The aluminum 6061 MMC with Graphite,Fly ash and Magnesium used as reinforcement has got the higher value of hardness, toughness,less wear rate and less ductility compared to pure aluminium. Hence this composite can be deployed to make an piston rods,bush,aircraft body and automotive body parts.

1. DEPARTMENT OF MECHANICAL ENGINEERING
“EVALUATION OF MECHANICAL PROPERTIES OF ALUMINUM BASED MMC”
Under the guidance of
Dr. CHANNABASAVARAJ
( HOD, Mechanical department)
Seminar By
Abhimanyu Sah [ 1PL12ME001]
Bishal Bhandari [1PL12ME012]
Harendra Kumar [1PL12ME043]
Mahesh Kr. Chaudhary[1PL12ME016]

2.  Introduction
 Problem Definition
 Objectives
 Methodology
 Composition Table
Comparison
 Results & Discussion
 Advantages, Disadvantages and Applications
 Conclusion
 Scope of Future Work
 References

3.  Composites material is the combination of two or more material
having similar or dissimilar physical or chemical properties
resulting the superior properties than individual material.
 Metal matrix composites (MMCs) possess significantly improved
properties. In MMCs, the reinforcement usually takes the form of
particles, whiskers, short fibers, or continuous fibers.

4. Composites
Based on Matrix
Ceramic
Metal
Polymer
Thermosets
Thermoplastics
Based on
Reinforcement
Fiber
Continuous
Undirectional
Reinforcement
Bi-directional
Reinforcement
Discontinuous
Aligned
Randomly Oriented
Whisker
Particle
Large Particle
Dispersion
Strengthened
Structural
Laminates
Sandwiched

5.  Conventional monolithic materials have limitations in achieving
good combination of strength, stiffness, toughness and density.
 To overcome these shortcomings and to meet the ever increasing
demand of modern day technology, composites are most
promising materials of recent interest.
The problem being addressed for the proposed work is to evolve
a development process for the best mix of the alloying elements for
Al, Mg, Graphite and fly ash for deriving optimal mechanical
properties.

6. The main objective of doing this project is to enhance the properties
of Al 6061 composite by reinforcing Magnesium and graphite.
 To form light weight composites.
 To improve stiffness.
 To improve solid lubrication.
 To improve cast ability.
 To improve Hardness value.
 To improve the toughness properties.
 To reduce the ductility value.

7. S.N. BASE METAL BASE METAL
%
MAGNESIUM
%
FLY
ASH
%
GRAPHITE
%
i Aluminium 92 5 3 -
ii Aluminium 89 5 6 -
iii Aluminium 89 5 3 3
iv Aluminium 86 5 6 3
V Aluminium 83 5 6 6

8. METHODOLOGY
 Fabrication of MMCs
 Preparation of test specimen according to ASTM
standard.
 Properties evaluation of test specimen
• Tensile properties
• Hardness value
• Wear rate
• Impact strength

9. FABRICATION OF MMCs
MMC can be processed by following techniques :
i. Solid State processing
a) Diffusion Bonding Process
b) Powder metallurgy
ii. Liquid State Processing
a) Stir Casting Method
iii. Semi Solid State Method
iv. Vapor Deposition Method
v. In-SITU Fabrication Technique

10. Stir casting is the liquid state method of fabrication of MMC in
which a dispersed phase is mixed with a molten matrix metal by
means of mechanical stirring.

12. E= 14990 Mpa
0
500
1000
1500
2000
2500
3000
0 0.05 0.1 0.15 0.2 0.25 0.3
Series1
E
x
Linear (E)
Linear (x)Proof Stress =1750 Mpa
S-S curve for 5% Mg + 3% Fly ash
E = 18568 Mpa
0
500
1000
1500
2000
2500
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16
Stress(Mpa)
Strain
S-S curve of Mg=5%,fly ash = 6%
Series1
E
YP
Linear (E)
Linear (YP)
Proof Stress = 1400 Mpa
Results and Discussion

13. E = 17871 Mpa
0
500
1000
1500
2000
2500
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16
Stress(Mpa)
Strain
S-S curve for Mg=5 %,Fly ash = 3%,Graphite = 3%
Series1
E
YP
Linear (E)
Linear (YP)
Proof Stess = 1100 Mpa
E = 20888 Mpa
0
500
1000
1500
2000
2500
3000
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 0.18
Stress(Mpa)
Strain
S-S curve of Mg=5%, Fly ash =6%, Graphite = 3%
Series1
E
YP
Linear (E)
Linear (YP)Proof Stress = 1450 Mpa

14. E = 17871 Mpa
0
500
1000
1500
2000
2500
3000
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16
Stress(Mpa)
Strain
S-S curve of Mg=5%, Fly ash= 6%, Graphite = 6%
Series1
E
YP
Proof Stress= 1100 Mpa

15. 0
500
1000
1500
2000
2500
3000
0 0.05 0.1 0.15 0.2 0.25 0.3
stress(Mpa)
strain
m5f3
m5f3g3
m5f6
m5f6g3
m5f6g6

16. 0.00E+00
2.00E-06
4.00E-06
6.00E-06
8.00E-06
1.00E-05
1.20E-05
1.40E-05
1.60E-05
A B C D E
Wearrate(gm/mm)
Composition
F1=0.5 Kg
F2=1 Kg
F3 = 1.5 Kg
Wear rate values at different loads
Where,
A = Al 6061 + 5% Mg + 3% Fly ash
B = Al 6061 + 5% Mg + 6% Fly ash
C = Al 6061 + 5% Mg + 3% Fly ash + 3% Graphite
D = Al 6061 + 5% Mg + 6% Fly ash + 3% Graphite
E = Al 6061 + 5% Mg + 6% Fly ash + 6% Graphite

17. 0
0.5
1
1.5
2
2.5
3
3.5
A B C D E
Series1
Energy absorbed for different composition
Where,
A = Al 6061 + 5% Mg + 3% Fly ash
B = Al 6061 + 5% Mg + 6% Fly ash
C = Al 6061 + 5% Mg + 3% Fly ash + 3% Graphite
D = Al 6061 + 5% Mg + 6% Fly ash + 3% Graphite
E = Al 6061 + 5% Mg + 6% Fly ash + 6% Graphite

18. Hardness value for different composition of Al based MMC
34
35
36
37
38
39
40
41
mg5f3 mg5f6 mg5f3g3 mg5f6g3 mg5f6g6
Hardness Chart
mg = magnesium
f = fly ash
g = graphite and
numerical digit represents percentage.

19.  Can cast any complex shape.
 High weldability.
 Can be rolled easily.
 High corrosion resistance.
 High machinability.
 High strength to density ratio.
 High stiffness.
 High toughness.
 High hardness.
 Good cast-ability.
 High reflectivity.
 High thermal conductivity.
 Less shrinkage.

20.  Casting defect may exist.
 High accuracy can’t be obtained.
 Skilled operator is required.
 High loss of material.
 Less flexibility to cast different materials.
 Parts have less chemical homogeneity then PM.
APPLICATIONS
 Bearing, bush and piston materials.
 Aircraft body.
 Automotive industry
 Marine industry.
 Beverage cans, hockey stick, fishing stick,
utensils.
 bicycle frame.

21. The following conclusion can be made from this project work.
 For 3% addition of fly ash,
• the modulus of elasticity is increased by 23.86%,
• proof stress is decreased by 20 %,
• wear rate is increased by 50%,
• impact strength is increased by 25% and
• hardness is increased by 2.778%.
 For 3% increase in graphite,
• the modulus of elasticity is increased by 19.2194%,
• proof stress decreased by 37.14%,
• wear rate is decreased by 50%,
• impact strength is increased by 66.667% and
• hardness is increased by5.556%.
CONCLUSION

22.  For 3% addition of fly ash and 3% increase in graphite
• the modulus of elasticity is increased by 39.34%,
• proof stress decreased by 17%,
• no change in the wear rate,
• impact strength is increased by 108.33% and
• hardness is increased by9.722%.
 For 3% addition of fly ash and 6% increase in graphite
• the modulus of elasticity is increased by 19.219%,
• proof stress decreased by 37.142%,
• wear rate is decreased by 50%,
• impact strength is increased by 150% and
• hardness is increased by 11.11%.
 From the above data the stiffness of the material seems to
increase for every 3% addition of fly ash and 3% addition of
graphite, decrease in proof stress indicates that the plastic
deformation can be done easily.

23. SCOPE OF FUTURE WORK
• Investigations can be extended on different types of fibres and
matrix materials.
• Fatigue tests can be carried to evaluate the fatigue life and impact
strength of the laminated composites.
• Vibration and modal analysis can be carried to evaluate vibration
strength of the MMC Acoustic studies can be carried on the MMC.
• Radiography tests and chemical degradation test can be performed
to analyse the resistance of the MMC for the environmental
conditions.
• The MMC can be formed by powder metallurgy process for better
properties.

24. REFERENCES
i. A. Anandha Moorthy, Dr. N. Natarajan, R. Sivakumar, M. Manojkumar, M. Suresh,
2012, Dry Sliding Wear and Mechanical Behavior of Aluminium/Fly ash/Graphite
Hybrid Metal Matrix Composite Using Taguchi Method, International Journal of
Modern Engineering Research (IJMER) Vol.2, Issue.3, pp-1224-1230.
ii. A. Manna, H.S. Bains, P.B. Mahapatra, 2011, Experimental study on fabrication of
Al--Al2O3/Grp metal matrix composites, Journal of Composite Materials.
iii. A. R. K. Swamy, A. Ramesha, G.B. Veeresh Kumar, J. N. Prakash, 2011, Effect of
Particulate Reinforcements on the Mechanical Properties of Al6061-WC and Al6061-Gr
MMCs, Journal of Minerals & Materials Characterization & Engineering, Vol. 10,
No.12, pp.1141-1152 .
iv. Abdalla Alrashdan, Ahmad T. Mayyas, Adel Mahamood Hassan, Mohammed T.
Hayajneh, 2011, Drilling of Al--Mg--Cu alloys and Al--Mg-Cu/SiC composites, Journal
of Composite Materials.
v. Adel Mahmood Hassan, Ghassan Mousa Tashtoush, Jafar Ahmed Al-Khalil, 2007,
Effect of Graphite and/or Silicon Carbide Particles Addition on the Hardness and
Surface Roughness of Al-4 wt% Mg Alloy, Journal of Composite Materials.
vi. J Babu Rao, Venkata Rao, I Narasimha Murthy, NRMR Bhargava, 2012, Mechanical
properties and corrosion behaviour of fly ash particles reinforced AA 2024 composites,
Journal of Composite Materials .

25. THANK YOU