PPT

1. Presented by:-
VIRENDRA KUMAR SHARMA
M.Tech (ME)
Roll. No.- 139511
KNIT, SULTANPUR
A
Dissertation
ON
CASTING AND CHARACTERIZATION OF
AL ALLOY BASED HYBRID MMC
Guided By :-
Mr. ANIL KUMAR
( Assistant Professor )
Deptt. Of Mechanical Engg.
KNIT, SULTANPUR

2. OVERVIEW OF SEMINAR
 Composite material
 Phases of composite material
 Classification of composite
 Why composites are important
 Objective of composite material
 Disadvantages and limitation
 Selection ofAlAlloy
 Selection of Reinforcing Materials
 Different Casting Process
 Characterization for MMC
 Literature Review
 Outcomes of the Literature Review
 A vision for the future
 References

3. 
A materials system composed of two or more
physically distinct phases whose combination produces
aggregate properties that are different from those of
its constituents .
•Examples:
 Cemented carbides
 Plastic molding compounds containing fillers
 Rubber mixed with carbon black
 Wood (a natural composite as distinguished from a
synthesized composite)
Composite Material Defined

4. A composite material consists of two
phases
Primary
• Forms the matrix within which the secondary phase is imbedded
• Any of three basic material types: polymers, metals, or
ceramics
Secondary
• Referred to as the imbedded phase or called the reinforcing agent
• Serves to strengthen the composite. (fibers, particles, flake etc.)

5. CLASSIFICATION OF METAL MATRIX COMPOSITES
COMPOSITE WITH METAL PHASE
INFILTRATION
COMPOSITE FIBRE COMPOSITE
DISPERSION
HARDENDAND
PARTICLE COMPOSITE

6. Classification

7. Why Composites are Important
 Composites can be very strong and stiff, yet very light in weight,
so ratios of strength to weight and stiffness-to weight are several
‑ ‑ ‑
times greater than steel or aluminum
 Fatigue properties are generally better than for common
engineering metals
 Toughness is often greater too
 Composites can be designed that do not corrode like steel
 Possible to achieve combinations of properties not attainable
with metals, ceramics, or polymers alone

8. OBJECTIVE OF COMPOSITE MATERIAL
 Increase in yield strength and tensile strength at room temperature and above while
maintaining the minimum ductility or rather toughness,
 Increase in creep resistance at higher temperatures compared to that of conventional
alloys,
 Increase in fatigue strength, especially at higher temperatures,
 Improvement of thermal shock resistance,
 Improvement of corrosion resistance,
 Increase inYoung’s modulus,
 Reduction of thermal elongation.
 Low Weight Considerations
 High Strength Considerations
 High Impact Resistance
 High Stiffness Considerations
 Low Cost Considerations
 Toughness is often greater too
 Composites can be designed that do not corrode like steel

9. DISADVANTAGES AND LIMITATIONS OF COMPOSITE
MATERIALS
Properties of many important composites are anisotropic the
‑
properties differ depending on the direction in which they are
measured – this may be an advantage or a disadvantage
Composite materials are generally expensive
Manufacturing methods for shaping composite materials are
often slow and costly

10. DESIRABLE PROPERTIES OF ALUMINIUM ALLOY
 Castability
 Machinability
 Finishing
 Weldability
 Corrosion Resistance
 Higher strength
 Lower coefficients of thermal expansion
 Better fatigue resistance
 Chemical compatibility

11. DESIRABLE PROPERTIES OF REINFORCING MATERIAL
 Low density,
 Mechanical compatibility (a thermal expansion coefficient
which is low but adapted to the matrix),
 Chemical compatibility,
 Thermal stability,
 HighYoung’s modulus,
 High compression and tensile strength,
 Good process ability,
 Economic efficiency.

12. PRODUCTION OF METAL MATRIX COMPOSITES
Metal Matrix Composite materials can be produced by many different
techniques. Such as
 Melting metallurgical processes (Liquid state methods)
Infiltration of short fiber, particle or hybrid performs by squeeze casting, vacuum
infiltration or pressure infiltration
Processing of precursor material by stirring the particles in metallic melts, followed
by sand casting, permanent mold casting or high pressure die casting
 Powder metallurgical processes (Solid state methods)
Pressing and sintering and/or forging of powder mixtures and composite
powders
Extrusion or forging of metal-powder particle mixtures
 Physical vapor deposition: (Vapor Deposition)
The fiber is passed through a thick cloud of vaporized metal, coating it.

13. DIFFERENT CASTING PROCESS USED FOR COMPOSITE
There are several CastingTechniques available for casting of
MMC Such as:
 Stir CastingTechnique
 Centrifugal castingTechnique
 Squeeze Casing Method
 Continuous Casting method (For wires)
 Sand Casting
 Gravitation Die casting
 Investment casing process
 High Pressure Die Casting

14. DIFFERENT CHARACTERIZATION FOR MMC
 Solidification Characterization ( Cooling environment)
 Microstructure Characterization (Optical, SEM ,TEM, )
 Differential HeatTransfer rate
 Thermo-Physical properties
Density, Coefficient of thermal expansion (CTE), Specific heat (Cp) and
thermal conductivity
 Wear characterization
 XRD and EDS
 Hardness Measurement
 TensileTesting
 CompressionTest
 Young’s Modulus
 Fractography
 Electrochemical Behavior (Corrosion)

15. LITERATURE REVIEW
S.N. Topic Auther’s Year
1 Evaluation Of Mechanical Properties Of AluminiumAlloy2024
ReinforcedWith Silicon CarbideAnd FlyAsh Hybrid Metal
Matrix Composites
Mahendra
Boopathi, M.,
K.P.Arulshri and
N. Iyandurai ,
2013
2 Mechanical Properties Of FlyAsh Reinforced Aluminium Alloy
(Al6061) Composites
.C.Anilkumar ,
H.S. Hebbar and
K.S. Ravishankar
2011
3 Thermo physical property measurement of metal-matrix
composites
B. Karthikeyan 2010
4 Microstructural characteristics and properties in centrifugal casting
of SiCp/Zl104 composite
WANG Kai et al 2009
5 Studies on Al6061-SiC andAl7075-Al2O3 Metal Matrix
Composites
G. B.Veeresh
Kumar, C. S. P.
Rao, N. Selvaraj
2010
6 Microstructure, tensile properties and electrochemical behavior of
Pb alloy–45 vol.% fly ash microballoon composites
A. Daouda 2009

16. OUTCOMES OF THE LITERATURE REVIEW
 Most of the Authors has done research on Aluminum Metal Matrix
Composite in which reinforcing Material are: SiC fibre, SiCp Particulate
TiC,WC,Alumina,Aluminum Borate , FlyAsh etc.
 But No one has done all the characterization on Al based hybrid
composite.
 Some of the authors used Fly ash as reinforcing material to decrease the
cost as well as weight.
 Some of theAuthors has done research on Mg-alloy and Cu-alloy based
composite

17. COMPOSITES: A VISION FOR THE FUTURE
 Transportation sector:-
 Automobiles- clutch plates, brakes, wheel, spring etc.
 Aerospace manufacturing.
 Marine- fans & blowers, propellers vanes, condenser shells etc.
 Bicycles- forks, handle bars, seat posts etc.
 Chemical Industry- underground storage tanks, racked bottle for
fire service etc.
 Electrical & Electronic- power line insulators, lighting poles,
switchgear frames etc.

18. COMPOSITES: A VISION FOR THE FUTURE
 Sports Goods- golf & polo rods, hand glinders, protective sports
wear etc.
 Future Business Opportunites- short & long term R & D,
application development, fabrication & testing support, quality
improvement etc.

19. References
 Material science & engg.an introduction william D.callister,jr.David G.Rethwisch
 Engg.Composite materials Bryan Harris the institute of materials,london 1999
 Fiber Composites,3rd edition,Wiley,Hoboken,
 TIFAC 2009 deptt. Of science & tech. Gov. of India
 Ashbee, K. H., Fundamental Principles of Fiber Reinforced
 Composites,2nd edition,CRC Press,
 Boca Raton, FL, 1993.
 ASM Handbook,Vol.21,Composites,ASM International,
 Materials Park, OH, 2001.
 Chawla, K. K., Composite Materials Science and
 Engineering,3rd edition,Springer,NewYork,
 2009.
 Gerdeen, J.C., H.W. Lord, and R.A. L. Rorrer, Engineering
 Design with Polymers and Composites,

20. References
 METAL-MATRIX COMPOSITES K.K. CHAWLA ,University of
Alabama at Birmingham and N. CHAWLAArizona State University
 Hull, D. and T.W. Clyne, An Introduction to Composite
 Materials, 2nd edition, Cambridge University
 Press, New York, 1996.
 Mallick, P. K., Composites Engineering Handbook,
 CRC Press, Boca Raton, FL, 1997.
 Mallick, P. K., Fiber-Reinforced Composites, Materials,
 Manufacturing, and Design, 3rd edition.
 Strong, A. B., Fundamentals of Composites: Materials,
 Methods, and Applications, 2nd edition,
 Society of Manufacturing Engineers, Dearborn, etc.

21. THANK YOU