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Study on Cold Forming Behavior of Aluminum Metal Matrix Composite
1.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 04 Issue: 11 | Nov -2017 www.irjet.net p-ISSN: 2395-0072 © 2017, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 1247 Study on Cold Forming Behavior of Aluminum Metal Matrix Composite KIRAN JABAR1, Prof. RAMESH KATTI2, Prof. NIRANJAN PATTAR3 1M.Tech Student (Design Engineering), KLE Dr. M S Sheshgiri College of Engineering and Technology, Belagavi, Karnataka, India 2,3 Professor, Department of Mechanical Engineering, KLE Dr. M S Sheshgiri College of Engineering and Technology, Belagavi, Karnataka, India ---------------------------------------------------------------------***--------------------------------------------------------------------- Abstract – Though much work has been reported to improve mechanical properties of different aluminum alloys by using different types of reinforcements sufficient dataisnot available. Present work focus on fabricationofcastaluminum reinforced with boron carbide and silicon carbide with different volume percent through stir casting process. Cold forming behavior of Al-B4C-SiC composite was investigatedby conducting cold upsetting test in Universal Testing Machine. Maximum true axial stress, true hoop stress and hydrostatic stress were determined for all compositespecimens. Intheend, it was concluded from stress-strain curve, reinforcements played a crucial role in improving compressive strength of Al- B4C-SiC composite. Key Words: Cast aluminium, Reinforcements, Boron carbide, Silicon carbide, Stir casting technique, Cold upsetting test, Stress-strain characteristics. 1. INTRODUCTION Composite materials are the product of continuous attempts to develop new engineering materials which are produced artificially, a multiphase materials possessing desirable combinations of finest properties of constituent phase. As a result structural performance of individual materials when stand-in independently is not that much superior, if measure up to composite materials. Itcanbesaid that the main aim is to combine the beneficial constituent material propertiestoobtain newanduniquematerial which are dependent upon the properties of their particular components. Hence to accomplish such aspire, clear crystal knowledge of individual propertiesofconstituentsmaterials which are to be used must be known in order to select compatible materials for fabrication purpose. Material property range as well as combinations have been and are yet being determined, as still there is lot of research work is still going on in composite field, it has no limit nor can range be determined. Many research works have been carried out in many of our modern technologies fordevelopmentofnew composite materials and experimentation is done, by trying many different combinations of materials to specify range and applications as well. In this work, an attempt hasbeen madetopreparehybrid aluminium metal matrix composite. To cast aluminiumalloy boron carbide (B4C) and silicon carbide (SiC) are added as reinforcements, so as to prepare hybrid metal matrix composite. Reinforcement’s particles are substituted in molten matrix by using stir casting methodology. Based on volume ratio composite samples are fabricated. Objective of this present investigation is to determine cold forming behaviour of hybrid metal matrix composite by adding ceramics particles in cast aluminium alloy. 1.1 Boron Carbide (B4C) In hardness material list, diamond and boron nitride ranking is first and second, the reinforcement used in this following experiment ranking in third place of hardness list. Structureof boron carbideisrhombohedraanditisthecause for material hardness and is recognized by chemical formula “B4C”. Boron carbideused isofceramictypeandfollowingfigure 1.1 shows the image of B4C used. Fig -1.1: Boron Carbide Properties:- Apparent Density = 2.52 gm/cm3 Colour = Black carbon powder Size = 37-44 microns (345 mesh) approximately Chemical composition:- Total Boron = 77.3 % Total Carbon = 21.7 % Total Boron + Total Carbon = 99 % Others = 1 %
2.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 04 Issue: 11 | Nov -2017 www.irjet.net p-ISSN: 2395-0072 © 2017, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 1248 Boron carbide possesses low density, high degree of chemical inertness, high temperaturestabilityandmoreover it is an attractive strengthening agent for aluminium based composites. Sometimes it could be an alternative to silicon carbide reinforced composites in applications where high stiffnessand wearresistancesaremajorrequirements.Boron carbide reinforced metal matrix composite are stronger, stiffer, lighter in weight and harder, possess higher fatigue strength and exhibit significant improvements over other materials. It has reported that the interfacial bonding between aluminium matrixand boroncarbidereinforcement seems to be better than between aluminium matrix and silicon carbide [1]. 1.2 Silicon Carbide (SiC) Naturally occurring silicon carbide in nature, up to its variety of crystalline polymorphs considered to be an extremely rare mineral known as “moissanite”. In the year 1893 first moissanite was found and it was studied and discovered by chemist of French country named Dr. Ferdinand Henri Moissan. Hence, it is also named as “Moissan” in year 1905. Image of silicon carbide used is shown in figure 1.2. Fig -1.1: Silicon Carbide Properties:- Apparent Density = 3.30 g/cm3 Colour = Black Size = 35 microns approximately Chemical composition:- Total Silicon = 69.64 % Total Carbon = 29.78 % Total Silicon + Total Carbon = 99.42 % Others = 0.58 % Silicon carbide possesses high strength and hardness and even fine elastic modulus when it is embedded in matrix, there is certainly improvement in wear resistance, strength of composite (i.e. improvement in yield strength), and corrosion resistance. This information is taken from the journal paper. In automobile sectors i.e. car clutch plates, cutting tools, structural materials, and bullet proof vests silicon carbide is implied [1]. 2. FABRICATION PROCEDURE Totally six specimens are to be fabricated, out of six specimens one specimen is of cast aluminum alloy which is named as specimen A. Remaining specimens are aluminum hybrid metal matrix composites named as B, C, D, E and F. In samples of hybrid aluminum metal matrix composite, boron carbide reinforcement is substituted in varying volume percent i.e. 3.5%, 7%, 10.5%, 3.5% and 3.5% in respective specimen B, C, D, E and F. In the same manner siliconcarbide reinforcement is substituted in varying volume percent namely 3.5%, 3.5%, 3.5%, 7% and 10.5% in respective specimens B, C, D, E and F. Details regarding percentage of composition in respective specimens is given in table 2.1. Table 2.1: Composition Percentage Five hybrid composite samples are fabricated through compo casting (stir casting) of conventional type and this is also known to be as two-step casting process. Compo casting is method of fabrication, in which composite materials are produced in liquid method state, ceramic particulates (reinforcements) are preheated before dispersing or incorporating with molten metal matrix by means of stirrer, once the reinforcement and matrix are properly mixed then composite material mixture,whichisin liquid state is casted into moulds as per required shapes [6]. First step in method of compo casting involves melting process i.e. in graphite crucible matrix material isplacedand heated above its liquidus temperature and maintained molten metal matrix material in semi solid state [6]. Speci men Al % B4C% SiC% Composition A 99 - - 99% Al B 93 3.5 3.5 93%Al-3.5%B4C- 3.5%SiC C 89.5 7 3.5 89.5%Al-7%B4C- 3.5%SiC D 86 10.5 3.5 86%Al-10.5%B4C- 3.5%SiC E 89.5 3.5 7 89.5%Al-3.5%B4C- 7%SiC F 86 3.5 10.5 86%Al-3.5%B4C- 10.5%SiC
3.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 04 Issue: 11 | Nov -2017 www.irjet.net p-ISSN: 2395-0072 © 2017, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 1249 Second step is preheating and addition of reinforcement. Preheating of reinforcement is carried out, as to remove volatile and moisture. Reinforcement is incorporatedwithin matrix and with the help of stirrer; it is stirred well at liquidus temperature for about 10-15 minutes. So as to ensure uniform distribution of reinforcement within composite mixture and then casted into moulds. To carry out first step in compo casting i.e. melting solid cast aluminium ingots to above liquidus temperature and to maintained at semi-solid state to disperse reinforcement. Melting process is carried out in oil fired furnace temperature ranging from 600°C to 750°C. Centrifugal blower equipped with motor is used, to ensure continuous supply of air into furnace. For melting process six graphite crucibles are used. In each crucible, cast aluminium alloy as per volume % mentioned for their respective specimens are weighed and placed inside crucible for further melting process. All six crucible containing different weights of cast aluminium alloy are charged into oil fired furnace and melting of cast aluminium alloy process is progressed uniformly at temperature range of 750±10°C (slightlyabove liquidus temperature). Reason for heating slightly above liquidus temperature is to eliminate volatile impurities present in cast aluminium alloy. Once the cast aluminium alloy reaches molten state, graphite crucible containing weightofaluminiummentioned for the specimen B is taken out from the furnace and weighed B4C and SiC reinforcement as per volume % mentioned in table 2.1 for respective specimen B is then dispersed within molten metal matrix and stirred well with the help of graphite stirrer to ensure uniform distribution of reinforcement. After stirring action, crucible containing mixture of composite B is placed back in furnace for further heating and then casted into mould of desired shape. Same process is repeated for remaining samples C, D, E and F. 3. COLD UPSETTING TEST PROCEDURE Cylindrical specimens are prepared with dimension of initial height (HO) of 40mm and initial diameter (DO) of 18mm. Specimens for cold upsetting test is as shown in figure 3.1. Fig -3.1: Cold upsetting test specimen before compression Purpose of cold upsetting test is to study cold forming behavior of aluminium hybrid composite by subjecting specimen to conventional compression test at room temperature incomputerised Universal TestingMachine and setup of this test is shown in figure 3.2. Fig -3.2: Cold upsetting test setup Considered load interval for testing is from 10 KN to 70 KN. After each interval of loading dimensional changes in the specimen such as height after deformation (HF), top contact diameter (DTC), bottom contact diameter (DBC) and bulged diameter (DB) were measured by means of vernier calliper [3]. Schematic diagram of specimen with change in dimensional parameters is shown in figure 3.3. [3]. Various cold upsetted specimens’ results are shownfromtable3.1 to 3.6. Fig -3.1: Schematic diagram of specimen before and after compression Table 3.1: Cold up settled results of specimen A Load KN HF DTC DB DBC 10 39.9 17.8 17.8 17.8 20 38.7 17.8 17.8 17.8 30 38.6 17.8 17.8 17.8 40 38.4 18 18 17.8 50 37.9 18 18 17.8 60 37 18.1 18.1 18.1 70 35.3 18.6 18.6 18.3
4.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 04 Issue: 11 | Nov -2017 www.irjet.net p-ISSN: 2395-0072 © 2017, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 1250 Table 3.2: Cold upsetted results of specimen B Load KN HF DTC DB DBC 10 39.5 18 18 18 20 39.4 18 18 18 30 39.2 18 18 18 40 38.7 18.2 18 18 50 38.1 18.2 18.3 18.2 60 37 18.4 18.5 18.3 70 34.8 18.9 19.2 18.7 Table 3.3: Cold upsetted results of specimen C Load KN HF DTC DB DBC 10 39.8 18 18 18 20 39.6 18 18 18 30 39.3 18 18.1 18 40 39.1 18 18.1 18 50 38.6 18.1 18.1 18.1 60 37.4 18.3 18.4 18.1 70 35.7 18.7 18.8 18.5 Table 3.4: Cold upsetted results of specimen D Load KN HF DTC DB DBC 10 39 18 18 18 20 38.8 18.02 18 18 30 38.7 18.03 18.01 18 40 38.5 18.05 18.1 18 50 38.1 18.1 18.15 18.1 60 37.2 18.4 18.5 18.3 70 35.2 18.75 19 18.9 Table 3.5: Cold upsetted results of specimen E Load KN HF DTC DB DBC 10 39.6 18 18 18 20 39.3 18 18 18 30 39.1 18 18 18.1 40 38.8 18.1 18.1 18.2 50 38.1 18.2 18.4 18.3 60 37 18.3 18.6 18.6 70 35.2 18.7 19.3 19 Table 3.6: Cold upsetted results of specimen F Load KN HF DTC DB DBC 10 39.5 18 18 18 20 39.3 18 18 18 30 39.2 18 18 18 40 39 18.1 18.1 18 50 38.6 18.2 18.1 18 60 37.8 18.3 18.5 18.1 70 36.8 18.5 19.5 18.4 4. THEORETICAL DISCUSSIONS AND RESULTS The various stress, strain characteristics such as true axial stress, linear strain, hoop stress and hydrostatic stress were calculated using the following equations [3]. By using true axial stress, hoop and hydrostatic stress equation following table is tabulated [3]. Table 5.1: Stress strain results of specimen A Load KN σZ in MPa Linear strain σθ in MPa σm in MPa 10 40.18 0.0025 20.09 26.786 20 80.37 0.0325 40.185 53.58 30 120.55 0.035 60.275 80.366 40 159.66 0.04 109.01 125.89 50 198.68 0.0525 127.829 151.44 60 233.70 0.075 151.58 178.95 70 266.13 0.1175 194.67 218.49
5.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 04 Issue: 11 | Nov -2017 www.irjet.net p-ISSN: 2395-0072 © 2017, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 1251 Table 5.2: Stress strain results of specimen B Load KN σZ in MPa Linear strain σθ in MPa σm in MPa 10 39.297 0.0125 19.64 26.192 20 78.595 0.015 39.297 52.396 30 117.89 0.02 58.946 78.59 40 153.75 0.0325 76.87 102.498 50 192.19 0.0475 138.308 156.268 60 225.64 0.075 164.44 184.84 70 249.50 0.13 197.185 214.623 Table 5.3: Stress strain results of specimen C Load KN σZ in MPa Linear strain σθ in MPa σm in MPa 10 39.297 0.005 19.64 26.19 20 78.595 0.01 39.297 52.39 30 117.89 0.0175 83.033 94.65 40 157.19 0.0225 104.35 121.96 50 194.32 0.035 118.46 143.75 60 228.11 0.065 162.89 184.63 70 254.87 0.1075 190.52 211.97 Table 5.4: Stress strain results of specimen D Load KN σZ in MPa Linear strain σθ in MPa σm in MPa 10 39.29 0.025 19.645 26.193 20 78.42 0.03 39.21 52.28 30 117.5 0.0325 60.235 79.323 40 156.3 0.0375 94.20 114.9 50 194.32 0.0475 120.46 145.08 60 225.64 0.07 167.456 186.85 70 253.51 0.12 195.07 214.55 Table 5.5: Stress strain results of specimen E Load KN σZ in MPa Linear strain σθ in MPa σm in MPa 10 39.29 0.01 19.64 26.19 20 78.59 0.0175 39.29 52.39 30 117.89 0.0225 58.94 78.59 40 155.45 0.03 97.37 116.73 50 192.19 0.0475 149.69 163.85 60 228.117 0.075 174.49 192.36 70 254.87 0.12 210.86 225.53 Table 5.6: Stress strain results of specimen F Load KN σZ in MPa Linear strain σθ in MPa σm in MPa 10 39.29 0.0125 19.64 26.19 20 78.59 0.0175 39.295 52.39 30 117.89 0.02 58.94 78.59 40 155.45 0.025 100.91 119.09 50 192.19 0.035 117.17 142.18 60 228.117 0.055 181.49 197.034 70 260.414 0.08 256.98 258.12 5. STRESS-STRAIN CHARACTERISTICS DISCUSSION Chart -1: Variation of True Axial Stress with respect to Axial Strain Chart -2: Variation of Hoop Stress with respect to Axial Strain
6.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 04 Issue: 11 | Nov -2017 www.irjet.net p-ISSN: 2395-0072 © 2017, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 1252 Chart -3: Variation of Hydrostatic Stress with respect to Axial Strain Chart 1, 2 and 3 shows stress strain characteristics of hybrid composites having different volume % of reinforcements. From chart 1 it is observed that true axial stress decreased with additionofreinforcements. Maximum true axial stress is found in specimen A (cast aluminum alloy) i.e. 266.13 MPa at load 70 KN and minimum true axial stress is 249.50 MPa for specimen B (Hybrid composite) at load 70 KN, it can be said that axial stress can be reduced by 6.24% by adding reinforcements in equal volume%. Chart2 and 3 is the representation of true hoop stress and hydrostatic stress with respect to axial strain respectively. Maximum hoop stress is for specimen F i.e. 256.98 MPa and maximum hydrostatic stress is 258.12 MPa. It seems that hoop stress and hydrostatic stress are increased with increase in volume % of reinforcements. For 10.5% of SiC and 3.5% of B4C content i.e.specimenF exhibitsgoodresults. Linear strain of specimen F is less compared to other specimen. For specimen C result is less when compared to specimen A as due to low interface bonding between matrix and reinforcement may be a reason. Due to addition of reinforcements to matrixmaterial strengthenedthematerial in handling compressive forces [3]. 6. CONCLUSION Hybrid metal matrix composite are successfully fabricated through stir casting and its forming behavior is investigated by cold upsetting testingusinguniversal testing machine and following conclusion is obtained [3]. Maximum true axial stress obtained was for specimen A and minimum true axial stressobtained is for specimen B, it can be concludedthatstress can be reduced by addition of equal volume percent of SiC and B4C reinforcements. Maximum hoop stress and hydrostatic stress are obtained in specimen F of composition (86%Al- 3.5%B4C-10.5%SiC). Linear strain for specimen F is 0.08 which is minimum strain obtained when compared to all specimens. Specimen F exhibits less deformation at 70KN load and can handle compressive load as reinforcement strengthened material. In future, using Al2O3 and SiC as reinforcement’s to aluminum matrix cold forming behavior can be studied. REFERENCES [1] Gowri Shankar C, Jayashree K, Sharma S. Individual and Combined Effect of Reinforcements on Stir Cast Aluminum Metal Matrix Composites- A Review. International Journal of Current Engineering and Technology, Volume 03, no 3,(2013). [2] Jayashree K, Gowri Shankar C, Sharma S. Review on Effect of Silicon Carbide on stir casting metal matrix composite. International Journal ofCurrentEngineering and Technology, Volume 03, no 3,(2013). [3] Thangadurai and Asha. Synthesis and Cold Upsetting Behavior of Stir Casted AA6061-B4CP Composites. Journal of Scientific and Industrial Research,Volume73, (2014). [4] Basithrahman and Arvind. Experimental Analysis of Mechanical PropertiesofAluminumHybridMetal Matrix Composites. International Journal of Engineering Research and Technology, Volume 05,(2016). [5] Prabhat K and Pradhan. Improvement in Mechanical Property of Aluminum Alloy LM-6 Reinforcement with Silicon Carbide and Boron Carbide Particles,Volume04, no 1,(2016). [6] Rohit S, Saurabh P, Khushboo K, Kushal K, Pradeep S. A Review of the Aluminum Metal Matrix Composite and it’s Properties. International Research Journal of Engineering and Technology, Volume 04,(2017).
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