Making a new metal for Aerospace applications which is made of many components .Major metals are Aluminium and Magnesium.Checking its structures and properties .

1. Devineni Venkata Ramana & Dr.Hima Sekhar
MIC College of Technology
(Approved by AICTE & Permanently Affiliated to JNTUK, Kakinada)
Structure property correlation of Modified Al-Mg alloys for
Aerospace Applications
Presented by
Sd. Naveed Ahamad (16H71A0376)
Ch. Pavan kumar (17H75A0353)
Ch. Siva Naga Raju (17H75A0342)
Y. Yeswanth (16H71A03A5)
Sk. Jaseem (16H71A0313)
Batch- 16
Under the Guidance of
Mr. P.Bhagat Singh

2. CONTENTS
ABSTRACT
INTRODUCTION
OBJECTIVES
MATERIALS USED
COMPOSITION STRUCTURE
WORKING METHODOLOGY
CASTING
TESTINGS
CONCLUSION
FUTURE SCOPE OF WORK
REFERENCES

3. ABSTARCT
Light weight and high strength is the eternal theme of material
development. Today with the rapid development of science and
technology, the application of light weight high strength materials is
widespread to all aspects like automobile, marine, aerospace fields.
Aluminium alloys are found to be best alternative because of their
characteristics properties like high strength, high stiffness, more
thermal stability, more corrosion and wear resistance. An attempt has
been made to fabricate an aluminium alloy by adding metals like
magnesium, copper, zinc, tin to aluminium.
The project deals with the fabrication of aluminium based alloy
and then finding out the Mechanical properties of the alloy such as
strength, hardness etc. 99% Pure aluminium, magnesium, copper, zinc,
tin were used. Stir casting technique has been employed to fabricate the
alloy

4. INTRODUCTION
In recent years, a great effort has been devoted to
developing a new generation of materials for aeronautic
applications. The driving force behind this effort is the
reduction of costs, by extending the service life of aircraft
parts (structural and engine components) and increasing fuel
efficiency, load capacity and flight range.
The present papers examines the most important classes
of metallic materials includes Al alloys, Ti alloys, Mg alloys,
steels, Ni super alloys with the scope to provide an overview
of recent advancements and to highlight current problems and
perspectives related to metals for aeronautics.

5. OBJECTIVES
 Light weight & high strength is the eternal theme of
material development. Today with the rapid
development of science and technology, the application
of light weight high strength materials is widespread to
all aspects like Automobile, Marine, Aerospace fields.
 Aluminium alloys are found to be best alternative
because of high strength, high stiffness, more thermal
stability, more corrosion and wear resistance.
 The project deals with the fabrication of aluminium
based alloy and then evaluated the tribological
properties.
 To achieve this objective stir casting technique has
been employed and the component obtained from this
casting process is then machined and cut into a number
of small parts.

6. In this we will make an alloy of Al+Mg+Zn+Sn+Cu with
different compositions .This work will explore the
microstructure of alloy ,its tensile and hardness properties.
Alloy

7. MATERIALS USED

9. Mg
(4%)
AL
(92%)
Zn
(3%)
Cu
(3%)
Sn
(3%)
AL
(87%)

10. WORKING METHODOLOGY

11. STIR CASTING
Stir casting is a liquid state
method for the fabrication of
composite materials in which a
dispersed phase is mixed with a
molten matrix metal by means of
mechanical stirring.
Stir casting is the simplest and
most cost effective method of
liquid state fabrication.

12. SPECIFICATIONS OF STIR CAST
SETUP

13. AS CAST BILLET
Casting has been done in
cylindrical shape by using Stir
casting.After the casting, the
specimen is cut into number of
small parts using hacksaw blade .

14. FINISHING AND PREPARING THE
SPECIMEN:
• Surface finishing is done by series of process like filing,
surface finishing by using emery paper and then polishing.

15. MICRO STRUCTURE
The average grain size of the alloy is measured to be 25μm. The grain refinement
during the solidification process is anticipated to provide strengthening effect to
the alloy during the various testing methods. The grain size refinement is due to
the evolution of various intermetallic compounds which are generally present in
the Al-Mg alloys. The intermetallic compounds such as Mg17Al12, Al2Cu, Mg2Sn
and Al2Zn. The intermetallic compounds act as a nucleating sites during the
solidification process. Thus, it resulted in the grain refinement process.

16. TGA (Thermo Gravimetric Analysis)
-0.00 200.00 400.00 600.00 800.00 1000.00
Temp [C]
6.00
8.00
10.00
12.00
14.00
mg
TGA
341.13x100COnset
201.81x100CEndset
3.492x100
mg
44.473x100
%
Weight Loss
609.72x100CMid Point
2020-03-07 A060320-TGA.tad TGA
The curve clearly indicate the constant rate till it reaches 500oC. After that
temperature the curve slowly starts to raise towards the oxidation state. It
indicates various alloying additions present in the microstructure decreases
the melting point of the alloy. Moreover, some of the melting of the
intermetallic compounds such as Mg17Al12 possess lower melting point
(432oC) and tends to reduce the melting of the alloy.

17. -0.00 200.00 400.00 600.00 800.00 1000.00
Temp [C]
-300.00
-200.00
-100.00
0.00
uV
DTA
549.36x100
COnset
597.24x100
CEndset
566.21x100
CPeak
-4.05x100
J
-516.19x100
J/g
Heat
808.61x100COnset
841.94x100CEndset
815.22x100
CPeak
-98.31x100J
-12.52x100kJ/g
Heat
2020-03-07 A060320-TGA.tad DTA
DTA (Differential Thermal Analysis)
As we can clearly see in the curves, that there is a dip at 566oC. It further
confirms the melting point of the alloy has been reduced. Moreover, the
melting point of the Sn and Zn are relatively lower. 220oC and 420oC,
respectively. It would deteriorate the melting point of the pure Al which is
660oC.

18. TENSILE TEST:
S.NO YIELD STRENGTH
(MPa)
UTS
(MPa)
ELONGATION
(%)
1. 120 155 10

19. HARDNESS TEST
BHN = Load on the ball/Indentation
area.
Load on ball P =500Kg f
Diamter of impression = 2.5mm
Brinel Hardness Number =100.2419

20. CONCLUSION
The modified Al-Mg alloy as-cast billets were subjected to various mechanical
tests. From the obtained results, the following conclusions are derived.
• Stir casting technic has been selected for making an metal having Al-Mg-
Cu-Zn-Sn in different percentages. From the cast billet , the specimens
prepared by disc-polishing and Emery papers.
• TGA and DTA tests are employed by changing the temperatures on the
specimens. By increasing the temperature on specimen the mass of the
specimen gets decreased as show in graphs.
• The Ultimate Tensile Strength(UTS) of 155 MPa and Yield Strength (YS)
of 120 MPa is achieved by elongation 10% in the specimen.
• The microstructure has taken with the simple micrometer at the range of
100X lens.
• The hardness of the specimen(Al-Mg-Cu-Zn-Sn) is test with the help of
brinell hardness machine and the
• Brinell Hardness Number(BHN)=100.24 at the load of 500 Kg f.

21. FUTURE SCOPE OF WORK
This research can be further extended to various
characterization techniques such as SEM, XRD techniques.
These studies may bring out the clear mechanism for grain
refinement which led to the enhanced mechanical properties.
Further, the wear behaviour of Al-Mg-Cu-Zn-Sn alloy can be
evaluated at the room and elevated temperature for the
tribological applications. The heat treatment of Al-Mg-Cu-Zn-
Sn alloy can be evaluated by identifying the evolution of
various intermetallic compounds through XRD and SEM-
EDS.

22. REFERENCE
1. Y. Wang et al. [2018] reported that adding Cu caused the
formation of MgZnCu phase with a face-center cubic
structure. Appropriate Cu addition could refine the
precipitates and increase the number of density of
precipitate of as-extruded alloys,which results in the
refinement of grains and weakening of texture intensity.
2. C. Meng et al.[2014] reported that the effects of Zn
addition of the intergranular corrosion behavior of high
strength Al–Mg alloy and its relationship to microstructure
evolution are systematically investigated in the present study.
results indicate that the addition of Zn increases the strength
and corrosion resistance of Al–Mg alloy

23. REFERENCE
3. B. Wang et al.[2017] reported that the addition of Sn has a
significant influence on the amount and the type of intermetallic
for phases in as-cast Mg-Zn-Al alloy.The addition of Sn results in
the refined recrystallized grains and the weakened basal texture in
as-extruded alloys. The grains get refined with the increase of Sn
addition in as-cast Mg-Zn-Al-Sn alloys.

24. THANK