Paper Publikasi on International Proceeding

1. Effect of Copper Addition on
Aluminum Matrix Composite by
Powder Metallurgy Method
Aswar, Muhammad Syahid, Azwar Hayat
Department Mechanical Engineering, Faculty of Engineering, Hasanuddin University, Makassar, Indonesia

2. Introduction
Lightweight materials with
optimized properties are a
dream in many applied fields.
The use of lightweight
materials can reduce fuel
consumption and improve
performance, resulting in an
environmentally friendly
system.
Lightweight Material
1
The danger of lead is a critical
issue today. Limitation efforts
have been made to reduce the
impact. Various regulations
and studies report it as a
hazardous material to the
environment and health.
Lead Risk For
Environment & Health
2
The use of lead in machine
element applications has
received attention. Many
studies of lead-free alternative
materials have been carried out
in recent years to optimize the
system and reduce the risk of
exposure to hazardous
substances.
Lead-free Automotive
Component
3
Research in recent years has
reported various methods and
treatments for optimizing the
properties of aluminum
composites. This condition
provides ideas for the
development of alternative
materials in automotive
applications.
Optimal Properties for
Alternative material
4

3. Research Background
In 2020, Charkiewicz et al. reported that lead exposure could accumulate in the body and
pose a risk of disease and body system disorders.(Charkiewicz & Backstrand, 2020).
Sakai et al. succeeded in synthesizing lead-free composites in bearing bush applications
for piston pins with Cu6Sn3Ni1.5Mo2C composites as a substitute for Cu10Sn10Pb with
high performance and meeting market standards (Sakai et al., 2004).
Du et al., in their study, at 620oC on the Al-Cu-Mg composite with the optimum conditions
were reported at a holding time of 2 hours with a relative density of 98.46%, and
hardness of 87.5 HBW (Du et al., 2020)

4. Aim Of Research
Producing lead-free copper-reinforced
aluminum matrix composites by the powder
metallurgy route
This research includes observation and analysis of physical
properties, mechanical properties, and microstructure of AMC with
(0, 4, 7, and 10)% wt Cu

5. Research Methodology
Adopted from Manufacturing Engineering and Technology ( Kalpakjian, 2010)
Analysis and
Result
- Wilson Hardness UH250
- Pin On Disk Test with #1000 abrasive
paper grit
Mechanical
Properties Testing
- Olympus Type OLS4100
Microstructure
Observation
Dry Mixing at 1500 Rpm-
2h, Miyako CH-501
Powder Mixing
At 150 MPa-held 5 min
Hydraulic Press Type 16T
Compaction Process
at 600oC-90’ in
Furnace Lindberg Blue M
Sintering Process
- Al, Cu, Mg and Gr with High Purity
are prepared as raw material
Powder Preparation
- Archimedes Density test
- Porosity Immerse (24h) test
Physical Properties
Testing

6. Research Methodology : Powder Preparation
Figure 1. Raw powder shape and size
Shown rounded aluminum particles (45 𝜇 m), irregular
magnesium particle (100 𝜇m), Angular Graphite particle (55
𝜇m), and dendritic Copper particle (85 𝜇m).
Figure 2. Mixture powder preparation
The picture shows the distribution and homogeneity of the
powder mixture after mixing. The results show a good
distribution.
1 2

7. Methodology : Composite Samples
Figure 3. Green Compact (a-d) and Sintered Compact (e-h)
The picture shows the shape of the sample before and after the sintering process. The sintering treatment affects the
density and strength of the composite sample.
Green
Compact
Sintered
Compact

8. Result : Physical Properties
4.14%
5.08% 5.10%
5.81%
7.30%
0.00%
2.00%
4.00%
6.00%
8.00%
10.00%
Pure Al 0%Cu 4%Cu 7%Cu 10%Cu
Porosity
Level
(%)
Al-1.5%Mg-5Gr-xCu
89.0% 89.6%
86.4% 87.2%
84.5%
90.3% 90.9%
87.8%
90.5%
92.4%
70.0%
80.0%
90.0%
100.0%
Pure Al 0%Cu 4%Cu 7%Cu 10%Cu
Relative
Density
(%)
Al-1.5%Mg-5Gr-xCu
Green Compact
Sintered
Figure 4. Physical Properties Testing Result
1. Figure a. shows the density increase in the larger copper
fraction due to copper having a high density (8.95 g/cm3)
contributing composite weight. Higher value is 3.04 g/cm3
2. Figure b. shows the tendency of increasing porosity in the
larger copper fraction due to the shape factor and the size of
the constituent particles. Higher value is 7.30%
3. Figure c. shows the increase in relative density of all
composite samples after sintering. Higher value is 92.4%
2.44 2.42
2.56
2.81
3.04
2.00
2.20
2.40
2.60
2.80
3.00
3.20
3.40
Pure Al 0%Cu 4%Cu 7%Cu 10%Cu
Density
(g/cm
3
)
Al-1.5%Mg-5Gr-xCu
a
b
c
Higher
Higher
Higher

9. Result : Mechanical Properties
16.1
23.8
51.1
77.8 81.5
0.0
20.0
40.0
60.0
80.0
100.0
Pure Al 0% Cu 4% Cu 7% Cu 10% Cu
Hardness
(HV)
Al-1.5Mg-5Gr-xCu
0.0000
0.0500
0.1000
0.1500
0.2000
0.2500
0.3000
0.3500
0.4000
2 N 2.5 N 3 N
Wear
Rate
(mm
3
/m)
Normal Load Variation
Pure Al 0%Cu
4%Cu 7%Cu
10%Cu
Figure 5a. Hardness Testing Result
The figure shows a significant increase in
hardness at a larger copper fraction associated
with Cu diffusion in the Al matrix boundary.
The formation of Al2Cu in the larger copper
fraction initiates the composite hardness. Higher
value is 81.5 HV
Figure 5b. Wear rate Testing Result
The figure shows decreased wear rate on composites with a
larger copper fraction. Low wear rates indicate good wear
resistance. Wear resistance shows a relationship pattern with
composite hardness, hard composites exhibit superior wear
resistance.
a b
Higher
Hard Composite High resistance

10. Result : Microstructure
Figure 6. Green Compact Micrograph
It can be seen that the constituent particles
are scattered in the matrix, the distance
between the particles is more open,
indicating that the density and strength are
still low.

11. Result : Microstructure
Figure 7. Sintered Compact Micrograph
1. It is seen that pore shrinkage is followed by
closer particle spacing as an indication of
the improvement in mechanical properties.
2. It can be seen that graphite is spread over
the grain boundaries, acting as a solid
lubricant that can reduce the wear rate.
3. It can be seen that there is a tendency for
agglomeration to occur in the larger copper
fraction.

12. Composite Properties vs. Market Requirement
Our composite today
1. The composites produced in this study are 3.5 times
lighter than the lead composites on the market.
2. This research composite (with 4%Cu, 7%Cu, and
10%Cu) meets the market minimum hardness value.
Product Id Composite Hardness
DYB-302, CSB-800, SY CuPb10Sn10 HB60-90
DYB-303, CSB-720 CuSn4Pb24 HB45-70
DYB-304,SP CuPb24Sn HB40-60
DYB-307, CSB-700 CuPb30 HB30-45
Source from Bi-metal bearing Product Catalogue, CSB-Bearing France and Jiashan
DY Bearing Co. Ltd
Composites with lead (Pb) on the global market have
Minimum hardness on 30 HB ( 32 HV)
With Density (10.72 g/cm3)
Steel back
Composite

13. Conclusion
1. The addition of larger copper increases the density and porosity of the composite. The highest density is 3.01
g/cm3, 7.3% porosity, and 92.4% relative density was obtained in the AMC with 10%Cu.
2. The addition of copper in several weight fractions increases the hardness is followed by good wear resistance of
the composite. The highest hardness of 81.5 HV with the best wear resistance was found in the AMC with 10%Cu.
3. The micrograph shows the distribution of the dominant constituent particles at the grain boundaries, then pore
shrinkage after sintering, followed by denser bonds between grains indicating increased mechanical properties.
4. AMC's lightweight, lead-free, and optimized properties with 4%Cu, 7%Cu, and 10%Cu composite make it
possible as an alternative material in automotive applications.

14. 14
THANK YOU
Thank for Organizer
Thank for Audience
Thank for All