International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN IN –          INTERNATIONAL JOURNA...
International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976 –6480(Print), ISSN 0976 – 649...
International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976 –6480(Print), ISSN 0976 – 649...
International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976 –6480(Print), ISSN 0976 – 649...
International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976 –6480(Print), ISSN 0976 – 649...
International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976 –6480(Print), ISSN 0976 – 649...
International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976 –6480(Print), ISSN 0976 – 649...
International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976 –6480(Print), ISSN 0976 – 649...
International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976 –6480(Print), ISSN 0976 – 649...
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Characterization of al sic metal matrix by stir-casting

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Characterization of al sic metal matrix by stir-casting

  1. 1. International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN IN – INTERNATIONAL JOURNAL OF ADVANCED RESEARCH 09766480(Print), ISSN 0976 – 6499(Online) Volume 3, Number 2, July-December (2012), © IAEME ENGINEERING AND TECHNOLOGY (IJARET)ISSN 0976 - 6480 (Print) IJARETISSN 0976 - 6499 (Online)Volume 3, Issue 2, July-December (2012), pp. 226-234© IAEME: www.iaeme.com/ijaret.asp ©IAEMEJournal Impact Factor (2012): 2.7078 (Calculated by GISI)www.jifactor.com CHARACTERIZATION OF AlSiC METAL-MATRIX BY STIR- CASTING Mr. Amol D. Sable1, Dr. S. D. Deshmukh2 1 Student of M.E. (Manufacturing Engg), Jawaharlal Nehru Engineering College (JNEC), Aurangabad, Dr. Babasaheb Ambedkar Marathwada University, Maharashtra, India, E-mail: amol672006@gmail.com 2 Principal, Jawaharlal Nehru Engineering College (JNEC), Aurangabad, Dr. Babasaheb Ambedkar Marathwada University, Aurangabad, Maharashtra, India, E-mail: sdeshmukh47@rediffmail.com ABSTRACT A tremendous development of the present engineering sectors, Metal-matrix composites plays a vital role in industrial metallurgical processes. The metal-matrix composite has a great advantageous properties and reasonable costing increases the performance of the machineries and it also much more profitable technology than powder metallurgical processes. Metal-matrix composites can mainly prepared by metallic materials, ceramic materials and non-metallic materials. In this paper, we adopted the metallic material like aluminium with silicon carbide (AlSiC) metal-matrix composites by stir-casting method. On the explore and augmentation of the engineering industrial sectors, this paper emphasizes the production of metal-matrix AlSiC composites by the continuous stir-casting method and prepared six rounded bars and six square bars samples of changeable percentile compositions of SiC – 5%, 10%, 15%, 20%, 25% and 30% with aluminium. Final samples were tested by hardness using Brinell hardness machine, impact strength test using Charpy-V-Notched machine and Microstructure examination conducted on Trinocular type Metallurgical Microscope. 226
  2. 2. International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976 –6480(Print), ISSN 0976 – 6499(Online) Volume 3, Number 2, July-December (2012), © IAEMEKeywords: Metal-Matrix Composite, AlSiC Stir-Casting, Hardness Test, Impact StrengthTest, Microstructure ExaminationI. INTRODUCTIONMetal-matrix composites has great role in the modern engineering fields. These are used forthe manufacturing the strong, hard and light-weighted engineering materials which sere usedin latest machineries, parts of the speedy motors and vehicles and other engineering works.Silicon carbide is very important constituents of the metal-matrix composites because of itsexcellent homogeneous uniting properties. It also the back bone of every structure metal-matrix composites. Metals like aluminium, magnesium, zinc, manganese, ferrous etc are usedfor fabricating the metal-matrix composites; here we prepared AlSiC metal-matrix. The rawmaterials like Al (98.41%) metal scraps homogeneously united with SiC (320 grit) bycontinuous stir-casting method. Stir-casting is the type of vortex heating with stirring methodin which the raw materials gets homogeneously mixed with each other at controlledtemperature rate. The slurry was poured into the desired shaped moulds i.e. rounded bars andrectangle bars. By this method, we prepared the samples of different composition of AlSiCmetal-matrix and then the testing treatments like hardness impact strength and micrographstructure analysis would be done which is discussed in this paper.II. METAL-MATRIX COMPOSITESMetal-matrix composite structure is generally designated purely by the term metal alloy ofthe matrix and the material in the form of the strengthening. The matrix is permeating softpart generally having excellent tensile strength, hardness, ductility and thermal conductivitywhich are set in the hard reinforcements having high tautness and low thermal expansion. Forthe development of metal-matrix, light metal composite materials mixed with light metalalloys are applied as matrix materials. During the metal-matrix production, the maincontribution of special alloys is used in powder metallurgy which is used for thesolidification.III. STIR-CASTING EXPERIMENTATIONStir Casting is a liquid state method of composite materials fabrication, in which dispersedphase is mixed with a molten metal-matrix by means of mechanical stirring. The liquidcomposite material is then cast by conventional casting methods. The term stir-casting is the 227
  3. 3. International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976 –6480(Print), ISSN 0976 – 6499(Online) Volume 3, Number 2, July-December (2012), © IAEMEprocess of stirring molten metal’s are used for continuous stirring particles into metal alloy tomelt and immediately pour into the sand mould then cooled and allow to solidify.The experimental arrangement has been assembled by the coupling motor and mild steel fourblade stirrer on the MS square pipes frame. The melting of the alluminium (98.41%) scrapsand silicon carbide powder (SiCp – 320 grit size) is carried out in the graphite crucible in tothe coal-fired furnace. First the scraps of aluminium (98.41%) were preheated for 3 to 4 hoursat 450°C and silicon carbide powder (SiCp – 320 grit size) also heated with 900°C and boththe preheated mixtures is then mechanically mixed with each other below their meltingpoints. This metal-matrix AlSiC is then poured into the graphite crucible and put in to thecoal-fired furnace at 760°C temperature. After completing the experiment the slurry has beentaken into the sand mould within thirty seconds allow it to solidify. Finally we prepared thesix types varying samples like rounded bars and square bars as per specified by the objectivesthis paper. This experiment should repeatedly conducted by varying the compositions of thecomposite powder of SiC (5%, 10%, 15%, 20%, 25% and 30%) as shown in the fig.1 givenbelow;After getting the final samples i.e. rounded bars and square bars, it is then ready for thetesting of hardness test, impact strength test and micrograph examination.IV. CONDUCTED TESTSThe main purpose this paper is to develop the strong light weighted metal-matrix AlSiCcomposite material which is useful in the industrial sectors as well as advanced machineries.After fabrication following test were conducted by this paper;4.1 Hardness Test (Brinell Hardness Test)Hardness test has been conducted on each specimen using a load of 500 Kg and a steel ball ofdiameter 10 mm as indenter. Hardness tester is employed to evaluate the interfacial bondingbetween the particles and the matrix by indenting the hardness with the constant load and 228
  4. 4. International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976 –6480(Print), ISSN 0976 – 6499(Online) Volume 3, Number 2, July-December (2012), © IAEME July Decemberconstant time. Test samples were sectioned from the cylindrical cast bars of size 30 mmdiameter and 30 mm height. Test specimens before test and after test are shown in given fig. est2; the mean result of the specimens trials are shown in the chart No.1 and its graphicalrepresentations are given in the graph No.1; 229
  5. 5. International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976 –6480(Print), ISSN 0976 – 6499(Online) Volume 3, Number 2, July-December (2012), © IAEME4.2 Impact Strength testImpact Strength test is done by Charpy V Notch pendulum impact testing machine. Thesquare bar test specimens is applied on a simply supported beam. A Specimen is adjusted bysquare cross section 10 mm x 10mm x 55mmin length with 45 degree v notch at center.Single blow of hammer is given at mid span of specimen. The blow should be sufficient tobend or break the specimen at center. The striking energy should be 310 ±10 joules. Theenergy spent in bending or breaking the specimen is taken as Charpy impact value shown inthe fig. 3, the mean result of the specimens trials are shown in the chart No.2 and its graphicalrepresentations are given in the graph No.2; 230
  6. 6. International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976 –6480(Print), ISSN 0976 – 6499(Online) Volume 3, Number 2, July-December (2012), © IAEME4.3 Microstructure Examination Metallographic samples were sectioned from the cylindrical cast bars. A 0.5 % HF solutionwas used to etch the samples wherever required. To see the difference in distribution of SiCparticles in the aluminum matrix, microstructure of samples were developed onTrinocular type Metallurgical Microscope (Made: JVC, Range-X10 to X1000) shown in thefig.4; 231
  7. 7. International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976 –6480(Print), ISSN 0976 – 6499(Online) Volume 3, Number 2, July-December (2012), © IAEME July DecemberFirst sample was prepared without applying any stirring process as shown in fig. 5. When the 5composite has been developed without applying stirring process, particle clustering occurredin some places, and some places were identified without SiC inclusion. This was due to thefact that when the SiC particles were added into the molten alloys, they were observed to be alloys,floating on the surface, though they have a large specific density than the molten metal. Thiswas due to high surface tension and poor wetting between the particles and the melt.A group of figures depicts micrographs of samples containing 5%, 15%, 25% SiC by weight frespectively developed with the help of two step mixing method of stir casting. It clearly two-stepshows the resulting homogeneous distribution of particles in the samples as shown in the fig.6; 232
  8. 8. International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976 –6480(Print), ISSN 0976 – 6499(Online) Volume 3, Number 2, July-December (2012), © IAEMEFigure 7 shows micrograph of sample containing 30% SiC by weight. Density of SiCparticles decreases inspite of an increase in concentration. This may be attributed to the factthat a this weight fraction, SiC particles greatly interact with each other leading to clusteringof particles and consequently settling down.V. RESULT AND CONCLUSION After getting the result of the composition AlSiC (5%, 10%, 15%, 20%, 25% and 30%) ready samples were tested and checked the hardness test, impact of strength test and uniform distribution study of reinforcement in metal-matrix with micro- spectrograph analysis as follows; 1) The results of study suggest that with increase in composition of SiC, an increase in hardness and impact strengths have been observed. 2) The best results has been obtained at 25% weight fraction of 320 grit size SiC particles. Maximum Hardness = 44.9 BHN and Maximum Impact Strength = 35.33 J. 3) Homogenous dispersion of SiC particles in the Al matrix shows an increasing trend in the samples prepared by without applying stirring process with manual stirring and with 2-Step method of stir casting technique respectively. 233
  9. 9. International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976 –6480(Print), ISSN 0976 – 6499(Online) Volume 3, Number 2, July-December (2012), © IAEMEVI. REFERENCES[1] Dunia Abdul Saheb, “Aluminum Silicon Carbide and Aluminum Graphite Particulate Composites”, ARPN Journal of Engineering and Applied Sciences, Vol. 6, No. 10, Oct 2011, ISSN 1819-6608[2] S. Das, “Development of Aluminium Alloy Composites for Engineering Applications”, Trans. Indian Inst. Met., Vol.57, No. 4, pp. 325-334Aug (2004)[3] Y. Sahin, “Preparation and some properties of SiC particle reinforced aluminium alloy composites”, Materials and Design 24 671–679 (2003)[4] S. Naher, D. Brabazon, L. Looney, “Development and assessment of a new quick quench stir caster design for the production of metal matrix composites”, Journal of Materials Processing Technology 166, 430–439 (2004)[5] Muhammad Hayat Jokhio, Muhammad Ibrahim Panhwar, Mukhtiar Ali Unar, “Manufacturing of Aluminum Composite Material Using Stir Casting Process”, Mehran University Research Journal of Engineering & Technology, Volume 30, No. 1, January, 2011, ISSN 0254-7821[6] Manoj Singla, Lakhvir Singh, Vikas Chawla, “Study Of Wear Properties Of Al-Sic Composites”, Journal Of Minerals & Materials Characterization & Engineering, Vol. 8, No.10, Page. 813-819, (2009)[7] Neelima Devi. C, Mahesh.V, Selvaraj. N, “Mechanical Characterization Of Aluminium Silicon Carbide Composite”, International Journal Of Applied Engineering Research, Dindigul Volume 1, No 4, 2011, ISSN 09764259[8] Gaurav Chigal, Gaurav Saini, “ Mechanical Testing Of Al6061/Silicon Carbide Metal Matrix Composite”, Ijreas Volume 2, Issue 2, Feb-2012, ISSN: 2249-3905[9] S. O. Adeosun, S.A. Balogun, O.S. Sanni And W.A.Ayoola, “ Improving The Strength And Ductility Of Wrought Aluminum Through Particle Addition”, Materials Science And Technology (Ms&T), October 25-29, 2009, Pittsburgh, Pennsylvania[10] Karl Ulrich Kainer, “Basics of Metal Matrix Composites”, WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim, (2006)[11] Karl Ulrich Kainer, “Metal Matrix Composites. Custom-made Materials for Automotive and Aerospace Engineering”, WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim, 2006, ISBN: 3-527-31360-5[12] J.U. Ejiofor, R.G. Reddy, “Developments in the Processing and Properties of Particulate Al-Si Composites”, JOM publication,of The Minerals, Metals & Materials Society (1997)[13] R.K. Jain, “Production Technology”, 16th Edition, Khanna Publishers, New Delhi (2006).[14] Pulkit Bajaj, “Mechanical behavior of Aluminium based metal matrix composites reinforced with SiC and alumina”, Department of Mechanical Engineering Thapar University, Patiala, India, Page – 10[15] Subhakanta Sarangi, Deepak Kumar, “Fabrication and characterization of aluminium – fly ash composites using stir casting method”, National Institute of Technology, department of metallurgical materials engineering, Rourkela (2009)[16] http://www.ipublishing.co.in[17] http://www.elsevier.com 234

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