Technical Epitome of Powder Metallurgy Composite

“A TECHNICAL EPITOME THROUGH POWDER METALLURGICAL PROCESS BY
ADDITION OF SILICON & ORIENTATION OF MICA
CAPSTONE PROJECT/DISSERATION
Submitted in Partial Fulfillment of the
Requirement
BACHELOR OF TECHNOLOGY
MECHANICAL ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING
LOVELY PROFESSIONAL UNIVERSITY
PHAGWARA, PUNJAB (INDIA)
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ECHNICAL EPITOME THROUGH POWDER METALLURGICAL PROCESS BY
ADDITION OF SILICON & ORIENTATION OF MICA’’
Requirement for Award of the degree
Of
IN
UNDER THE GUIDANCE OF
MS. NEETU
PHAGWARA, PUNJAB (INDIA)-144411
JAN-MAY 2016
SUBMITTED BY:
VINAY KUMAR (11305216)
GOVIND SINGH (11307165)
NEERAJ KUMAR
PURNEET SINGH
ECHNICAL EPITOME THROUGH POWDER METALLURGICAL PROCESS BY
SUBMITTED BY:
SINGH (11307165)
NEERAJ KUMAR (11300173)
PURNEET SINGH (11301659)

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“A TECHNICAL EPITOME THROUGH POWDER METALLURGICAL PROCESS BY
ADDITION OF SILICON & ORIENTATION OF MICA’’
Requirement for Award of the degree
Of
IN
UNDER THE GUIDANCE OF
MS. NEETU
PHAGWARA, PUNJAB (INDIA)-144411
JAN-MAY 2016
SUBMITTED BY:

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CERTIFICATE
I hereby certify that the work which is being presented in the capstone entitled “A technical
epitome through powder metallurgical process by addition of silicon & orientation of
Mica’’.
In partial fulfillment of the requirement for the award of degree of “BACHELOR OF
TECHNOLOGY” and submitted in Department of Mechanical Engineering, Lovely
Professional University, Punjab is an authentic record of my own work carried out during period
of Capstone under the supervision of Ms. NEETU, Assistant Professor, Department of
Mechanical Engineering, Lovely Professional University, Punjab.
The greatest proposed value of this project is that all the information profiled in this capstone
project report is based on our own intensive work and is genuine.
.
The Capstone project proposal is fit for the submission and partial fulfillment to the candidates to
award the degree of Bachelor of Engineering in Mechanical.
MS. NEETU
Date:

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ACKNOWLEDGEMENT
This capstone was a welcome and challenging experience form easy to hard. It took a great deal
of hard work and dedication for its successful completion. It’s my pleasure to take this
opportunity to thank all those who help us directly or indirectly in preparation of this report.
I would also like to very sincere thanks to Ms. NEETU & Dr. UDAY K. RAVELLA
who supported us technically as well as morally in every stage of the project. Without their
guidance and support, this project would not have seen light of the day.
It gives us immense in expressing a deep sense of gratitude and sincere thanks to
Lovely Professional University.
There times in such project when clock beats you again and again and you run out of
energy and you want to finish it once and forever. Last but not the least we thank our family and
friends for their boost and support in every sphere. Their vital push in fused a sense of insurgency
within us.

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ABSTRACT
The development and characteristic approach of the title is to transform a original matter into
new performing state of matter in a composite form. This composite form is obtained by
introducing Copper, Mica & Ferro-Silicon substances which has become optimized due powder
metallurgy process. The scientific technique by sintering and metal forming transformed the
assumed specimen into a proficient one. The idealized function is being compared to that of real
undertaking process for the approach of efficiency in product.
Our decisive option for the manufacturing relates that the processes of physical, chemical
and mechanical is actually depend upon the degree of drawing and forming them into real. The
ability to transmit and absorb the respective effects are required by the representation. The
overviews of various different techniques are equipped to conclude the analysis of this type of
composite structure.
The motive is to attenuate possible and diversified applications in the developing criteria for
industrialization. This is confined for the possible utilization and enhancing the part in related
areas of specialist.

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TABLE OF CONTENT
CERTIFICATE…………………………………………………………………………………...3
ACKNOWLEDGEMENT………………………………………………………………………..4
ABSTRACT………………………………………………………………………………………5
LIST OF FIGURES………………………………………………………………………………8
CHAPTER 1……………………………………………………………………………………..10
INTRODUCTION……………………………………………………………………………….10
1.1 POWDER’S OPTIMIZATION………………………………………………………..…10
1.1.1 DESCRIPTION OF COMPONENTS…………………………………………………11
1.1.2 METAMORPHIC ROCKS…………………………………………………………….13
1.1.3 METAMORPHIC MINERALS………………………………………………………..13
1.1.4 MICA……………………………...................................................................................14
1.1.5 MUSCOVITE………………………………………………………………..…………18
1.1.6 SILICON……………..…………………………………………………………………23
1.1.7 COPPER………………,,,,,,,,,,,,,,,,,,,…………………………………………………...26
CHAPTER 2……………………………………………………………………………………..28
LITERATURE REVIEW………………………………………………………………………..28
2.1 COMPOSITES OF MINERAL TRANSFORMS…………………………………………28
2.2 MUSCOVITE MICA TRANSFORMS…………………………………………………..30
CHAPTER 3……………………………………………………………………………………..31

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RATIONALE AND SCOPE OF STUDY……………………………………………………….31
3.1 PROBLEM STATEMENT………………..……………………………………………….31
CHAPTER 4………………………………………………………………………….…….…....32
RESEARCH METHODOLOGY…………………………………………………………..…....32
4.1 OBSERVATION FOR SELECTION OF POWDER……………………………….......32
4.1.1 MIXING & AFFIIXING OPERATIONS……………………………………………..33
4.1.2 PRESSING & COMPACTING :( CONSTRUCTION/WORKING)…………………40
4.1.3 SINTERING /HEAT TREATMENT PROCEDURES…………………………….....43
4.1.4 TESTING OF PROPERTIES WITH DIFFERENT METHODS……………………...45
CHAPTER 5……………………………………………………………………………………..50
RESULTS & DISCUSSIONS……………………………………..………………………………………50
CHAPTER 6……………………………………………………………………………………..58
CONCLUSIONS………………………………………………………………………………….58
SCOPE OF FUTURE WORK…………………………………………………………………………….58
CHAPTER 7……………………………………………………………………………………..59
REFERENCES…………………………………………………………………………………..59

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LIST OF FIGURES
FIG.1 MUSCOVITE IN A DIFFERENT MINERAL FORM………………………………………..12
FIG.2 CYCLIC PROCESSES OF METAMORPHISM AND EARTH EVACUATIONS………...14
FIG.3 A MUSCOVITE MICA VIEW………………………………………………………………….19
FIG.4 SILICON FORMING, FERRO-SILICON…………………………………………………......25
FIG.5 (A).IDEALISED COPPER………………………………………………………………………27
(B). ELEMENTAL COPPER…………………………………………………………………..27
FIG.6 (A) ELECTRONIC WEIGHING BALANCE…………………………………………………38
(B) MIXED POWDERS FRACTION…………..………….…………………………………..39
FIG.7 AFFIXING MEASURED VALUE IN IMPLEMENTATION………………………………..39
FIG.8 HYDRAULIC COMPACTING MACHINE…………………………………………………...41
FIG.9 IDEAL COMPACTED PIECE IN 3D VIEW WITH DIMENSIONS …………………..42
FIG.10 SINTERING PROCESS IN FURNACE……………………………………………………...44
FIG.11 (A) EMERY PAPERS ………………………………………………………………………....46
(B) SIZES AND CHARTS …............................................….………...……………………….46
FIG.12 (A) POLISHING MACHINE DISKS,………………………………………………………...46
(B) LUBRICANTS……. ….…………………………………………………………………...47
FIG.13 HARDNESS TESTING OPERATION……………………………..…………………………47
FIG.14 PENETRATING OBSERVATION…...………………………………………………………48
FIG.15 MICROSCOPIC DEVICE …………..………………………………………………………...49

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FIG.16 REAL COMPACTED PIECE OF (A) “MI-FE-SI,....………………………………………..51
(B) (CU-FE-SI),(CU-MI)…………………..…………...51
FIG.17 SINTERED PART OF (A) (MI-FE-SI)……………………………………………………….52
(B) (CU-MI)…………….……………...……………….52
FIG.18 SINTERED PART OF (A) (CU-FE-SI)……………………………………………………….52
(B) (CU-MI-FE-SI)……………………...………………52
FIG.19 PERSPECTIVE CRYSTALLOID VIEW OF COPPER…………………..……………...…53
FIG.20 MAGNIFIED CRYSTALLITES OF (A) (CU-FE-SI-MI……………………………………54
(B) (CU-FE-SI-MI).…….……...........…...........................54
FIG.21 CRYSTAL POROUS AND STABILIZATION FLAKES …………..……………...……….55
FIG.22 CLOSED VIEW EQUAL SPACED CRYSTAL STRUCTURE…………………………….55
FIG.23 AN OVERVIEW OF STATIC AND DYNAMIC SIMULATION ………………………….57

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CHAPTER 1
INTRODUCTION
1.1 POWDER’S OPTIMIZATION:
Collection of respective powders named “MUSCOVITE dry ground Mica, Ferro-Silicon and
Copper” are stepped to involve process assistance.
These powders are obtained as in the form of fine grain sizes with performable operation and
usable in industrial applications also. Muscovite ground Mica consist of ‘white’ in color further
transformed in minimum grain size (usually of 10micron size).
Ferro-Silicon consists of ‘blackish-grey’ in color further obtained as mixture of two
elements (usual size of 10 micron). The size in equal dimension is stepped for performance.
Cooper consists of darkish orange in color which is obtained as of fine grain elemental (usual
size 10-15 micron). The size is usually in tiny flakes.
The ordered quantity of Muscovite is maximum as compared to that of (Fe-Si, Cu). Being
consideration of developing property in mica and abundance is undertaken. The developing
criteria for a composite material valuing the ideal optimization before creation are being
envisaged. The idea of composite in the opted materials were observed and exemplified properly
including their compatibilities. The new idea of forming the same material in different ways is
profiling in this technique. Concepts related to Mica and its properties are considered on ideal
conditions and same on the other materials also. Because of its shining and insulating properties
which is abundantly available in India the option for selection is done.
The all of Mica & Fe-Si, Mica, Fe-Si, and Cu are obtainable by earth sediments,
metamorphism rocks formation due to continuous heat and pressure impositions within crust.
The implemented proportion and the credentials are based upon their chemical, physical,
thermal, and mechanical properties.
In this powder metallurgical task the ideal to that of the real powder compaction for
composites is compared. Observations are obtained for the proper transformation in the ideal
processing.

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1.1.1 DESCRIPTION OF COMPONENTS:
Minerals:
Minerals can be described by various physical properties which relate to their chemical structure
and composition. Common distinguishing characteristics include crystal structure and habit,
hardness, luster, diaphaneity, color, streak, tenacity, cleavage, fracture, parting, and specific
gravity. More specific tests for minerals magnetism, taste or smell, radioactivity and reaction to
acid. The abundance and diversity of minerals is controlled directly by their chemistry, in turn
dependent on elemental abundances in the Earth. The majority of minerals observed are derived
from the Earth’s crust. Eight elements account for most of the key components of minerals, due
to their abundance in the crust. These eight elements, summing to over 98% of the crust by
weight, are, in order of decreasing abundance: oxygen, silicon, aluminum, iron, magnesium,
calcium, sodium and potassium. Oxygen and silicon are by far the two most important — oxygen
composes 46.6% of the crust by weight, and silicon accounts for 27.7%. A mineral can be
identified by several physical properties, some of them being sufficient for full identification
without equivocation.
In other cases, minerals can only be classified by more complex optical, chemical or X-ray
diffraction analysis; these methods, however, can be costly and time-consuming. Physical
properties applied for classification include crystal structure and habit, hardness, luster,
diaphaneity, color, streak, cleavage and fracture, and specific gravity.
Changes in temperature and pressure, and composition alter the mineralogy of a rock
sample. Changes in composition can be caused by processes such as weathering or
metasomatism (hydrothermal alteration). Changes in temperature and pressure occur when the
host rock undergoes tectonic or magmatic movement into differing physical regimes. Changes in
thermodynamic conditions make it favorable for mineral assemblages to react with each other to
produce new minerals; as such, it is possible for two rocks to have an identical or a very similar
bulk rock chemistry without having a similar mineralogy.
Phyllosilicates consist of sheets of polymerized tetahedra. They are bound at three
oxygen sites, which gives a characteristic silicon:oxygen ratio of 2:5. Important examples

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include the mica, chlorite, and the kaolinite serpentine groups. The sheets are weakly bound by
Vander Waals forces or hydrogen bonds, which causes a crystallographic weakness, in turn
leading to a prominent basal cleavage among the phyllosilicates.In addition to the tetrahedra,
phyllosilicates have a sheet of octahedra (elements in six-fold coordination by oxygen) that
balanced out the basic tetrahedra, which have a negative charge (e.g. [Si4O10]4.
These tetrahedra (T) and octahedra (O) sheets are stacked in a variety of combinations to
create phyllosilicate groups. Within an octahedral sheet, there are three octahedral sites in a unit
structure; however, not all of the sites may be occupied. In that case, the mineral is termed
dioctahedral, whereas in other case it is termed trioctahedral.
Micas are also T-O-T-stacked phyllosilicates, but differ from the other T-O-T and T-O-
stacked subclass members in that they incorporate aluminium into the tetrahedral sheets (clay
minerals have Al3+ in octahedral sites). Common examples of micas are muscovite, and the
biotite series. The chlorite group is related to mica group, but a brucite-like (Mg(OH)2) layer
between the T-O-T stacks. Because of their chemical structure, phyllosilicates typically have
flexible, elastic, transparent layers that are electrical insulators and can be split into very thin
flakes.
Micas can be used in electronics as insulators, in construction, as optical filler, or even
cosmetics. Chrysotile, a species of serpentine, is the most common mineral
species in industrial asbestos, as it is less dangerous in terms of health than the amphibole
asbestos..
Fig1 .Muscovite in a different mineral form

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1.1.2 METAMORPHIC ROCKS
Metamorphic rocks arise from the transformation of existing rock types, in a process
called metamorphism, which means "change in form". The original rock is subjected to heat
(temperatures greater than 150 to 200 °C) and pressure (1500 bars), causing profound physical
and/or chemical change. The original rock may be a sedimentary rock, an igneous rock or
another older metamorphic rock.
Metamorphic rocks make up a large part of the Earth's crust and are classified by texture
and by chemical and mineral assemblage (metamorphic faces). They may be formed simply by
being deep beneath the Earth's surface, subjected to high temperatures and the great pressure of
the rock layers above it. They can form from tectonic processes such as continental collisions,
which cause horizontal pressure, friction and distortion. They are also formed when rock is
heated up by the intrusion of hot molten rock called magma from the Earth's interior.
The study of metamorphic rocks (now exposed at the Earth's surface following erosion
and uplift) provides information about the temperatures and pressures that occur at great depths
within the Earth's crust. Some examples of metamorphic rocks are gneiss, slate, marble, schist,
and quartzite.
1.1.3 METAMORPHIC MINERALS:
Metamorphic minerals are those that form only at the high temperatures and pressures associated
with the process of metamorphism. These minerals, known as index minerals,
include sillimanite, kyanite, staurolite, andalusite, and some garnet.
Other minerals, such as olivines, pyroxenes, amphiboles, micas, feldspars, and quartz,
may be found in metamorphic rocks, but are not necessarily the result of the process of
metamorphism. These minerals formed during the crystallization of igneous rocks. They are
stable at high temperatures and pressures and may remain chemically unchanged during the
metamorphic process. However, all minerals are stable only within certain limits, and the
presence of some minerals in metamorphic rocks indicates the approximate temperatures and
pressures at which they formed.

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The change in the particle size of the rock during the process of metamorphism is
called recrystallization. For instance, the small calcite crystals in the sedimentary rock limestone
and chalk change into larger crystals in the metamorphic rock marble, or in metamorphosed
sandstone, recrystallization of the original quartz sand grains result in very compact quartzite,
also known as metaquartzite, in which the often larger quartz crystals are interlocked.
Fig2. Cyclic processes of metamorphism and earth evacuations
1.1.4 MICA
A natural occurring mineral that is based on a collection of silicate minerals and composed of
varying amounts of potassium, iron, aluminum, magnesium and water is Mica. It is found having
thin‐sheet like or plate‐like structure with various composition and physical properties. Mica
forms flat six‐sided monoclinic crystals along with an extraordinary split in the direction of

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larger surfaces. This allows the mineral to be easily cleaved into optically flat films. High in
silica, this stone has the extensive capacity to remain elastic and tough even at high temperatures.
This helps the people to handle and work with the stone in those places with high and humid
temperatures.
A superior insulator and a biaxial birefringent crystal, Mica possesses average refractive
index and its visible spectrum is about 1.6. Due to this nature Mica can be used to cause a point
delay between two orthogonal elements of an input linear polarization and therefore can also be
used as a retardation device.
The birefringence is not constant and because of this very reason the optical and physical
thickness will vary. It has the absorption of 2 to 5% in the perceptible range. The best part is
Mica can resist nearly all mediums like chemicals, acids, gasses, alkalis, and oils.
Uses of Mica:
Mica is a naturally occurring stone that directly applies to a set of minerals containing silica in its
highest form. This mineral is mostly used in gypsum wallboard combined compound where it
acts as wadding and prevents cracking. There are a variety of uses of this mineral. It is used in
paints as a pigment extender and also helps to brighten the tone of colored pigments.
In the electrical industry the same as thermal insulation and electrical insulators are
used for the equipment. Its shiny and glittery appearance makes it ultimate for toothpaste and
cosmetics. The high thermal resistance allows it to be used as an insulator in various electronics.
The highest level of silica content in it makes it the most preferred mineral to be used in
various industries and also for other personal uses. It is invariably used for fillers, extenders
along with providing smoother uniformity, improving workability and prevents cracking.
This can be used as an insulator in home attics, concrete blocks and also poured into open top
walls. It can also be added to grease to increase its durability and giving it a better surface. Mica
can also be used as a soil conditioner particularly in potting soil mixes and in gardening plots.

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Processing
The ordinary mica crystals as they come out of a mine is in form of rough books or lumps of
irregular shape, size and thickness, associated with impurities and structural imperfections.
They have to undergo a long operation of cutting, sorting and processing from crude to
commercial quality. The waste resulting from the production of crude to commercially useful
sheet mica forms about 90 per cent. Sometimes even the total output of mica from a mine is sold
as scrap mica and it can be used as Mica Scrap or can be used for Grinding Mica Powder. The
trimming of mica is a skilled hand operation in which cracks and imperfections are removed at
the edges of the sheets using a knife while saving the best area of usable sheet.
The knife dressed sheet mica of irregular polygonal shapes is finally graded into different
standard sizes and commercial qualities before they are offered for marketing.
Classification
For commercial and industrial purpose natural mica are mainly divided into three catagories,viz :
1. Processed Mica
2. Fabricated Mica
3. Manufactured Mica.
 Processed Mica is fundamentally a natural sheet mica of an irregular size and polygonal
shapes that is relatively flat and free from physical defects and structural imperfections
having a minimum usable area of 4.8 sq. cm. (0.75 sq. inch), suitable to be cut, punched
or stamped into specific size and shape chiefly for use by the electronic and electrical
industries.
 Fabricated Mica is basically natural sheet mica cut, stamped or punched to specified size,
shape and thickness for industrial and uses, such as; disc, washers, cut films or sheets,
joints, backing plates, plates, spacers, mica formers for irons, toasters, rice cookers,
etc.
 Manufactured Mica means mica based products manufactured from natural mica, such as,
micanite or built up mica, mica paper, mica heating elements, mica capacitors, mica
flakes and powder, mica bricks etc.

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PROPERTIES OF MICA:
Mica belongs to a very important and rather large group of minerals that are highly
suitable for several applications. However, its advanced properties make it highly suitable for use
in various places. These are:
Physical: Mica is translucent, easily split into thin films along its cleavage, optically flat,
colorless in thin sheets, elastic and incompressible.
Chemical: It is a compound hydrous silicate of aluminum, which also contains iron, magnesium,
potassium, sodium fluorine, lithium and also few traces of numerous other elements.
It is constant and entirely static to the action of water, acids (except for hydrofluoric and
concentrated sulphur), alkalies, conventional solvents, bases, and oil. It remains almost
unchanged by atmospheric action.
Electrical: Mica has the exclusive combination of uniform dielectric steadiness, capacitance
stability, enormous dielectric power, high Q factor and lower power loss, high electrical
resistance and low temperature coefficient.
It is highly regarded for its resistances to arc and corona discharge without causing any
lasting injury.
Thermal: It is highly fire proof, incombustible, non‐ flammable, infusible, and also can resist
temperatures of up to 1000 degrees Celsius/1832 degrees Fahrenheit. However this depends on
the type and variety of Mica used.
It has excellent thermal stability, lower heat conductivity, and can be easily exposed to high
temperatures without visible effect.
Mechanical: Mica is highly tough, having high tensile strength, elastic, and along with being
flexible. It has immense compression power and can be machined, die‐punched, or hand cut.
Quality
The quality classification of mica, is based visual tests, depends on individual opinion. Also
products of different mines vary in physical characteristics to such an extent that the
development of a single standard with reasonable limits of tolerance becomes an acutely difficult
task.

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The application of common sense to the task of procurement is therefore always helpful
especially so in the matter of choosing a right supplier as only an experienced supplier knowing
the individual buyer’s specific requirements is able to deliver to the near correct material. In fact,
it is an expert’s job to process and assort mica to suit to individual buyers requirements and
maintain uniform and satisfactory supplies.
1.1.5 MUSCOVITE
Muscovite is the most common mineral of the mica family. It is an important rock forming
mineral present in igneous, metamorphic and sedimentary rocks. Like other micas it readily
cleaves into thin transparent sheets. Muscovite sheets have a pearly to vitreous luster on their
surface. If they are held up to the light they are transparent and nearly colorless, but most have a
slight brown, yellow, green or rose color tint.
The ability of muscovite to split into thin transparent sheets sometimes up to several feet
across gave it an early use as window panes. In the 1700s it was mined for this use from
Pegmatite’s in the area around Moscow, Russia. These panes were called "Muscovy glass" and
that term is thought to have inspired the mineral name "Muscovite".
Sheet Muscovite is an excellent insulator and that makes it suitable for manufacturing
specialized parts for electrical equipment. Scrap, flake and ground muscovite are used as fillers
and extenders in a variety of paints, surface treatments and manufactured products.
The pearlescent luster of muscovite makes it an important ingredient that adds "glitter"
to paints, ceramic glazes and cosmetics. Mica, any of a group of hydrous potassium, aluminum
silicate minerals. It is a type of phyllo-silicate, exhibiting a two-dimensional sheet or layer
structure. Among the principal rock-forming minerals, micas are found in all three major rock
varieties—igneous, sedimentary, and metamorphic.
Muscovite can form during the regional metamorphism of argillaceous rocks. The heat
and pressure of metamorphism transforms clay minerals into tiny grains of mica which enlarge
as metamorphism progresses. Muscovite can occur as isolated grains in schist and gneiss or it
can be abundant enough that the rocks are called "mica schist”.

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Fig3. A Muscovite mica view
CHEMICAL COMPOSITION:
Muscovite is a potassium rich mica with the following generalized composition...
(KAl2 (AlSi3 O10 )(OH)2)
In this formula potassium is sometimes replaced by other ions with a single
positive charge such as sodium, rubidium or cesium. Aluminum is sometimes replaced by
magnesium, iron, lithium, chromium or vanadium.
When chromium substitutes for aluminum in muscovite the material takes on a green color
and is known as "fuchsite". Fuchsite is often found disseminated through metamorphic rocks of
the green schist faces.

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Occasionally it will be abundant enough to give the rock a distinct green color and for those
rocks the name "verdite" is used.
Chemical
Formula
KAl3Si3O10(OH)2
Composition Basic potassium aluminum silicate, sometimes with some chromium or
manganese replacing the aluminum
Variable
Formula
K(Al,Cr,Mn)3Si3O10(OH)2
Color Colorless, white, beige, yellow, brown, gray, green, pink, purple, red, black;
occasionally multicolored
Streak Colorless
Crystal System Monoclinic
Crystal Forms
and
Aggregates
Crystals are in thick flakes, Micaceous masses and groupings, and
in tabular, foliated, flaky, and scaly forms. Crystals may also be elongated with
one dimension flat, or stubby triangular or hexagonally shaped crystals.
Muscovite also forms interesting aggregates of dense bladed crystals,
thick rosettes, uniquely twinned star-shaped formations, and
rounded Botryoidal and globularmasses of dense flakes.
Muscovite may also form Pseudomorphs after other minerals, assuming the
original minerals crystal shape.
Transparency Transparent to translucent

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Specific
Gravity
2.7 - 3.0
Luster Pearly
Cleavage 1,1
Fracture Uneven
Tenacity Sectile, Elastic
Other ID
Marks
Tendency for small pieces or flakes or peel off.
In Group Silicates; Phyllosilicates; Mica Group
Striking
Features
Flaky habit, crystals, sectility, and mode of occurence.
Environment Muscovite is a very common rock-forming mineral and is an important
constituent in many environments. Its presence is noted especially
in granite pegmatites, in contact metamorphic rocks, in metamorphic schists,
and in hydrothermal veins. Important Muscovite deposits where large
significant crystals occur are almost exclusively from granite pegmatites.
Rock Type Igneous, Metamorphic
Tensile Strength - 1750 kgf/cm2 or lbf/in2
Shear Strength- 2200 kgf/cm2 or lbf/in2
Compression Strength- 1900 - 2850 kgf/cm2
Modulus of Elasticity- 1400- 2100 kgf/cm2

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THE PHASE RULE
The Phase Rule is P + F = C + 2, where
 P = number of phases present
 F = Degrees of freedom,
 C = number of components present
 The familiar systems below illustrate the phase rule. In both cases, C = 1 so P + F = C + 2 = 3.
 In the middle of a field, we can vary temperature and pressure at will (within limits); There is
only one phase (P = 1) and F = 2.
 On a phase transformation boundary, two phases are present but we only have one degree of
freedom. If we modify pressure we have to change temperature to stay on the boundary. If we
modify both temperature and pressure at will we move off the boundary into a region where F =
2 but P = 1.

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 At the triple points we have all three phases present but no freedom at all. We have to be at that
temperature and pressure to have all three phases present; F = 0
The phase rule applies only to chemical systems in equilibrium. It plays very little role in
sedimentary petrology, where rocks consist of diagenetic minerals that may be in equilibrium,
but also detrital minerals that may be wildly out of equilibrium. It may play a role at times in
igneous petrology, but igneous rocks are often non-equilibrium because crystals may be zoned or
rimmed and their interiors isolated from the rest of the magma. The phase rule figures
prominently in metamorphic petrology, where equilibrium is commonly the rule.
What constitutes a component is sometimes a matter of definition, for example, if a
component is always present, we may simply ignore it. If a rock contains Al2SiO5 and quartz, we
might choose to ignore the quartz, if it doesn't participate in any chemical reactions. Or we might
choose to count quartz as a phase, in which case we must also count SiO2 as a component. We
don't need to consider Al2O3 and SiO2 as separate components if they always occur as Al2SiO5.
However, if there were the possibility that quartz or corundum might occur as well, then we
would have to consider Al2O3 and SiO2 as separate components.
Most of the time F = 2; temperature and pressure. Occasionally F can be greater, for example if
total pressure and water pressure are different, or if the relative pressures of water and carbon
dioxide are important, or if oxidation potential is important.
If F = 2 then P + 2 = C + 2 and P = C.
We see this to some extent in calculating norms for igneous rocks; titanium is assumed to go into
titanite or ilmenite, phosphorus into apatite, and so on. For each component, there is a phase.
1.1.6 SILICON
The name for silicon is taken from the Latin silex which means "flint". The element is second
only to oxygen in abundance in the earth's crust and was discovered by Berzelius in 1824. The
most common compound of silicon is SiSiO2, is the most abundant chemical compound in the
earth's crust, which we know it better as common beach sand.

24
Silicon, the second most abundant element on earth, is an essential part of the mineral world.
It's stable tetrahedral configuration makes it incredibly versatile and is used in various way in our
everyday lives. Found in everything from spaceships to synthetic body parts, silicon can be
found all around us, and sometimes even in us. Silicon is a chemical element with the symbol Si
and atomic number 14. A tetravalent metalloid, it is less reactive than its chemical analog carbon,
the nonmetal directly above it in the periodic table, but more reactive than germanium, the
metalloid directly below it in the table.
Silicon is a solid at room temperature, with relatively high melting and boiling points of
approximately 1,400 and 2,800 degrees Celsius respectively. Interestingly, silicon has a greater
density in a liquid state than a solid state. Silicon is a semiconductor, readily either donating or
sharing its four outer electrons, allowing for many different forms of chemical bonding.
Even though it is, similar to carbon, a relatively inert element, silicon still reacts with
halogens and dilute alkalis, but most acids (except for some hyper reactive combinations of nitric
acid and hydrofluoric acid) have no known effect on it.
Alloys
Ferrosilicon, an iron-silicon alloy that contains varying ratios of elemental silicon and iron,
accounts for about 80% of the world's production of elemental silicon, with China, the leading
supplier of elemental silicon, providing 4.6 million tonnes (or 2/3 of the world output) of silicon,
most of which is in the form of ferrosilicon. It is followed by Russia (610,000 t), Norway
(330,000 t), Brazil (240,000 t) and the United States (170,000 t). Ferrosilicon is primarily used
by the steel industry.
Elemental silicon not alloyed with significant quantities of other elements, and usually > 95% is
often referred to loosely as silicon metal. It makes up about 20% of the world total elemental
silicon production, with less than 1 to 2% of total elemental silicon (5–10% of metallurgical
grade silicon) ever purified to higher grades for use in electronics.

25
Metallurgical grade silicon is commercially prepared by the reaction of high purity silica with
wood, charcoal, and coal in an electric arc furnace using carbon electrodes. At temperatures over
1,900 °C (3,450 °F), the carbon in the aforementioned materials and the silicon undergo the
chemical reaction SiO + 2 C → Si + 2 CO.
Fig4. Silicon forming, Ferro-Silicon
Elemental silicon is added to molten cast iron as ferrosilicon or silico-calcium alloys to improve
performance in casting thin sections and to prevent the formation of cementite where exposed to
outside air. The presence of elemental silicon in molten iron acts as a sink for oxygen, so that the
steel carbon content, which must be kept within narrow limits for each type of steel, can be more
closely controlled.

26
Ferrosilicon production and use is a monitor of the steel industry, and although this form
of elemental silicon is grossly impure, it accounts for 80% of the world’s use of free silicon.
Silicon is an important constituent of electrical steel, modifying its resistivity and
ferromagnetic properties.
Ferrosilicon is used as a source of silicon to reduce metals from their oxides and to
deoxidize steel and other ferrous alloys. This prevents the loss of carbon from the molten steel
(so called blocking the heat); ferromanganese, spiegeleisen, silicides of calcium, and many other
materials are used for the same purpose. It can be used to make other ferroalloys.
Ferrosilicon is also used for manufacture of silicon, corrosion-resistant and high-
temperature resistant ferrous silicon alloys, and silicon steel for electro motors and transformer
cores.
1.1.7 COPPER
Copper is found as a pure metal in nature, and this was the source of the first metal to be used by
humans in 8,000 BC; it was the first metal to be smelted from its ore, 5,000 BC; it was the first
metal to be cast into a shape in a mold, ca. 4,000 BC; and it was the first metal to be purposefully
alloyed with another metal, tin, to create bronze, 3,500 BC.
Copper, silver and gold are in group 11 of the periodic table, and they share certain
attributes: they have one sorbital electron on top of a filled d-electron shell and are
characterized by high ductility and electrical conductivity. The filled d-shells in these elements
do not contribute much to the interatomic interactions, which are dominated by the s-electrons
through metallic bonds. Unlike metals with incomplete d-shells, metallic bonds in copper are
lacking a covalent character and are relatively weak.
At the macroscopic scale, introduction of extended defects to the crystal lattice, such as
grain boundaries, hinders flow of the material under applied stress, thereby increasing its
hardness. For this reason, copper is usually supplied in a fine-grained polycrystalline form,
which has greater strength than mono crystalline forms.

27
Numerous copper alloys exist, many with important uses. Brass is an alloy of copper and
zinc. Bronze usually refers to copper-tin alloys, but can refer to any alloy of copper
such as aluminum bronze.
Copper is one of the most important constituents of carat silver and gold alloys, and
carat solders are used in the jewelry industry, modifying the color, hardness and melting point of
the resulting alloys. The alloy consisting of 90% copper and 10% nickel is remarkable for its
resistance to corrosion and is used in various parts that are exposed to seawater.
Fig5 (a). Idealized Copper Fig5 (b). Elemental Copper

28
CHAPTER 2
LITERATURE REVIEW
2.1 COMPOSITES OF MINERALS TRANSFORMS
F. Gridi-Bennadji et al. [1] demonstrated that an organized network of mullite
anisotropic crystals embedded in a silico-aluminate matrix material is obtained at interfaces of
sintered alternate layers of muscovite and kaolinite minerals. The nucleation and growth of
mullite anisotropic crystals occur preferentially along the muscovite basal planes through
topotactic reaction with the high temperature form of muscovite. Flexural strength, Young’s
modulus and fracture toughness are closely related to size and organization degree of the mullite
network. Based upon the conclusion it is proposed that not only high mullite length is necessary
to increase strength, but also the existence of an interconnected network of crystallite.
M.Gharabbi et al. [2] and belonging represented the boundary between
daigenesis and metamorphism most likely involves the change of illite into mica. Observations
of this change can be made using decomposed X-Ray diffraction (XRD) spectra of illitic clay
mineral assemblages in politic sedimentary rocks. Metamorphic illites (probably muscovites)
show no smeltic interlayers in any fraction. Metamorphism of illites then produces new mica
phases . Based upon discussion Illite is not a mica(high temperature phase),hence not a part of
solid solution. In pelitic composition rocks, mica are then either metamorphic or magmatic
minerals[2]. There was solid solution gap between illite and mica. Whether or not illite is
metastable with respect to mica.
Navjeet Kaur et al. [3] and members performed thermo luminescence is the
phenomenon of emission of light (mainly visible) that takes place during heating of a phosphor
or material as a result of previous exposure to different types of radiation such as UV, electron,
neutron, beta, gamma and X-rays etc. The thermo luminescence (TL) studies of micas are of
great importance because these are of low cost and available abundantly in natural form. Mica is
a natural valuable mineral that has found significant applications in radiation research such as

29
dosimetry and dating, etc. The TL properties of natural mica samples have been found to depend
upon their formation, chemical composition, impurity content and geological history.
Based upon conclusion a systematic investigation of the thermo luminescence
characteristics of gamma irradiated mica has been presented. There is a need to understand and
improve the characterization of the remarkable material, which can enhance the effectiveness of
dosimetry and help our community to utilize this material for innovative applications in radiation
technology.
Stephen Guggenheim et al. [4] shows the unit-cell dimensions of muscovite-2M, from
the Diamond mine, South Dakota, were determined to 1000'C,single-crystal X-ray structural
refinements were made at 20'C and 300'C, and additional structural refinements at 20, 525.and
650'C were made on similar material. Single-crystal data showed linear expansivity of the metric
dimensions to about 850"Cfollowed by a phase change to muscovite dehydroxylate with
increased parameters and a decrease in a near 850'C. The mean atomic distances of the K
polyhedron increased more rapidly than those for the other polyhedral as temperature increased.
Dehydroxylation occurs at temperatures where the silicatering is ditrigonal. Therefore, possible
misfit between the dioctahedral-tetrahedral sheet interface is not an important consideration in
the thermal-decomposition mechanism of muscovite.
Dept. of Elsevier et al. [5] performed a reinvestigated in order to resolve conflicting
evidence regarding tetrahedral disorder in muscovite, KAl (AlSi )O (OH) :
Results for the first reaction in the range 1.0–3.0 kbar and second reaction in the range 1.0–6.0 k
bar, together with data on the compositions of 1 molal HCl KCl solutions limited by the third and
fourth reactions at 400–500°C. 1 k bar favor total tetrahedral disorder in muscovite, but this
conclusion applies only to synthetic muscovite grown under relatively low pressure conditions.
The stable assemblage for the first and second reactions was based on growth and dissolution
textures of muscovite observed with an SEM.
The slopes of the dehydration boundaries are smaller than those determined by most
previous work. Results for the fourth reaction are in good agreement with other recent work, but
quench pH values for the third reaction are less acidic at 400°C, hence, the muscovite stability
field in KCl HCl solutions is narrower than previously determined.

30
2.2 MUSCOVITE MICA TRANSFORMS
Stanley Ruth berg et al. [6] transformed the three spectral types of muscovite sheet
mica, i.e., very pink ruby, light green, and dark green, were subjected to heat treatments at
temperatures up to 600 °C. The changes in the apparent optic axial angle and in the absorption
spectra (0.3 to 15) are studied along with color. As per the differentiation of muscovite sheet
according to these spectral types extends to the behavior of apparent optic axial angle and to
certain regions of t he spectrum under heat treatment. The pink associated absorption region
(0.47 to 0.6 JJ. ) can be enhanced or bleached away by appropriate thermal treatment, although
the associated infrared multiplet at 3 to 3.5 JJ. is little affected.
Lakhwant Singh et al. [7] and members experimented on an electrical and dielectric
response of muscovite ruby mica has been investigated by measuring various parameters
(Impedance, Impedance phase angle, Susceptance, Admittance, Dissipation factor, Quality
factor, Static capacitance in series-equivalent circuit mode. Work reveals the influence of
thermal treatment on the electrical/dielectric characteristics of muscovite ruby mica. The high
temperature annealed mica shows approximately 72% low quality factor as compared to the un-
annealed mica.
It is concluded that various electrical/dielectric characteristics of muscovite ruby mica are
greatly affected by thermal treatment. The present paper reveals that the high temperature
annealed mica shows approximately 72% low quality factor as compared to the un-annealed
mica. There exists a critical threshold frequency (~105-110 MHz) where the present mica.
Electrical and dielectric characteristics of annealed muscovite ruby mica 65 show the negligible
thermal effect.
Allen N. Towne et al. [8] of and his colleague by United states of Patent prepared a
process for Mica sheets composite in which Mica is ground dry to yield finely divided mica
particles prior to forming a sheet. A single sheet of uniform thickness is formed at one time by
pouring a colloid mixture of the ground mica, water and a colloid agent onto a mesh screen.
Vacuum means and a hydraulic press are used to complete the formation of a sheet. The sheet
also includes a resin binder surface coating of composites tends uniform thickness of stability.

31
CHAPTER 3
RATIONALE & SCOPE OF STUDY
3.1 PROBLEM STATEMENT:
Generally the mica has been expelled much properties in physical, chemical and mechanical
properties with having low resistance of abrasion and hardness. Being operational in painting,
coating insulation aspects the state of matter is optimized in manufacturing processes.
This worked ability shows that the involvement of Ferro-Silicon as reinforcing matrix
controls the ability to lose state when contacted with hydrofluoric acid due to addition. The acid
resistant up to definite level is overwhelmed in Silicon base metal. It consist a quantity of more
than 70% proportion which is acting as Silicon. The hardness due mica low-tightens improves
when Ferro-Solicited crystals allowed to bind itself with the matrix phase.
Meanwhile, the excess stability and hardenebility is increased by introducing copper which is
transferring more in electric, physical, effects. The copper which is usually not used for
insulating purpose is being easily utilized to insulate or coated including further resistances. Only
the rate of stabilization in particular condition may vary when used in developing purpose. The
equal or partial distribution of work factor would be considered or the maximum input by the
matrix added material. Only the copper stature is possibly tending to produce in favorable
measures for uses and same in Mica.
However, the composite inbuilt is assisted in different compatible factors and viewed
for productive output.

32
CHAPTER 4
RESEARCH METHODOLOGY
4.1 OBSERVATION FOR SELECTION OF POWDER:
Chemical Composition of Muscovite Mica Materials Specifications
Silica (SiO2) 45.57%
Alumina (Al2O3) 33.10%
Potassium Oxide (K2O) 9.87%
Ferric Oxide (Fe2O 2.48%
Sodium Oxide (Na2O) 0.62%
Titanium Oxide (TiO2) Traces
Calcium Oxide (CaO) 0.21%
Magnesia (MgO) 0.38%
Moisture at 100oC 0.25%
Phosphorus (P) 0.03%
Sulphur (S) 0.01%
Graphite Carbon (C) 0.44%
Loss on Ignition (H2O) 2.74%
Muscovite
Color- White Silicate
Hardness- 2.9(Moh’s Scale)
Specific Gravity- 2.9gm/cm3
Grain Size- (10-15) micron size
Melting Temp.- 900 degree C
Ferro-Silicon
Color- Black
Hardness- 7 (Moh’s Scale)
Specific Gravity- 3.855gm/cm3
Grain size- (10-15) micron size
Melting Temp.- 1250 degree C
Ferro-Silicon’s composition
Silicon (Si) 70%
Aluminum (Al) 2%
Phosphorus (P) 0.03%
Carbon (C) 0.07%
Iron (Fe) 27%
Copper
Color- Darkish Orange
Hardness- 3.0 (Moh’s Scale)
Specific Gravity- 8.96 gm/cm3
Grain size- (Fine grain(10-15)micron)
Melting temp.- 1300 degree C

33
The illustrated figure shows the ideal observations of Mica, Fe-Si & Cu which depicts possible
changes on the state of matter. The characteristics of identical information are added and reduced
in expense to perform better and degrade as per metallurgies.
A composite material is basically a combination of two or more materials, each of
which retains its own distinctive properties. The composite formation of the material in
following ways:
Components of Composite Materials
• Matrix phase1: bulk materials as:
Muscovite ground Mica
• Matrix phase2: bulk material as:
Copper (Cu)
• Reinforcement: Particulates
such as: Ferro-Silicon in-builted performance
• Interface: area of mechanical
4.1.1 PROPORTION FOR EVALUATION OF POWDERS
 Calculations of the specific density of both materials including their physical
representation.
 Calculations of the required mass of material on particular volume of substance in
different dimensions.
 Approximation of five to six proportions of mixing elements for operating the task is
assumed. The table shows the respective observations.
 The assumed level of approximation was kept differently and the level of quantity is
shifted as per considering factors.
 The powders are measured by the electronic weighing balance machine.
 The shifted titration of first two compositions and then three is taken to check possibility
of compatibleness.

34
 The main matrix phases1, 2 are increased in order to exemplify more ability in
performance and reinforced as lower amount for the same.
Sl.no. Mica gms/cm3 Ferro-Silicon gms/cm3
1.
2.
3.
4.
5.
6.
60% of 100
50% of 100
60% of 100
70% of 100
30% of 100
20% of 100
3.5
4.4
5.2
2.61
2.666
3.488
40% of 100
50% of 100
40% of 100
30% of 100
70% of 100
80% of 100
7.02
5.85
4.68
3.5
8.155
9.32
Fig. Tabular representation of real mixing
The considered values are by the real assumption for operations in performing a composite
material. The order of powder metallurgy is confined by mixing, compacting, isostatic hydraulic
pressing and sintering operations.
Sl.no Another Titration’s Composition gms/cm3
1.
2.
3.
Copper+ Mica+ Ferro-Silicon = (90%+ 5%+ 5%) of 100%
Copper+ Mica = (90%+ 10%) of 100%
Copper+ Ferro-Silicon = (90%+ 10%) of 100%
29.27+1.02= 30.29
29.27+1.41= 30.68
29.27+1.10= 30.37
Fig. Mixing of the credentials based upon above calculation

35
Numerical Analysis:
])[(3/104.27
),025.3/(96.8
])[(3/722.8
),025.3/(9.2
])[(3/661.11
),025.3/(855.3
)/Density
)/Density
)/Density
)3(3/96.8copperofgravitySpecific
)2(3/9.2MicaofgravitySpecific
)1(3/855.3Silicon-FerroofgravitySpecific
(
(
(
)(3025.31.15.05.5h)b(ll)matter(reaofVolume
)(305.61.115.5h)bl(al)matter(ideofVolume
Copperiiicmgmmass
mass
Micaiicmgmmass
mass
SiliconFerroicmgmmass
mass
volumemass
volumemass
volumemass
cmgm
cmgm
cmgm
iicm
icm
















1. The above calculated mass for mixture is in different substance with different proportion is
evaluated.
2. The respective values are considered in actual measurement values to be profiled.
3. The volume of matter considered in the hollow portion of die which is obtained as in 5mm
from 10mm after compacting to green mould.
4. The mass which is transformed into given mode is equipped as per designated volume after
measurement.

36
3/4361.0)100/5(722.8)(
3/583.0)100/5(661.11)(
3/8722.0)100/10(722.8)(
3/166.1)100/10(661.11)(
3/39.24)100/90(96.8)(
3/74.1)100/20(722.8)(
3/2.5)100/30(722.8)(
3/4.4)100/50(722.8)(
3/22.3)100/40(772.8)(
3/32.9)100/80(661.11)(
3/155.8)100/70(661.11)(
3/85.5)100/50(661.11)(
3/02.7)100/60(661.11)(
cmgmsv
cmgmsiv
cmgmsiii
cmgmsii
cmgmsi
cmgmsiv
cmgmsiii
cmgmsii
cmgmsi
cmgmsiv
cmgmsiii
cmgmsii
cmgmsi
Copper
Mica
SiliconFerro















37
4.1.2 MIXING AND AFFIXING OPERATIONS
The mixing is performed by axial and centrifugal rotating medium by a stirrer of glass rod in a
beaker. Manual mixing is being performed. The mixing time depend on the value of grain sizes
creation and stability. Coarse grain causes delay in mixing whereas the color varies periodically.
Continuous axial mixing causes optimum adherence of attached particles of powders as partially.
The particles started releasing gases and some of powders emissions during continuous
rotation. The particles growth is obtained denser when forcefully surpassed with the punch.
Equal mixing with segregated proportions was developed for transforming into a green mould
structure.
Then the mixed part contained in a clean transparent glass is measured on specified
machine named as Electronic weighing balance. The machine indicates a digital display of
numeric value in which the density of substance is measuring in gms/cm3 precisely.
As per tabulated observations the density of the powders are measured systematically. The
each and every different mixture requires the repeating value within started process. This tends
the mixed powders in one container. Further the involvement of Punch and Die is introduced into
which the partial affixing is to be done.
The specified dimensioned Die consist of hollow rectangular cavity oriented in the extreme
middle of the area is possessed. The same is the Punch being prepared of optimum clearance so
that green mould can be evacuated. The powder is filled among cavity up to top level and then
compressed by applying equal manual force through punch. The adjustment is allowed to pass
until it obtains 5 mm thickness.
The powder causes linear compressing by fractionating around surface with new color
appearance. The base plate below the die is necessarily being placed to keep constant force and
stability ratio for punching. The equal distribution of compressing force is achievable due to
surface orientation.

38
Fig.6 (a) Electronic Weighing Balance

39
Fig.6 (b) Mixed powders fraction
Fig7. Affixing measured value in implementation

40
4.1.2: PRESSING & COMPACTING :( CONSTRUCTION/WORKING)
The pressing is formed after compression of the powder into cavity of the die under Hydraulic
compacting machine.
The machine consists of two plungers profiled with mass springs on the opposite side of
fluctuations. A lever is introduced to provide angular torque for the uniform plunger movements.
The lever is installed at the middle edge of the pivoted ground where both plungers a
functioning. The fluid as oil is improved for the optimum performance & machining.
The machine contains cylindrical slab which 2/3 rd part is immersed into hydraulic system
situated at the bottom upon base. It is easily movable in vertical direction. The upper elevated
portion is of placing adjustable plate and circular rotating wheel which is highly oriented by
helical gear profiled flat grooves with equi-spaced dimension.
The hand wheel rotator performs linear compaction with uniform load distribution. A load
measurer is also being hydraulically introduced with a phenomenon to display the load carried in
each and every unit of iso-compacting load variance.
Then the affixed powders are placed including base plate on the adjustable plate above
cylindrical slab. The optimum centered attenuation is checked before indenting the hand wheel
on it.
Including clearance the possibility of a fluid locking key is introduced on the right bottom side of
plungers which tends to lock the fluid by-passing through the bottom side of compacting
machine. The key is being tightened to allow the uniform wheel down slipping. The load is set to
zero just before applying pressure on punch. After checking of attached punch with wheel it is
partially tightened manually to attain fix stature.
Then the continuous appliance of torque is being processed until the load reaches up to
300-350 KN of load. The black needle on the dial analogue indicator shows the accurate load
attainted. Further the load is being released by first releasing the locking key and hand wheel
upward for evacuating the processed part.

41
A new technique is manifested to remove out the green compact with a hollow squared profiled
die greater in size of that die. The same idea is performed by experimenting by releasing and
loading the keys. Hence the green compact is obtained.
Fig8. Hydraulic Compacting Machine
Maximum Load = 1000KN
Applied Load = 250-300, 300-350KN respectively

42
Two Hard speed steel plunger, One lever, base, column, analogue pressure indicator, hand wheel
rotator (helically grooved oriented), fluid releasing key, vertical cylinder fluid container and
adjusting barrel.
Fig. Stepwise view of compacting and pressing
Fig9. Ideal Compacted piece in 3d view with dimensions

43
4.1.3 SINTERING /HEAT TREATMENT PROCEDURES
During sintering, the individual particle structures disappear and the material forms as a mass.
Conventional sintering will not eliminate all porosity in the part; however it does reduce the
porosity further. In addition to being reduced in volume, sintering may also isolate areas of the
interconnected open porosity in the green compact
For the process of sintering by Muffle furnace is used in which the heat treatment process is
performable. Muffle furnace consist of an operating temperature of 1000 degree Celsius. In this
we keep the maximum operating temperature as 900 degree Celsius respectively.
The green compacted material is being placed inside the furnace with equi-spaced
distance between them. The next part is kept on a ceramic piece to allow the transfer of heat on
all sides. The frequency of the heating medium is kept (200-300) Hz with a specific time of 4
hours. The furnace attains its original performance above 400 degree Celsius.
The process of heat treatment is of continuous heating method in which the increasing
constant temperature is allowed to attain and then up to 3-4 hours respectively. The temperature
is varied from initial-final in two different titrations. After the constant heating up to required
time the heated mould part is taken out carefully and kept for normalizing at room temperature.
The substance was allowed to cool at original condition and then placed for usage.
Tabular Observation
Sl.no Sintering Temperatures
Copper-Mi-Fe-Si(0C) Mica-Fe-Si(0C) Time(hrs)
1.
2.
3.
750-850
750-800
800
750-800
600-650
700-800
6hrs
7hrs
8hrs

44
Fig10. Sintering process in furnace

45
4.1.4 TESTING OF PROPERTIES WITH DIFFERENT METHODS
The sintered output is taken and kept for the testing analysis. The operations by emery papers are
to be performing by applying as per provided grit sizes as follows:
(100, 400, 800, 1000) abrasive grain sizes
The allowable grit sized paper is cleaned by smooth continuous rubbing in forward
direction restrict. The definite concern for the removal of black surface on the layer of part is
performed. The repetition of the removal due to kinetic friction in one direction provided
optimum appearance of fine surface.
First of all 100 grit size is rubbed then 400-1000 respectively to clear the surface for shiny
appearances. The equal and sequential order of surfacing technique is performed only on the
copper based matrix phase produced part because of proper withstand of stressful impacts. The
metallic piece is cut on the small portion of extreme right for checking its micro structural
properties.
Further the emery paper required to clean and shine the surface after partitions within
rectangular based part. Then the polishing machine is used by applying diamond chemical paste
for enhancing the surface clearance.
The polishing machine consists of disks which rotates clockwise in definite rpm inbuilt a red
coated cloth on its surface. Before performing the experiment some amount of distilled water is
used and then switched on to proceed. Intermittent chemical is sprayed over the rotating disk.
The applied metallic piece is slightly placed on the disk and checked with a time until it’s appear
extreme shined. The same procedure is performed on the other pieces for experimentation.
Now the obtained piece is smoothly cleaned by cotton and handled for structuring analysis.
A new chemical etchant for cooper alloys is opted to evaluate the crystal structures of the
developed material. The testing of the hardness is performed by Rockwell hardness tester on
each produced part periodically. The testing is suitable to analyze the hardenebility of material.

Fig.11 (a) Emery papers
Fig. 12(a)
46
Emery papers Fig.11 (b) Sizes and charts
Fig. 12(a) Polish machining disks
Sizes and charts
g.

47
Fig.12 (b) Polish machining Lubricants
The above lubricants are utilized for metallurgical process which are composed of (Distilled
water and Alumina spray) respectively.
Rockwell Hardness Testing:
Fig13. Hardness testing on the produced part

48
Fig.14 Penetrating observation
Microstructure :
The Metallurgical microscope is used to view the directive crystal structures. Etched part is
placed over light emitting rays through the column’s mid space. A handle is being fixed on the
left and right side which is oriented with adjustable rotating knobs. The magnifying camera
adjusted on the mid-right side of the machine transform images when light rays imparts in the
etched surface.
The structure clarification is obtained by setting the handle in which the resolution at
peak level is obtained. Blurred image is converted into refined image respectively. Image is
being transforming until it attains clear appearance level. The upper settled piece where light
rays are releasing to display is placed over a simple holed washer for greater stability and
stagnant properties.

49
Now the image is displayed over the computer screen inbuilt software application of
microstructures. The position is changed and the view being saved at different areas. The image
captured is based upon magnification nearly 200-220pixels of resolutions. The different structure
shows the grain growth with no of porosity between them.
Fig.15 Microscopic Device
Eye piece, Knurled Knob, Star Handle screw, Sighting Microscope, Rotary circular table,

50
CHAPTER 5
RESULTS & DISCUSSION
The perspective discussion over the analyst of performance is about to represent by valuing task
operations and their technical preparations.
The optimized value for powder’s optimization of First titration results the lower
hardenebility capacitance whereas numerous proportion were transformed to obtain the optimum
level of stability. But the substance shows upper layer deformation by removal of surface layers
due to friction occurring and external stress impact. Generally, the specimen which is of
composite material of (Mica-Ferro-Silicon) has been produced in different color with 5mm-6mm
thickness is providing fine output of insulation. The specimen fails under sudden impact
maximum force usually its lower toughness, low ductility, brittle material and adhesion property.
The contact with water and oil causes loss in its strength and formability. Due to the abrasion the
particles remove and the size reduces rapidly. This tend further breakdown in the mechanical and
other physical properties with rate of time.
Only the thermal conductivity and brittleness is overwhelmed to be used as well
as in the purpose of insulation and coating purposes over many solid materials.
Second titration values more to the purpose of a productive task. This titrated
proportion in which the copper has been mixed with an accurate profile bothers higher
hardenebility as compare to the previous transformed specimen. The subjugation of copper
involvement with (Mi-Fe-Si) stands fine grains size and lower porous surface introduction within
it. Its specific density IS 8.96 gms/cm3. The metal forming expelled maximum strength in
ability. Even the green compact was that much tough to bear sudden impact force in free fall of
body. The powders during compaction stands greater stressed as compared to ( Mi-Fe-Si)
performances.

51
SINTERING RESULTS:
Fig16. (a) Real compacted piece of “Mi-Fe-Si”[30%-70%](Upper)], [60%-40%](Lower]
Fig16. (b) Real compacted piece of “Left(Cu-Fe-Si)[90%-10%], Right(Cu-Mi)[90%-100]

52
Fig17. (a) Sintered part of (Mi-Fe-Si) Fig17. (b) Sintered part of (Cu-Mi)
Fig18. (a) Sintered part of (Cu-Fe-Si)
Fig18. (b) Sintered and etched part of (Cu-Mi-Fe-Si)

53
The timing delay causes here some defect in low hardened material. Though they lose strength
due to heating the easier wrecking stability is deduced. The most case viewed in the Mica matrix
based composite. The lower temperature also provided instability ratio in the base metallic
growth. Hence the availability of furnace fails to recognize the mica bonding with other
applications. The instant heat stayed proficient in Copper based metallic growth.
MICROSTRUCTURE RESULTS:
Following are the figures:
Fig19. Perspective crystalloid View of composite phase Copper

54
Fig20. (a)Highly magnified crystallites of Cu-Fe-Si-Mi in different portions
Fig20. (b)Closed magnified structure of Cu-Fe-Si-Mi in equal portions

55
Fig21. An overview of crystal porous and stabilization flakes of matter
Fig.22 Closed view of equal spaced structures

56
Description of micro structures:
The different structures shows the appearance of different crystal stability at spatial spaces as per
illustrated in the figure. The applied imposition of three phase’s distribution is impregnated over
the substrate.
There are depictions of copper, mica, ferrosilicon in each material’s microstructure. These
are uniformly deposited over there surface in different colors, some are of equally spaced,
separated distantly, creation of porous surface including vacancies between particles. The
maximum porous part stands higher vulnerable to break.
In figure (a) the crystals are highly spatial and porous due to non optimum diffusion
performance between particles. The fig.(b) shows the increased quantity of copper and mica
crystal which depicts lower porous surface. The fig.(c)shows the Cu-Mi-Fe-Si proper
distribution. The fig.(d) shows the stabilization of cooper and mica flakes which further causes
lower strengthen property. Fig. (e) Depicts the proper crystal formalities within three phases of
property. It has lower porosity formation.
ROCKWELL HARNESS TEST:
Sl.no
Rockwell hardness testing
Cu-Mi-Fe-Si Cu-Mi Cu-Fe-Si
1. 94 HRC 100 HRC 99 HRC
2. 100 HRC 85 HRC 103 HRC
3. 115 HRC 95 HRC 89 HRC
4. 110 HRC 89 HRC 82 HRC
The above readings are considered to perform for the analysis of testing.

SIMULATION RESULTS:
Fig.23 shows the static and dynamic simulation on Punching the Die
However the testing becomes performable on the copper based analysis. Further the
testing was distributed among different stages. The shiny surface and durability to withstand
more thermal, electrical and mechanical effect in the form o
experiment at ‘Brinell’ hardness doesn’t assisted fine because of surface breakdown and high
stress effect on material. The Vickers hardness
in the specimen due to a composite fo
57
the static and dynamic simulation on Punching the Die
more thermal, electrical and mechanical effect in the form of composite is obtained. The
hardness doesn’t assisted fine because of surface breakdown and high
erial. The Vickers hardness needs extra shine surface which was not possible
composite formation.
the static and dynamic simulation on Punching the Die
f composite is obtained. The
hardness doesn’t assisted fine because of surface breakdown and high
extra shine surface which was not possible

58
CHAPTER 6
CONCLUSION
The behavior of the transformed material is assisting different performance in the performing
methods. Optimization for work ability is procuring beneficial information through output after
involving in analysis. Possible demonstration is forward during work to acquire property.
The compatibility issues in the technical input depicts that some retardation was happened
during performance because of damping coefficients, load fluctuations, clearances and
evacuating improperness, temperature values and timings correspondence for the purpose.
 Compacting Technique provided efficiency to develop new atomic structure with metal
forming and metallurgy aspects.
 Sintering process improved the molecular structure with grain growth between crystal
spaces due thermal energy enhancement.
 Micro structural review after possible etchant apply provided the optimum clarification
within material grains, crystalloids, volume spaces, porosity etc.
 The hardness tester based upon the composite materials development provides better
efficiency in all three phased alternative structures.
 Simulation on the work ability of punching-die is iso-statically demonstrated.
 The theoretical analysis based upon hardness is predictable for mechanical usages.
 Heat treatment enhanced the understanding physical creature for method and productivity
in affirmative tasks.
SCOPE OF FUTURE REVIEW:
The theme to perform in forthcoming era of development is by improving the new and
technology proved resources so that the maximum efficiency should be achievable. Our motto
must be in supremely enhanced and profitable conclusive results. The physical and mechanical
effects by those analyses would stand better in industrialization purposes.

59
CHAPTER 7
REFERENCES
1. Deonath, “Preparation of cast aluminum alloy mica composites” Journals of Material Science
15 (1980)
2. Journal of the European Ceramic Society 29 (2009) 2177–2184, [Science Direct],
Mechanical properties of textured ceramics from muscovite–kaolinite alternate layers.
(www.elsevier.com/locate/jeurceramsoc)
3. Clays and Clay minerals, Vol.46, No. 1, 79-88, 1998[Transformation of illte to muscovite in
politic rocks.]
4.Radiation Physics and Chemistry 87 (2013) 26–30, [Investigation of thermo luminescence
characteristics of gamma irradiated phlogopite mica], www.elsevier.com/locate/radphyschem
5. American Mineralogist, Volume 72, pages 537-550, 1987, [Muscovite dehydroxylation study}
Department of Geo Sciences, University of Illionis at Chicago,USA
6. Experimental study of muscovite stability in pure H2O and 1 molal KCl HCl solutions
www.elsevier.com/locate/radphyschem
7. JOURNAL OF RESEARCH of the National Bureau of Standards- A. Physics and Chemistry
Vol. 67A, No. 6, November-December 1963,[ Thermal Behavior of Muscovite Sheet Mica
Stanley Ruthberg]
8. Materials Physics and Mechanics 11 (2011) 60-67, [electrical and dielectric characteristics of
annealed muscovite ruby mica], mohansinghphysics@gmail.com
9. Contributions to mineralogy and petrology, {September 1974, Volume44, Issue 3, pp 173-
194,}, Calculation of Muscovite, Paragonite-alkali feldspar phase relations
10. United states of Patent, Towne’s [PROCESS FOR MANUFACTURING MICA
SHEET COMPOSITES]

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