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2021ume1435.pptx composite material matrix
- 1. MET- 427 Assignment –1 Presented By: Pankaj Barupal (2021UME1435) Presented to : Dr. Mukesh kumar Assistant professor Aluminium cast alloy and Alumina 1 Department of Mechanical Engineering Malaviya National Institute of Technology, Jaipur
- 2. Content Introduction Aluminiumcast alloy Alumina 2
- 3. INTRODUCTION 3 What are CompositeMaterials? •Composites are materials made by combining two or more distinct phases (matrix + reinforcement) to achieve enhanced properties. •They offer superior strength, stiffness, and lightweight characteristics compared to conventional materials. Matrix and Reinforcement •Matrix: The continuous phase that holds the reinforcement together and transfers the load. •Reinforcement: The dispersed phase that enhances mechanical properties like strength and wear resistance.
- 4. ALUMINIUM CAST ALLOY 4 Analuminum cast alloy is an aluminum-based alloy designed for casting, where molten metal is poured into a mold to create a specific shape. These alloys typically contain elements like silicon (Si), copper (Cu), magnesium (Mg), and zinc (Zn) to enhance mechanical properties, corrosion resistance, and castability. Al CAST ALLOY DESIGNATION
- 5. 5 CASTING METHODS A. SandCasting • Molten aluminum is poured into sand molds. • Suitable for large and complex parts like engine blocks. • Lower production speed but cost-effective for low-volume production. B. Investment Casting (Lost Wax Casting) • Produces intricate and high-precision parts. • Used in aerospace and high-performance applications. C. Permanent Mold Casting (Gravity Die Casting) • Uses reusable steel molds. • Produces stronger and denser castings compared to sand casting.
- 6. 6 Property Al-Si (A356,319) Al-Cu (206, 213) Al-Mg (535, 518) Al-Zn (ZA-27, 7075) Density (g/cm³) 2.65 – 2.75 2.75 – 2.85 2.64 – 2.68 2.75 – 2.80 Tensile Strength (MPa) 200 – 320 250 – 450 150 – 300 300 – 500 Yield Strength (MPa) 100 – 180 120 – 320 90 – 220 250 – 400 Elongation (%) 3 – 12 1 – 5 5 – 20 1 – 8 Hardness (Brinell, HBW) 50 – 100 80 – 120 45 – 80 90 – 150 Thermal Conductivity (W/m·K) 100 – 160 120 – 180 80 – 140 100 – 150 Corrosion Resistance High Low Excellent Moderate Castability Excellent (good fluidity) Moderate (prone to shrinkage) Good (low porosity) Moderate (risk of hot cracking) Machinability Good Poor to Moderate Good Moderate Heat Treatability Yes (T6 for strength) Yes (T4, T6 for strength) Limited Yes (T6 for strength) PROPERTIES OF AL CAST ALLOYS
- 7. 7 Comparison of microstructuresof A356 alloy that were prepared by different processes A356 alloy was prepared using a vibrating slope and squeeze casting, which refined grain size and reduced eutectic phase segregation, improving tensile strength and elongation by 12% and 21%, respectively
- 8. 8 Advantages: • Lightweight • GoodCastability • High Corrosion Resistance • Good Thermal Conductivity • Cost-Effective • Recyclability Disadvantages: • Lower Strength Compared to Other Metal • Brittleness in Cast Form • Limited High-Temperature Resistance • Poor Wear Resistance • Susceptibility to Fatigue Failure • Difficulty in Bonding with Certain Reinforcements
- 9. 9 APPLICATIONS 1. Automotive Industry •Engine blocks, cylinder heads, transmission housings, and wheels. • Aluminum casting provides lightweight, high strength, and corrosion resistance. 2. Aerospace Industry • Used in aircraft structural components, landing gear parts, and turbine blades. • Aluminum cast alloys provide high strength-to-weight ratio and fatigue resistance. 3. Marine Applications • Used in ship hull coatings, propellers, and pumps. • Aluminum cast alloys offer excellent corrosion resistance in marine environments. Aluminum Cast Engine Block Aerospace Aluminum Casting Marine propeller
- 10. 4. Industrial Equipment •Used in pumps, valves, machinery housings, and gearboxes. • Aluminum cast alloys provide durability, heat resistance, and precision casting. 5. Consumer Electronics & Appliances • Used in laptop casings, smartphone frames, and kitchen appliances. • Aluminum casting allows for lightweight, durable, and heat-dissipating components. Aluminum laptop frame Aluminum Cast Machinery Parts
- 11. ALUMINA 11 Alumina is thecommon name given to aluminum oxide (Al2O3). Alumina is produced from bauxite, an ore that is mined from topsoil in various tropical and subtropical regions. The Bayer process, discovered in 1887, is the primary process by which alumina is extracted from bauxite
- 12. 12 TYPES OF ALUMINA TypeDescription Applications α-Alumina (Corundum) Most stable, hard, and crystalline form Abrasives, ceramics, refractory materials γ-Alumina (Gamma Alumina) Porous, high surface area, metastable Catalysts, adsorbents, filtration θ-Alumina (Theta Alumina) Intermediate phase, transitions to α-alumina at high temperatures Catalyst support, coatings δ-Alumina (Delta Alumina) Transitional phase with moderate surface area Catalyst support, ceramics η-Alumina (Eta Alumina) Highly porous, unstable at high temperatures Catalyst applications, adsorbents χ-Alumina (Chi Alumina) Another transitional phase, transforms to γ-alumina Catalysts, surface coatings ρ-Alumina (Rho Alumina) Highly porous and water- absorbent Drying agents, adsorbents Tabular Alumina Large, sintered, and dense grains of α-alumina High-performance refractories, ceramics Fused Alumina Produced by melting alumina at high temperatures Abrasives, cutting tools Activated Alumina High porosity, used for adsorption Desiccants, water purification
- 13. 13 • It isthe prinicipal process of refining Bauxite to produce alumina • Bauxite is the most important ore of Aluminium • It contains 40-60% of Al2O3 • Rest being the mixture of Silica , Iron Oxide and other oxides ALUMINA MANUFACTURING METHOD BAYER PROCESS:
- 14. 14 PROPERTIES OF ALUMINA PropertyValue Chemical Formula Al₂O₃ Appearance White, odorless solid Density 3.95–4.1 g/cm³ Melting Point ~2,072°C (3,762°F) Boiling Point ~2,977°C (5,391°F) Hardness (Mohs) 9 (very hard) Thermal Conductivity 30 W/m·K at 25°C Electrical Resistivity ~10¹² Ω·cm at 20°C Dielectric Strength 8–10 MV/m Refractive Index 1.76–1.77 Crystal Structure Trigonal (Corundum) Solubility Insoluble in water, soluble in acids & alkalis Specific Heat Capacity ~0.88 J/g·K at 25°C Thermal Expansion Coefficient ~7.5 × 10⁻⁶ /K at 25°C • High Thermal conductivity • Wear and Corrosion resistant • High Strength and Stiffness (300 to 630 Mpa) • Chemical and Thermal stability • Very good Electrical resistivity • Very high compression Strength (2000 to 4000 Mpa) • High Hardness (15 to 19 GPa) • Resists Strong Acid & Alkali at elevated temperatures • Low Density (3.75 to 3.95 g/cm3 )
- 15. 15 Advantages • High Hardness& Wear Resistance • High Strength & Stiffness • Good Thermal Stability • Chemical Inertness • Low Density • Electrical Insulation • Cost-Effective Disadvantages • Brittleness • Poor Ductility • Weak Interfacial Bonding • Difficult Machinability • Thermal Expansion Mismatch • Lower Toughness Compared to Other Reinforcements
- 16. 16 APPLICATION Filler It is usedas a filler for plastics and also a common ingradient in cosmetics such as Lipstick & Nailpolish Catalysis Alumina is the Catalyst in the Claus process for converting hydrogen sulphide waste gases in to elemental sulphur in refineries. It is also useful for dehydration of alcohols to alkenes Purification Alumina is widely used to remove water from gas streams
- 17. 17 Abrasive Many types ofSand paper use Alumina crystal. Its low Specific heat make it widely used in grinding operations Paint It is used in paints for reflective decorative effects such as in the automotive or cosmetic industries Composite fiber Aluminium oxide has been used in a few experimental and commercial fiber materials for high-performance appliications • Transparent aluminium oxide is used in some sodium vapor lamps • Aluminium oxide is also used in preparation of coating suspensions in compact fluorescent lamps
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Editor's Notes
- #3 Thermal spraying is a line-of-sight process, wherein feedstock material, in the form of powder, wire, rod, or suspension, is fed into a spray torch and heated up to a molten or near-molten state and propelled toward a base material illustrates the flexibility offered by TS in terms of the wide spectrum of flame temperature–particle velocities available. Plasma spray (atmospheric and vacuum), high-velocity arc spray, HVOF, warm spray, and cold spray have been employed to syn thesize thermal sprayed HEA coatings. Figure 1 (Ref 4) illustrates the spread of particle size, temperature, and velocity offered by TS processes. Using this scheme, an appropriate processing window can be identified based on the nature of the feedstock material (metallic/ceramic) and the desired coating microstructure, such as density and phase content. For example, for cera mic coatings with a predetermined porosity requirement, such as hydroxyapatite coatings for orthopedic applica tions, APS would be preferred. However, for depositing dense metal coatings, such as coating aluminum alloys onmagnesium parts for corrosion protection, cold spray would be the preferred method.
- #4 Thermal spraying is a line-of-sight process, wherein feedstock material, in the form of powder, wire, rod, or suspension, is fed into a spray torch and heated up to a molten or near-molten state and propelled toward a base material illustrates the flexibility offered by TS in terms of the wide spectrum of flame temperature–particle velocities available. Plasma spray (atmospheric and vacuum), high-velocity arc spray, HVOF, warm spray, and cold spray have been employed to syn thesize thermal sprayed HEA coatings. Figure 1 (Ref 4) illustrates the spread of particle size, temperature, and velocity offered by TS processes. Using this scheme, an appropriate processing window can be identified based on the nature of the feedstock material (metallic/ceramic) and the desired coating microstructure, such as density and phase content. For example, for cera mic coatings with a predetermined porosity requirement, such as hydroxyapatite coatings for orthopedic applica tions, APS would be preferred. However, for depositing dense metal coatings, such as coating aluminum alloys onmagnesium parts for corrosion protection, cold spray would be the preferred method.
- #11 Thermal spraying is a line-of-sight process, wherein feedstock material, in the form of powder, wire, rod, or suspension, is fed into a spray torch and heated up to a molten or near-molten state and propelled toward a base material illustrates the flexibility offered by TS in terms of the wide spectrum of flame temperature–particle velocities available. Plasma spray (atmospheric and vacuum), high-velocity arc spray, HVOF, warm spray, and cold spray have been employed to syn thesize thermal sprayed HEA coatings. Figure 1 (Ref 4) illustrates the spread of particle size, temperature, and velocity offered by TS processes. Using this scheme, an appropriate processing window can be identified based on the nature of the feedstock material (metallic/ceramic) and the desired coating microstructure, such as density and phase content. For example, for cera mic coatings with a predetermined porosity requirement, such as hydroxyapatite coatings for orthopedic applica tions, APS would be preferred. However, for depositing dense metal coatings, such as coating aluminum alloys onmagnesium parts for corrosion protection, cold spray would be the preferred method.