The document discusses a study on the mechanical properties of aluminium 6063-based hybrid composites reinforced with silicon carbide and graphite particles. The objectives are to study the tensile strength and hardness of the composites and correlate these properties with the amount of graphite added. Aluminium 6063 was chosen as the matrix material due to its medium strength, good toughness and corrosion resistance. Silicon carbide and graphite particles were used as reinforcements to improve hardness, wear resistance and provide self-lubrication respectively. Composites with varying graphite content were fabricated using stir casting and tested for hardness and tensile strength after heat treatment. Results showed that hardness and tensile strength increased with increasing graphite
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A metal matrix composite (MMC) is composite material with at least two constituent parts, one being a metal necessarily, the other material may be a different metal or another material, such as a ceramic or organic compound. When at least three materials are present, it is called a hybrid composite.
Metal matrix composites (MMCs) possess significantly improved properties including highspecific strength; specific modulus, damping capacity and good wear resistance compared to unreinforced alloys. There has been an increasing interest in composites containing low density and low cost reinforcements. Among various discontinuous dispersoids used, fly ash is one of the most inexpensive and low density reinforcement available in large quantities as solid waste by-product during combustion of coal in thermal power plants. Hence, composites with fly ash as reinforcement are likely to overcome the cost barrier for wide spread applications in automotive and small engine applications.
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A metal matrix composite (MMC) is composite material with at least two constituent parts, one being a metal necessarily, the other material may be a different metal or another material, such as a ceramic or organic compound. When at least three materials are present, it is called a hybrid composite.
Metal matrix composites (MMCs) possess significantly improved properties including highspecific strength; specific modulus, damping capacity and good wear resistance compared to unreinforced alloys. There has been an increasing interest in composites containing low density and low cost reinforcements. Among various discontinuous dispersoids used, fly ash is one of the most inexpensive and low density reinforcement available in large quantities as solid waste by-product during combustion of coal in thermal power plants. Hence, composites with fly ash as reinforcement are likely to overcome the cost barrier for wide spread applications in automotive and small engine applications.
Composites are made by combination of two or more natural or artificial materials to maximize their useful properties and minimize their weaknesses.
Example: The oldest and best-known composites,
Natural: Wood combination of cellulose fibre provides strength and lignin is the "glue" that bonds and stabilizes. Bamboo is a very efficient wood composite structure.
o is a very efficient wood composite structure
Artificial: The glass-fibre reinforced plastic (GRP), combines glass fiber (which are strong but brittle) with plastic (which is flexible) to make a composite material that is tough but not brittle.
70 to 90% of load carried by fibers
Provide structural properties to the composite
Stiffness
Strength
Thermal stability
Provide electrical conductivity or insulation
Example: Glass, Carbon, Organic Boron, Ceramic, Metallic
Function of Fiber/Dispersion phase
Using the scholar data and researcher point of view on composite materials. We illustrate the application of composite material in aerospace industry. Composites are highly efficient to make the parts and structure of aircrafts. We found the characteristics of the composite material make it very suitable material for aerospace industry. Composites like carbon fiber, carbon epoxy, and glass epoxy are very light and high strength which is mostly used in aircraft industries. In addition, our study takes the first step to highlight the uses of composite material to manufacture the different parts of aircraft's.
Autoclave is a closed vessel (Round or Cylindrical) in which processes occur under simultaneous application of high temperature and pressure. Autoclave molding technique is similar to vacuum bag and pressure bag molding method with some modifications. This method employs an autoclave to provide heat and pressure to the composite product during curing.
Fabrication and evaluation of mechanical properties of al6061 IJARIIT
Metal matrix composite are widely used in automotive industries because they exhibits different mechanical properties
such as high strength and good wear resistance, high specific stiffness, low weight and high hardness etc. Due to these properties
metal matrix composite with particulate reinforcement and fabricating method has become one of the most important areas of
research. The work is mainly focus on fabrication of Al 6061 reinforced with 4% B4C (particle size 100 mesh) & 4% Cu and
method used for fabrication is stir casting method. Tensile strength, hardness, impact strength, microstructure of fabricated
composite are used to characterize it. By addition of B4C & Cu tensile strength and hardness of the fabricated composite has
increased and slightly decreased in impact strength. Scanning Electron microscopy is used to confirm the microstructure and
uniform distribution of B4C & Cu particles in metal matrix composite. The value of tensile strength increase up to 20% and
hardness increase upto15% due to addition of B4C & Cu paritcles.The physical and mechanical properties of composite are
improved so it can be used for automotive industrial applications.
Composites are made by combination of two or more natural or artificial materials to maximize their useful properties and minimize their weaknesses.
Example: The oldest and best-known composites,
Natural: Wood combination of cellulose fibre provides strength and lignin is the "glue" that bonds and stabilizes. Bamboo is a very efficient wood composite structure.
o is a very efficient wood composite structure
Artificial: The glass-fibre reinforced plastic (GRP), combines glass fiber (which are strong but brittle) with plastic (which is flexible) to make a composite material that is tough but not brittle.
70 to 90% of load carried by fibers
Provide structural properties to the composite
Stiffness
Strength
Thermal stability
Provide electrical conductivity or insulation
Example: Glass, Carbon, Organic Boron, Ceramic, Metallic
Function of Fiber/Dispersion phase
Using the scholar data and researcher point of view on composite materials. We illustrate the application of composite material in aerospace industry. Composites are highly efficient to make the parts and structure of aircrafts. We found the characteristics of the composite material make it very suitable material for aerospace industry. Composites like carbon fiber, carbon epoxy, and glass epoxy are very light and high strength which is mostly used in aircraft industries. In addition, our study takes the first step to highlight the uses of composite material to manufacture the different parts of aircraft's.
Autoclave is a closed vessel (Round or Cylindrical) in which processes occur under simultaneous application of high temperature and pressure. Autoclave molding technique is similar to vacuum bag and pressure bag molding method with some modifications. This method employs an autoclave to provide heat and pressure to the composite product during curing.
Fabrication and evaluation of mechanical properties of al6061 IJARIIT
Metal matrix composite are widely used in automotive industries because they exhibits different mechanical properties
such as high strength and good wear resistance, high specific stiffness, low weight and high hardness etc. Due to these properties
metal matrix composite with particulate reinforcement and fabricating method has become one of the most important areas of
research. The work is mainly focus on fabrication of Al 6061 reinforced with 4% B4C (particle size 100 mesh) & 4% Cu and
method used for fabrication is stir casting method. Tensile strength, hardness, impact strength, microstructure of fabricated
composite are used to characterize it. By addition of B4C & Cu tensile strength and hardness of the fabricated composite has
increased and slightly decreased in impact strength. Scanning Electron microscopy is used to confirm the microstructure and
uniform distribution of B4C & Cu particles in metal matrix composite. The value of tensile strength increase up to 20% and
hardness increase upto15% due to addition of B4C & Cu paritcles.The physical and mechanical properties of composite are
improved so it can be used for automotive industrial applications.
Development of Aluminium Metal Matrix Composite Using Stir Casting Methodtheijes
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A STUDY ON MECHANICAL PROPERTIES OF ALUMINUM 6063 BASED HYBRID COMPOSITES
1. A STUDY ON MECHANICAL PROPERTIES OF ALUMINIUM
6063 BASED HYBRID COMPOSITES
SURYA PRAKASH.J 512216114086
THAMIZHARASAN.M 512216114087
VIJAY.M 512216114097
VISHNU KUMAR.E 512216114102
UNDER THE GUIDANCE OF
MR.C.NAVEENKUMAR M.E,
Asst Prof/Mechanical
DEPARTMENT OF MECHANICAL ENGINEERING
S.K.P ENGINEERING COLLEGE
TIRUVANNAMALAI
2. OBJECTIVES
• To study the tensile strength and hardness of aluminium- Silicon carbide- graphite
composites.
• Attempt to achieve good mixing of the reinforcement with the metal by stir casting
process.
• Correlating the tensile strength and hardness properties of the composite with
wrought aluminium.
• The size of the graphite particle added and its influence on the tensile strength and
hardness of the composite is new to be studied.
3. INTRODUCTION
COMPOSITE MATERIALS:
A composite can be classified as any material having two or
more distinct phases where one phase is termed as the matrix
which is continuous and surrounds the other dispersed phase.
MAJOR TYPES:
Polymer Matrix Composites (PMC’s)
Ceramic Matrix Composites (CMC’s)
Metal Matrix Composites (MMC’s)
4. LITERATURE REVIEW
S.NO
AUTHORS TITLE OF THE
PAPER
OBSERVATIONS SOURCE
1
W.B.WanNik et.al
The effect of boron
friction modifier on the
performance of brake
pads
It is possible to modify a
specific tribological property
of a brake friction material
by changing the amount of
Boron in a systematic
manner
The hardness values for
Boron mixed brake pads
were significantly higher
than the commercial brake
pad samples.
International
Journal of
Mechanical and
Materials
Engineering
(IJMME),Vol.7(20
12),No.1, 31-35
2
T.R. Chapman
et.al
Wear-resistant
aluminum–boron–
carbide cermets for
automotive brake
applications
Al–B4C cermets are more
than an order of magnitude
more wear resistant than
current materials on the
market.
Wear 236 1999.
81–87
5. S.NO AUTHORS TITLE OF THE
PAPER
OBSERVATIONS SOURCE
3
P. Ravindran
K.Manisekar
R.Narayanasamy
P.Narayanasamy
Tribological behaviour of
powder metallurgy
processed aluminium
hybrid composites with the
addition of graphite solid
lubricant.
Sliding wear
increases with load
and distance.
Increase in
Graphite content
reduces the wear.
Ceramics
International 39
(2013) 1
ELSEVIER
PUBLICATION
Available online
24 July 2012
4
A.Baradeswaran
A. Elaya Perumal
Influence of B4C on the
tribological and mechanical
properties
of Al 7075–B4C
composites
K2TiF6 IS used as a
flux to increase
wettabilty between
Aluminium and
boron carbide
Composites: Part B
54 (2013) 146–152
ELSEVIER
PUBLICATION
5
K. Rajkumar
S. Aravindan
Tribological performance
of microwave sintered
copper–TiC–graphite
hybrid composites
Microwave
sintering technique
is used other than
conventional
sintering.
Tribology
International 44
(2011) 347–358
ELSEVIER
PUBLICATION
6. SLIDING CONTACT IN AUTOMOTIVES
Sliding wear is a common form of wear experienced by various
automotive components (Brakes,Rotor drum,cylinder blocks,
pistons, piston insert rings, etc.) and brake pads that are
fabricated from Al-MMCs.
Sliding or adhesive wear is defined as the transfer of material
from one surface to another during the relative motion of
contacting surfaces.
7. Brakes Rotor drum
• The functioning of sliding contact is affected by friction and wear
• The sliding motion induces the wear of the contact surfaces leading to
formation and contamination on contact surfaces and finally it will
premature failure and break.
• It is desirable for a material to be used in the sliding contact system to
have a combination of properties
8. PROPERTIES REQUIRED
• Wear resistance,
• High hardness
• Good thermal conductivity
• High melting and evaporation temperatures
• Low contact resistance
• Good electrical conductivity
• Self lubricating
These properties requires unique materials which are not satisfied by
pure metal or their alloys
9. METAL-MATRIX COMPOSITES (MMCs)
The most commonly used commercial MMCs are based on aluminium,
magnesium, and titanium alloys reinforced with either silicon carbide
(SiC), alumina (Al2O3) and graphite.
Advantage of MMC
Increased resistance to stress-limited high cycle fatigue,
Increased high temperature resistance
Better thermal conductivity
Better dry lubrication (with graphite reinforcement),
Lower density (depending on density of reinforcement).
10. ALUMINIUM-SILICON CARBIDE-
GRAPHITE
• Matrix-Aluminium having medium strength.good toughness
and surface finish.
• Particle reinforcement-Silicon Carbide having extreme hardness
,wear resistance and temperature resistance.
• Particle reinforcement-Graphite is self lubricating, low thermal
expansion.
13. PROPERTIES OF Al 6063
From material science and engineering handbook CRC
Aluminium
6063
Tensile strength
(MPa)
Hardness
Brinell
Fatigue
strength
(MPa)
Yield strength
(MPa)
Elongation
T6 241 73 68.9 214 12%
14. Composition of Aluminium 6063
Alumini
um
Al Si Cu Mn Mg Cr Zn others
6063 97 0.9 0.6 0.28 - 1.0 0.2 -
15. SILICON CARBIDE
• Silicon Carbide is one of the hardest materials known. It is the hardest
material produced in tonnage quantities.
Key Properties
• Extreme hardness
• Difficult to sinter to high relative densities without the use of sintering aids
• Good chemical resistance
• Good nuclear properties
• Low density
16. Properties of Silicon carbide
Molar mass : 40.096 g/mol
Density : 3.16 g/cm
Melting point : 2830 ̇c
Refractive index : 2.55
Solubility : Insoluble in water
Appearance : Iridescent crystals
Electron mobility : 900 cm²/v-s
Flexural strength : 550 Mpa
Poission’s Ratio : 0.14
Compressive strength : 3900 Mpa
17. Particle reinforcement-Graphite
Key properties
• self lubricating,
• low thermal expansion
• Specific gravity is 2.2
• Cleavage is perfect in one direction.
• Density: 2.09-2.23 g/cm3
• crystal system: Hexagonal
• Mohs Scale Hardness: 1.5-2
• Graphite melts at 3,927°C.
Composition of graphite powder
23. PREPARATION
• Silicon Carbide particles of 25 µm size were used in this study
• Graphite particles of below 30µm size were used in this study.
• Two step stir casting method was used to fabricate the Al-SiC-Graphite.
• Aluminium alloy was melted up to 700 ̊C. Varying volume % of
reinforcement (SiC and graphite) was added with this molten Al-6063alloy.
• It is allowed to cool to solidus temperature and stirred at 120 rpm using
steel impeller.
• In this way 100% of the SiC particles were transferred to the metal.
Simultaneously, graphite was added with Al-SiC. The same amount of k2TiF6
the wetting agent is added for to increase the bond between the matrix and
reinforced materials.K2TIF6 is added
• Then stirred composite material is transferred to metal mould. Composites
were cast into a cylindrical rod in required diameter and length. (15mm dia
x150mm length)
29. HEAT TREATMENT
• 1500W muffle furnace was used to heat treat the Al 6063-SiC-Graphite.
• In order to obtain T6 property of Al-6063 alloy, solution heat treatment was
carried out over the material and it was heated up-to 520oC in muffle
furnace.
• After reaching required temperature, the composite material was
maintained for definite holding time at 520oC for 10 Hours.
• All samples were heated using the same procedure
37. CONCLUSION
• When the graphite percentage is increased the tensile strength is
increased.
• When adding constant 5% of Silicon carbide the hardness is
increased.
38. SCOPE
• The popular use of Aluminium and its alloys in the automobiles
and aerospace industries gives a clear indication of the desirable
properties possessed by these materials.
• But the technology has progressed there has been a need to
fabricate materials with these properties enhanced.
• The area of advanced materials has made open to us limitless
avenues of achieving these desired characteristics in materials.
Thus to achieve specific properties we can choose from an array
of composites materials, each tailor made to satisfy specific
needs.
• The work that is planed aims to fabricate a material that has
enhanced properties of the popular Aluminium 6063 as well as
the Aluminium-Silicon Carbide-graphite MMC.
39. References
1.S Weinert, K (1993). “A consideration of tool wear mechanism when
machining metal matrix composites (MMC),”CIRP Ann, 42: 95-98.
2.K. Reinmuth, A. Lipp, H. Knoch, K.A. Schwetz, Boron carbide as neutron
absorbent, Journal of Nuclear Materials 124 (1984) 175–184.
3.C. Wood, High-temperature thermoelectric energy converions—II
Materials Survey, Energy Conversion and Management 24 (1984) 331–343.
4.H. Werheit, Boron rich solids—a chance for high-efficiency
hightemperature thermoelectric energy conversion, Materials Science and
Engineering B 29 (1995) 228–232.
5.P.G. Karandikar, G. Evans, S. Song, M.K. Aghajanian, M. Sennett, A review of
ceramics for armor applications, advanced ceramics, in: L.P.
6.Franks (Ed.), Armor IV—Ceramic Engineering and Science Proceedings,
vol.29, John Wiley and Sons, Inc, Hoboken, NJ, 2009 in.
7.A.R. Kennedy, “The microstructure and mechanical properties of Al-Si-B4C
metal matrix composites”, Journal of materials Science 37 (2002) 317-323.
8.K. Rajkumar,S.Aravindan “Tribological performance of microwave
sinteredcopper–TiC–graphite hybrid composites”, Tribology International
44 (2011) 347–358.
40. 9. Kestursatya M, Kim JK, Rohatgi PK. Wear performance of copper–
graphite composite and a leaded copper alloy. Mater Sci Eng A
2003;339:150–8.
10. D.F.Hasson , S.M.Hoover, C.R.Crowe , “Effect of thermal treatment on
mechanical and toughness properties of extrude SiCw/Al 6061 metal matrix
composite” , Journal of material science (20) 1985 , 4147 – 4154
11.H.Fujji, M.Maeda , K.Nogi “Tensile properties and fracture locations of
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science letters , 22,2003 , [1061-1063]
12.J. Hashim , L Looney , M.S.J .Hashmi “Metal matrix composites:
production by the stir casting method “ , Journal of material processing
science , Volume 92-93 , 30 August 1999, 1 – 7
13.I.A.Ibrahim ,F.A.Mohammed , E.J.Lavernia ,”Particulate reinforce metal
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