5].Optical microscopy of the heat-treated specimens is less than that of
conventional cast and stir cast the specimens in the as-cast condition. The
hypereutectic alloy has shown that stir main reason for this improvement is clearly
casting causes refinement of primary related to the hardness enhancement after
silicon particles and modification of the aging treatment [10].The wear
eutectic silicon compared to conventional resistance of the as-cast Al–Si alloy and
cast alloy[6].The formation of TiB2 composites was decreased with increasing
particles occurred via diffusion of Boron sliding distance, while the wear resistance
atoms through TiAl3 particles interface, of Al–Si alloy matrix composites has
thereby reacting to form fine TiB2 particles increased with increasing wt% of Al2O3
[7].The use of aluminium-based particulate particles. This is due to higher load-
reinforced MMCs for automotive carrying capacity of the hard reinforcement
components and aircraft structures have Al2O3 particles, which limits the amount
been shown to be highly advantageous over ofplastic deformation of the matrix
their unreinforced alloys, due to their high [11].Literature survey did not reveal any
specific strength and stiffness and superior systematic study of Al 6351/Al2O3metal
wear resistance in a wide temperature matrix composites. Objective of the present
range. SEM analyses of the fracture work Fabrication of Al 6351/Al2O3 metal
surfaces of the tensile specimens showed matrix composites with different
substantially similar morphologies for the percentage of reinforcement by stir carting
as-cast and forged composites, both at method.Microstructure observation of all
room and high temperature. The fabricated samples to observe distribution
mechanism of damage was mainly of reinforcement. Investigation of
decohesion at the matrix–particle interface mechanical properties of all samples.
2. EXPERIMENTATION corrosion resistance, Al 6351 offers
extremely low maintenance. The
MATRIX MATERIAL experimental results were found
Most of the aerospace structures and its satisfactory to propose the alternative alloy
allied infrastructure are made of aluminum for aircraft structures. The mechanical and
alloy. In this context considering Al 6351 physical properties of aluminum alloy
which was used for making pressure vessel (6351) have been reviewed from literature
cylinders is now testing for aircraft data for the purpose of characterizing the
structures. Al 6351 has high corrosion mechanical for manufacturing process in
resistance and can be seen in forms of engineering application. Aluminum alloys
extruded rod bar and wire and extruded are used in many applications in which the
shapes. It is easily machinable and can combination of high strength and low
have a wide variety of surface finishes. It weight is attractive in air frame in which
also has good electrical and thermal the low weight can be significant value. Al
conductivities and is highly reflective to 6351 is known for its light weight (density
heat and light. Due to the superior = 2.7g/cm3) and good corrosion resistance
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ITSEC International Journal of Engineering Sciences, Vol. 1, No. 1, January 2020, Greater Noida pp. 4-11
to air, water, oils and many chemicals. times greater than steels. The chemical
Thermal and electrical conductivity is four composition of alloy is follows
Table 1: Properties of aluminum alloy (Al 6351) [12]
aluminum Cu magnesium Silicon iron Manganese Others Remaining
alloy
Al 6351 0.1 0.4-1.2% 0.6-1.3% 0.6% 0.4-1.0% 0.3% Al
%
It has higher strength amongst the 6000 structural alloy, in plate form. This alloy is
series alloys. Alloy Al 6351 is known as a most commonly used for machining.
REINFORCEMENT MATERIAL toughness and ultimate tensile strength due
to the presence of micro-sized
Aluminum oxide (Al2O3) is widely
reinforcement particles into the matrix.
used as the reinforcement in the metal
Generally, regards to the mechanical
matrix composites.The mechanical and
properties, the reinforcements result in
physical properties of alumina (Al2O3) have
higher strength and hardness, often at the
been reviewed from literature data for the
expense of some ductility. Aluminum-
purpose of characterizing the mechanical
matrix composites (AMCs) reinforced with
properties of alumina for manufacturing
particles and whiskers are widely used for
process in engineering application.
high performance applications such as in
automotive, military, aerospace and
Table 2: Mechanical properties of (Al2O3)
Alumina Grade pH Mesh
electricity industries because of their
(Al2O3) value size improved physical and mechanical
Neutral(1344- Brockman 1 6.5- 100 properties. In the composites relatively soft
28-1) or 2 7.5 alloy like aluminum can be made highly
resistant by introducing predominantly hard
Metal–matrix composites (MMCs) are but brittle particles such as Al2O3 and SiC.
most promising in achieving enhanced
mechanical properties such as: hardness,
EXPERIMENTAL PROCEDURE mixed slowly in molten aluminium alloy
with the help of stirrer. The material is left
The materials used in the present work are for cool down in the crucible in which it
aluminium alloy (Al 6351) and aluminium was melted and mixed.There are three
oxide (Al2O3 as reinforcement). These samples in different ratios which are
materials are chosen due to their easily prepared for testing mechanical properties.
mixable property and gives good The ratios are shown below in the Table 3.
mechanical properties. The aluminium Table 3: Composition selection
alloy (Al 6351) is heated up to its melting Material Sample Sample Sample
temperature 6000C in a mufflefurnace. 1 2 3
Temperature measurement is done with (Al 6351) 97.5% 95% 92.5%
help of K-type thermocouple. (Al2O3) 2.5% 5.0% 7.5%
Preheatedaluminium oxide at 1000Cis
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ITSEC International Journal of Engineering Sciences, Vol. 1, No. 1, January 2020, Greater Noida pp. 4-11
Figure 1 a. Muffle furnace Figure 1 b. Preparation of sample by stir casting
Now the mixed composite after cooling and electrically driven machine which is used
solidification is cut into desired shapes for to cut the hard composites. The MMC
testing mechanical properties on the band samples prepared are shown in figures
saw machine. The machine is an given below.
Figure 2: MMC (Al 6351+2.5% of Al2O3) Figure 3: MMC (Al 6351+ 5% of Al2O3)
Figure 4: MMC (Al 6351+7.5% of Al2O3)
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ITSEC International Journal of Engineering Sciences, Vol. 1, No. 1, January 2020, Greater Noida pp. 4-11
Figure 5: MMC sample prepared for
Figure 6: MMC sample for tensile test
hardness test
Figure 7: MMC sample prepared for Figure 8: MMC sample prepared for
toughness test microstructure
Grinding/polishing for a considerable time in order to get a
smooth and clear surface of the samples.
The cut samples prepared above
had an uneven surface. So, the cut samples 3.RESULTS AND DISCUSSION
were then taken for grinding/polishing Analysis of Microstructure
operation. The sample was first held over a The microstructures of the MMC samples
grinding machine with a moving belt to are seen using metallurgical microscope.
obtain a smooth surface. The grinding was The term ‘microstructure’ in metal matrix
done in such a way so that all the scratches composites is used to describe the
are in the same direction and the grinded appearance of the reinforcement material.
surface becomes flat. After this the samples Microstructure shows that the Al2O3
were polished using different grits of emery reinforcement distributed uniformly
papers. Because the samples being throughout the casted component. Here
aluminium alloy composites it is rubbed Al2O3 distribution did not show any
over the emery paper for a small time. It segregation.Uniform distribution was
was rubbed over an emery paper of 400, observed of all selected composition as
600, 800, 1000 grit and then over a very shown in figure 9.
fine emery paper of 1200, 1600,2000 grit
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ITSEC International Journal of Engineering Sciences, Vol. 1, No. 1, January 2020, Greater Noida pp. 4-11
X100 X100
Figure 9: (a) Al 6351+2.5 % Al2O3 reinforcement (b) Al 6351+5 %Al2O3 reinforcement
X100
(c) Al 6351+7.5 % Al2O3 reinforcement
Analyses of Tensile Strength The specimens were tested according to
Tensile tests are used to determine the ASTM E8M-01 standard. Specimens of sub
elastic limit, elongation, tensile sized sample are length of 100 mm, width
strength, yield strength and reduction in of 6 mm and gauge length is 36 mm.The
area. Tensile tests were carried out at room ultimate tensile strength, percentage
temperature using computerized universal elongation was calculated for each prepared
testing machine with a capacity of 40 KN. sample.
Table 4: Tensile Test of Al 6351+Al2O3 MMC
Samples Ultimate Elongation Break load Break True UTS Area
(of Al2O3) strength(N) (mm) (N) Elongation (N/ sq mm) (sq. mm)
(mm)
2.5% 698.3 0.52 146.1 0.62 26 27.341
5.0% 642.5 0.51 209.9 0.69 21.4 24.453
7.5% 1531.1 2.42 1315 3.23 67.2 26
Analysis of Toughness Test initial energy of 300 J. According to ASTM
E-23, standard specimen, sizes are 10 mm x
In these MMC specimens toughness is 10 mm x 55 mm. for charpy impact test
tested by breaking it with impact force of a analysis. The table shows the results while
hammer weighing 21 kg. The Hammer is testing as follows:
leaved from 140 degree of angle with the
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Table 5: Toughness of Al6351+Al2O3 MMC
Trial Average
Sample Composite Sample Energy (Joule)
A B C
No. Name (A+B+C) / 3
1 Al6351+2.5 % Al2O3 14 16 18 16.00
2 Al6351+5 % Al2O3 12 14 14 12.66
3 Al6351+7.5 % Al2O3 10 10 12 10.66
ANALYSIS OF HARDNESS TEST Al6351/2.5, 5, 7.5% wt. Al2O3 composite
were prepared as per dimension (10 mm x
The hardness test was carried on
10 mm x 25 mm) as ASTM E18-05,
Rockwell Hardness testing method. For
standard.
hardness testing, the samples of
Figure 10: MMC sample after indentation
on hardness testing machine.
Table 6: Hardness of MMC
Rockwell Hardness at
Sample Composite Sample Name (HRC) scale Mean Hardness
No. Trial 1 Trial 2 Trial 3
1 Al6351+2.5 % Al2O3 42 45 51 46
2 Al6351+5 % Al2O3 50 51.5 53 51.5
3 Al6351+7.5 % Al2O3 57 58.4 60 58.4
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CONCLUSION S.K. Chaudhury, A.K. Singh, C.S.
Sivaramakrishnan, S.C. Panigrahi, “Wear
The following conclusions are arrived and friction behavior of spray formed and
based on the experimental investigation on stir cast Al–2Mg–11TiO2 composites”,
the distribution of Al2O3 in themechanical Wear 258 (2005) 759–767.
stir casting and its effect on mechanical [5] M. Baki Karma’s， Fehmi Nair,
properties of the as cast MMCs at different “Effects of reinforcement particle size in
weight fraction of Al2O3. MMCs on extrusion die wear”, Wear 265
1. In the present investigation, it was (2008) 1741–1750.
observed that maximum mechanical [6] T.V.S. Reddy, D.K. Dwivedi, N.K.
properties were obtained for Al Jain, “Adhesive wear of stir cast
6351/7.5% Al2O3. hypereutectic Al–Si–Mg alloy under
2. The tensile strength of the as cast reciprocating sliding conditions”, Wear 266
composites increases on increasing (2009) 1–5.
the weight fraction of Al2O3. [7] M. Emamy, M. Mahta, J. Rasizadeh,
3. The hardness of the MMCs is “Formation of TiB2 particles during
higher than the unreinforced matrix dissolution of TiAl3 in Al–TiB2 metal
metal and the hardness of the cast matrix composite using an in situ
composites increases linearly with technique”, Composites Science and
increasing the weight fraction of Technology 66 (2006) 1063–1066.
Al2O3. [8] L. Ceschini, G. Minak, A. Morri,
4. Microstructural observation “Forging of the AA2618/20 vol.% Al2O3p
suggests that stirring action composite: Effects on microstructure and
produces MMC with smaller grain tensile properties”, Composites Science and
size and there is a good particulate Technology 69 (2009) 1783–1789.
matrix interface bonding. [9] S.M. Olhero, J.M.F. Ferreira,
5. The increase in Al2O3 constituent “Rheological characterisation of water-
toughness decreases with respect to based AlN slurries for the tape casting
base metal. This is due to increase process”, Journal of Materials Processing
in brittleness between the alloy Technology 169 (2005) 206–213.
Al6351 and Al2O3 interfaces. [10] Karakulak Erdem, Zeren Muzaffer,
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