This document summarizes a project to fabricate metal-matrix composites using stir casting. The project aims to produce aluminum-silicon carbide (AlSiC) composites through stir casting to create strong, lightweight materials for use in industries like automotive and aerospace. Experiments are conducted by varying the composition of silicon carbide added to molten aluminum from 5-30% and stirring to ensure homogeneous mixing. The composites are then tested for properties like hardness and impact strength. The goal is to develop low-cost metal-matrix composite materials for industrial applications requiring high strength, stiffness, and other properties.

1. Fabrication Of Metal-Matrix
Composites Using Stir Casting Method
Presented By:-
1. Harisagar Gupta ( 15UME024 )
2. Amarjeet Kumar ( 15UME004 )
3. Abhishek Kumar Singh ( 15UME009 )
Guided By:
Sir Dr. Anil Kr. Birru
HOD & Professor-In-Charge,
Mechanical Engineering Department
PROJECT WORK-I

2. CONTENTS
1. ABSTRACT
2. INTRODUCTION
3. OBJECTIVES
4. COMPOSITE MATERIALS
5. METAL MATRIX COMPOSITES
6. STIR CASTING
7. APPARATUS SETUP
8. EXPERIMENTATION
9. RESULTS
10. APPLICATIONS
11. A BRIEF LOOK OF THE PROCESS (VIDEO)

3. ABSTRACT
• Composite Materials play a vital role in the Automobile,
aircraft industries & manufacturing industries.
• Preparation of metal-matrix composites are light weighted,
high strength, extremely hard materials.
• Growth of these sectors emphasize the production of
metal-matrix AlSiC composites using stir casting and at the
end the composition of SiC would be varied along with the
composition of Al.
• Then the hardness and impact testing will be done.

4. INTRODUCTION
• Metal Matrix Composites are extremely hard, abrasion
resistance and mostly light weighted.
• Useful for the preparation of the high temperature and
speed parts like pistons, axles, high speed wheels and
so on.
• Main focus is on the preparation of AlSiC composites
using stir casting with high temperature into the
graphite crucible with coal-fired furnace(or electrical
furnace using KANTHAL & NIKROTHAL heating wires)
followed by die casting.
• These composites have very high strength, fatigue
resistance, abrasion resistance, corrosion resistance,
stifness etc.,
• Keywords :- Composite Materials, Metal-Matrix
Composite, AlSiC Stir-Casting.

5. OBJECTIVES
• To Develop the strong light weighted metal-matrix AlSiC
composite material which are uselful in the industrial
Sectors and aerospace industries.
• The most important objective is to fabricate AlSiC metal-
matrix by homogeneous stir casting to produce High
Strength Low Cost Material (HSLCM).
• To test the hardness and the Impact Strength of the
metal-matrix composite so obtained for varying
compositions of the Al & SiC.
Fig: MMC simulation
Image

6. COMPOSITE MATERIALS
• Composites are considered to be mixture of materials(or metals) of
different composition.
• The materials retain their identities in the matrix, i.e, they do not dissolve
completely into each other.
• These materials can physically be verified and reveal an interface between
one another.
• The various types of composites used :- MMCs, PMCs & CMCs but
nowadays the use of metal-matrix, ceramic-matrix plays a significant job
whereas SiC is the best used matrix for fabrication.
• SiC is made by 60% sand and 40% coke with addition of saw dust in an
electric furnace at very high temperature about 1500°C with traces amount
of salts.
• The SiC particles are mixed with a temporary binding agent like glue resins
and then compressed and dried at temperature 2000°C which gives
homogenous interlocked SiC crystals.
Fig: Composite Material

7. METAL-MATRIX COMPOSITES
•Metal-Matrix composite consists
atleast two materials, one being METAL
necessarily, the other may be metal or
any other material.
• And thus they gain high strength,
hardness, ductility and thermal
conductivity.

8. STIR CASTING
• Stirring is done to ensure homogeneous mixing of the
components.
•It is also done to ensure proper melting.
• A electrical motor is used to facilitate automatic
stirring.
•A dimmer is also used to control the RPM of the
stirrer.

9. APPARATUS SETUP

10. EXPERIMENTATION
• Aluminium is heated till it is completely melted in the furnace.
Fig: FurnaceFig: Al Plates

11. EXPERIMENTATION
• SiC is Preheated in the Preheat Furnace(Muffle Furnace).

12. EXPERIMENTATION
• Mg Powder is put in Al melt (to increase the wettability of the Al
with SiC to improve the solubility).

13. EXPERIMENTATION
• The Molten Metal is then stirred for uniform melting.

14. EXPERIMENTATION
• SiC is added uniformly through the pathway after being preheated.

15. • The Mixture is stirred and then is poured into the die for casting.
EXPERIMENTATION

16. • The experiment is repeated by varying the compositions of composite
powder SiC ( 5%, 10%, 15%, 20%, 25% and 30% ), weight of Al +
weight of SiC are also varied.
EXPERIMENTATION
Percentage Al-98.41% SiC-320 Grit
5% 1900gm 100gm
10% 1800gm 200gm
15% 1700gm 300gm
20% 1600gm 400gm
25% 1500gm 500gm
30% 1400gm 600gm

17. RESULT
•The objective was to prepare aluminium
based silicon carbide MMC with an
objective to develop a conventional low
cost method of producing MMC.
•To achieve this stir casting was adopted.

18. APPLICATIONS
Fig: In Aircraft’s Propulsion Manufacturing Fig: In autmobiles Fig: In Engines and Piston Manufacturing

19. A BRIEF LOOK OF THE PROCESS

20. THANK YOU