JASC: Journal of Applied Science and Computations ISSN NO: 1076-5131 STUDY ON FABRICATION AND CHARACTERIZATION OF ALUMINIUM METAL MATRIX COMPOSITES AND NANOCOMPOSITES

Prof. Pankaj P. Awate1, Prof. Dr. S. B. Barve2 1 Ph.D.Scholar, Department of Mechanical Engineering, MIT WPU Pune, India 2 Prof. Head, Department of Mechanical Engineering, MIT WPU Pune, India [email protected] [email protected]

Abstract – In today’s competitive world need has been increased towards development of low cost, efficient, lightweight, corrosion resistive, highly reflectivity, tough, conducive materials. Aluminium alloy composites are well known for its better thermal expansion coefficient, wear resistance, corrosion resistance and other mechanical properties. Composites are materials which are made up of two or more materials; when combined together it shares some properties of these combined elements. These combinations can be designed to have different properties like stiffness, resistance to impact or use in high temperature Environments. Nanocomposite is emerging as high strength advanced materials for the industrial applications that have potential of satisfying recent demands of advanced engineering applications. In this paper an attempt has been made to provide a brief review on aluminium and its alloy, aluminium matrix composites and nanocomposites, fabrication and characterization technology and to suggest a least expensive method for production of nanocomposites.

Keywords— Fabrication, Characterization, Aluminium, Composites, Nanocomposites etc

I. INTRODUCTION The application of an advanced material may be the key to revolutionizing a product line and keep pace with accelerated market change and technology developments. The aluminium matrix composites (AMCs) are low-weight and high- performance materials that have potential to replace conventional materials in many advanced applications. These materials can provide excellent combination of properties such as high specific strength, high specific stiffness, low density, improved dimensional stability and greater wear resistance. The metal matrix composites have various advantages over other types of composites. Such as high strength, high modulus, high toughness and impact properties, Low sensitivity to changes in temperature or thermal shock, high surface durability and low sensitivity to surface flaws, high electrical conductivity.

The Aluminium metal matrix composites are finding widespread applications in engineering, automobile, aircraft, marine, aerospace, and defense and recreation industries etc. Nanocomposite is emerging as high strength advanced materials for the industrial applications that have potential of satisfying recent demands of advanced engineering applications. Nanocomposites are usually added nanoparticles or nanosized structure and fibers to enhance mechanical strength, toughness and electrical or thermal conductivity. The mechanical behaviors of nano-composite with reinforced particles and fibers, such as bending, buckling, vibration, etc., have attracted attention of many researchers around the world. We can expect superior capacities and remarkable enhancement in various properties in nanocomposites, as compared to traditional materials. Here an interest has been focused on the nano structured aluminium metal matrix composites, due to their predominant mechanical properties. An interest has been focused on the nano structured aluminium metal matrix composites, due to their predominant mechanical properties. Here attempt will be made to develope new nano structured aluminium metal matrix nanocomposite (AMMNC) with predominant mechanical, thermal, physical and vibration properties.

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II. COMPOSITES A material is composite when two or more different materials are combined together to create a superior and unique material. Benefits of Composites are weight savings, Non-corrosive, Non-conductive, Flexible, will not dent, Low maintenance, Long life, Design flexibility etc. Metal matrix composites are made of a continuous metallic matrix and one or more discontinuous reinforcing phases. The reinforcing phase may be in the form of fibers, whiskers or particles. The metal matrix composites have various advantages over other types of composites. Such as high strength, high modulus, high toughness and impact properties, Low sensitivity to changes in temperature or thermal shock, high surface durability and low sensitivity to surface flaws, high electrical conductivity.

1. A. Aluminium Matrix Composites Aluminium material has been most attracted as matrix element in composites due to its special properties such as lower density, higher ductility and high strength to weight ratio. Aluminium matrix composites replaced cast iron and bronze alloys, steel and steel alloys in various sectors resulting in excellent predetermined properties. Composites are classified depending upon 1) matrix and 2) reinforcements. The role of matrix is to hold the fiber or particulate reinforcements in particular orientation as designed and protects from environmental reactions.

2. B. Classification of Composites 1. On the basis of matrix constituent 1.1 Organic Matrix Composites (OMCs) are Organic matrix composites are also known as polymer matrix composites, the polymers used as matrix may be of either thermoset or thermoplastics. Epoxy resins, phenolic olyamide resins and polyester resins are used as thermoset matrix elements. Polyethylene, polyamides nylons and polypropylene are used as thermoplastics matrix elements applications. 1.2 Ceramic Matrix Composites (CMCs) use silicon di-oxide, alumina, glass, ferrites and titanates. These composites have high hot hardness property. They offers high melting point, good corrosion resistance, stability at elevated temperatures up to 1500oC and low coefficient of thermal expansion. 1.3 Carbon Carbon Composites (CCCs) - Carbon and graphite have special place in composite materials as their strength and rigidity can be maintained at temperatures around 2300oC. Carbon Carbon composites retain their properties at room temperature as well as at elevated temperature. Their dimensional stability makes them an obvious choice for aeronautics, military, industry and space applications

2. On the basis of reinforcement constituent 2.1 Fiber Reinforced Composite satisfies the desired properties of composites and transfer strength to matrix constituent. The orientation of the fiber in the matrix determines the strength of the composites and the strength is greater along the longitudinal direction of the fiber. Most commonly used fibers are glass fibers, metal fibers, Alumina fibers, boron fibers, silicon carbide fibers, graphite fibers and multiphase fibers. Composites with non continuous fiber as reinforcements do not have improved mechanical properties as continuous reinforced composites. But their production cost is lower, processing methods are more adaptable to conventional ones and their performance is acceptable. 2.2 Laminar Composites consists of different layers of materials arranged in particular orientation. Clad and sand-which laminates have many areas of applications as it ought to be. Powder metallurgical process such as roll bonding, hot pressing and diffusion bonding can be employed for the fabrication of different laminated composites. 2.3 Particulate Composites are composites in which particles of one phase strewn into the other, which is visible through microscope in metal and ceramic matrix composites. The size of the dispersed particles is of the order of few microns and their volume concentration varies as per the strength requirements. These dispersions strengthen the material matrix by arresting the motion of dislocations and hence enhancing the forces requiring for fracture.

III. NANOCOMPOSITE Nanocomposite is multiphase solid material with its one dimension, two dimensions or three dimension less than 100 nanometer or phases having a nanoscale repeat distance that makes up the material. Nanocomposites are usually added nanoparticles and fibers to enhance mechanical strength, toughness and electrical or thermal conductivity. The mechanical behaviors of nano-composite with reinforced particles and fibers, such as bending, buckling, vibration, etc., have attracted attention of many researchers around the world. Aluminium-based metal matrix composites (MMCs) reinforced with nanoparticles are attractive for many applications attributable to their excellent properties such as light weight, high stiffness and strength, high thermal stability, superior wear resistance. The fundamental component of nanotechnology is the nanoparticles. Nanoparticles are particles between 1 and 100 nanometres in size and are made up of carbon, metal, metal oxides or organic matter . The nanoparticles exhibit a unique

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physical, chemical and biological properties at nanoscale compared to their respective particles at higher scales. This phenomena is due to a relatively larger surface area to the volume, increased reactivity or stability in a chemical process, enhanced mechanical strength, etc. These properties of nanoparticles has led to its use various applications. The nanoparticles differs from various dimensions, to shapes and sizes apart from their material. A nanoparticle can be either a zero dimensional where the length, breadth and height is fixed at a single point for example nano dots, one dimensional where it can possess only one parameter for example graphene, two dimensional where it has length and breadth for example carbon nanotubes or three dimensional where it has all the parameters such as length, breadth and height for example gold nanoparticles. The nanoparticles are of different shape, size and structure. It be spherical, cylindrical, tubular, conical, hollow core, spiral, flat, etc. or irregular and differ from 1 nm to 100 nm in size. The surface can be a uniform or irregular with surface variations. Some nanoparticles are crystalline or amorphous with single or multi crystal solids either loose or agglomerated

A. Advantages of Composites / Nanocomposites – Can be designed to have high corrosion and fatigue resistance. High stiffness or strength to weight ratio can be attained. Directional orientation of reinforcements can be easily achieved to enhance strength properties. Hard particle reinforcements can be easily achieved to enhance wear resistance properties. Can be easily tailored to suit for various applications such as lightweight, low coefficient of thermal expansion, hot hardness, wear resistance and fatigue resistance.

IV. ALUMINIUM AND ITS ALLOY Symbol: Al, Density: 2.7 g/cm³ (g/cm3), Atomic mass: 26.981539 u ± 8 × 10^-7 u, Melting point: 660.3 °C. Aluminium or aluminum is a chemical element with atomic number 13. It is a silvery-white, soft, nonmagnetic and ductile metal in the boron group. By mass, aluminium makes up about 8% of the Earth's crust; it is the third most abundant element after oxygen and silicon and the most abundant metal in the crust, though it is less common in the mantle below. The chief ore of aluminium is bauxite. It is the second most malleable element (after gold) and it is the sixth most ductile element. It is three times lighter than steel and yet it offers high strength in its alloy form. It is of face cubic crystal (fcc) structure which makes aluminium components to be produced and fabricated more easily and with less cost. Pure aluminium is soft and has low tensile strength of 40-50 MPa in annealed condition. It is strengthened by making it undergoing several processes like alloying, cold working and heat treatment. Aluminium is alloyed with numerous other elements to improve its formability, thermal conductivity, high strength and corrosion resistance. Aluminium alloys provide a wide range of capability and applicability owing to its several advantages that makes the material in demand in fabrication industries, automobile industries, aeronautical industries and other structural applications of transport and buildings.

A. Classification of Aluminium alloys Aluminium alloys are classified as wrought aluminium alloys and cast aluminium alloys. American society for testing materials has adopted 4 digit systems to indicate wrought. aluminium alloys and 3 digit system (plus decimal) for cast aluminium alloys. The number series ranges from 1xxx - 9xxx series for wrought aluminium alloys and 1xx.x - 9xx.x for cast aluminum alloys. These series are classified according to the major alloying elements that are added to the aluminium. They are again subdivided under heat treatable and non heat treatable aluminium alloys.1xxx, 3xxx, 4xxx, 5xxx series of wrought aluminium alloys and 1xx, 2xx are grouped under non heat treatable aluminium alloys. 2xxx, 6xxx, 7xxx of wrought aluminium alloys and 3xx, 4xx of cast aluminium alloys are grouped under heat treatable aluminium Alloys.

Number Alloyed with Information Series 99% pure aluminum. It can be work Used in applications that require a the electrical conduciveness and hardened and possessed high level of makes it perfect for use in high power electrical lines. They possesses 1XXX electrical conductivity and high low mechanical properties, relatively easy workability and a high thermal conductivity resistance to corrosion. It is alloyed with copper. It Can be Used in situations that require aluminum that has been strengthened. hardened to strengths comparable to Formerly referred to as duralumin & have a limited weldability, steel. Initially they were once the superior machinability, most commonly used in the construction of 2XXX most common aerospace alloys, but aircraft. were susceptible to stress corrosion They do not have a high resistance to corrosion and, in some cases, cracking and are increasingly replaced might even be subject to inter-granular corrosion. by 7000 series in new designs.

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It Added strength to alloys useful in making cooking utensils, as Alloyed with manganese, and can 3XXX well as beverage cans and 20% higher strength than series 1xxx grades be work hardened. of aluminum. They are used in automotive applications, are also known as 4XXX alloyed with silicon silumin, suitable for use in welding wire. Alloyed with magnesium, good Popular is 5XXX, and this is due to its ability to withstand moisture, weldabilty and a relatively good 5XXX and therefore, it is used in many marine applications. superb corrosion resistance to corrosion in marine resistance, making them suitable for marine applications environments. They are easy to machine, are weldable, and can be precipitation Alloyed with magnesium and hardened, but not to the high strengths that 2000 and 7000 can reaches. silicon. 6061 alloy is one of the most It often used as an external coating on series 2XXX aluminum alloy 6XXX commonly used general-purpose because it adds a level of protection. Alloy heat treatable. This aluminium alloys. aluminum alloys series has: 1) Weldability 2) A relatively good resistance to corrosion 3) A good formability 4) Medium strength

They are implemented in the aircraft sector. It can be precipitation hardened to the highest strengths. Used in highly stressed parts such as mobile equipment and airframe structures, higher strength 7xxx series Alloyed with zinc , created using 7XXX aluminum alloys show a reduced resistance to stress corrosion magnesium cracking. These alloys are often used in a lightly over-aged temper in order to provide a better strength, a higher resistance to corrosion and toughness against fractures.

8XXX Aluminium -lithium alloys Alloyed with other elements which are not covered by other series

B. For Aerospace applications – AA 2024 alloy is somewhat stronger than AA6061 but they do not have a high resistance to corrosion and, in some cases, might even be subject to inter-granular corrosion. AA 6061 - This aluminum alloys series has: 1) Weldability 2) A relatively good resistance to corrosion 3) A good formability 4) Medium strength which is not the case for 2024, which is usually used with a thin Alclad coating for corrosion resistance. They are easy to machine, are weldable, and can be precipitation hardened, but not to the high strengths that 2000 and 7000 can reaches. It often used as an external coating on series 2XXX aluminum alloy because it adds a level of protection. 7075 Series aluminum alloys show a reduced resistance to stress corrosion cracking.

C. Benefits of aluminum  Aluminum is a light metal, about the third of the density of steel, copper, and brass.  Aluminum has good corrosion resistance to common atmospheric and marine atmospheres. Its corrosion resistance and scratch resistance can be enhanced by anodizing.  Aluminum has high reflectivity and can be used for decorative applications.  Some aluminum alloys can match or even exceed the strength of common construction steel.  Aluminum retains its toughness at very low temperatures, without becoming brittle like carbon steels.  Aluminum is a good conductor of heat and electricity. When measured by equal cross-sectional area, electrical grade aluminum has conductivity which is approximately 62% of electrical grade annealed copper. However, when compared using equal weight, the conductivity of aluminum is 204% of copper.  Aluminum is readily worked and formed using a wide variety of forming processes including deep- drawing and roll forming.  Aluminum is non-toxic and is commonly used in contact with foodstuffs.Aluminum can be readily recycled.

D. Aluminum Temper Designations The temper designation follows the alloy code and is separated by a hyphen. -F As Fabricated: Applies to products of rolling or forming where there is no special control over the thermal or work-hardening conditions. Since mechanical properties may vary widely, no limits have been assigned. This temper usually applies to sheet products which are at intermediate stages of production.

-H Strain-Hardened: Applies to wrought products which are strengthened by cold-rolling or cold-working.

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-O Annealed: Applies to wrought products which have been heated above the recrystallization temperature to produce the lowest tensile strength condition of the alloy.

E. Designations of The –H Strain Hardened Tempers The First Digit - There are three different methods used to achieve the final temper of strain hardened material. –H1 Strain Hardened Only: Applies to products which are strain hardened to obtain the desired strength level without any subsequent thermal treatment. –H2 Strain Hardened and Partially Annealed: Applies to products that are strain hardened to a higher strength level than desired, followed by a partial anneal (or “back anneal”) which reduces the strength to the desired level. –H3 Strain Hardened and Stabilized: This designation only applies to magnesium-containing alloys which gradually age- soften at room temperature after strain hardening. A low temperature anneal is applied which stabilizes the properties.

The Second Digit The amount of strain hardening, and hence the strength level, is indicated by a second digit. -Hx2 Quarter hard -Hx4 Half hard -Hx6 Three quarter -Hx8 Full hard Extra hard (the minimum tensile strength exceeds that of the Hx8 temper by -Hx9 2 ksi or more) Hx1, Hx3, Hx5 and Hx7 tempers are intermediate between those defined above. The mechanical property limits that correspond to each temper designation can be found by referring to an appropriate aluminum standard such as the Aluminum Association Standards and Data or ASTM B 209.

The Third Digit A third digit is sometimes used to indicate a variation of the basic two-digit temper.

F. Heat Treatment Tempers Alloys in the 2xxx, 6xxx and 7xxx groups can be strengthened by a heat treatment process. The aluminum is heat treated by carrying out a solution treatment process, in which the metal is heated to an elevated temperature followed by rapid cooling, then a precipitation hardening process (or “aging” process). The tempers are designated by –T followed by a digit. Some common –T tempers are as follows: –T3 Solution heat-treated, cold worked, and naturally aged: Applies to products that are cold-worked to improve strength after solution heat-treatment, or which the effect of flattening or straightening is recognized in mechanical property limits. –T4 Solution heat-treated and naturally aged: Applies to products that are allowed to age harden at room temperature following a solution treatment. –T6 Solution heat-treated and artificially aged: Applies to products that are reheated to a low temperature following a solution treatment. This allows the metal to achieve its highest heat-treated strength level.

V. FABRICATION TECHNOLOGY Fabrication of the composite materials is focused on obtaining materials with improved properties compared to the matrix material. A key challenge in the processing of composites is to homogeneously distribute the reinforcement phases to achieve a defect-free microstructure. Primary processes for manufacturing of AMCs at industrial scale can be classified into two main groups. Accordingly; the processes can be classified into two categories: 1. Liquid State Processes, 2. Solid State Processes.

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1) Liquid State Processes

6.2) Solid State Processes

VI . CHARACTERIZATION A. Microstructure Analysis is used widely throughout industry to evaluate products and materials. Metals have a preferred microstructure obtained by a specified processing or heat treatment to achieve desired material properties. This can be achieved using Scanning electron microscope (SEM), Transmission electron microscopy, X-ray Powder Diffraction (XRD).

Scanning electron microscope (SEM) is a type of electron microscope that produces images of a sample by scanning the surface with a focused beam of electrons. The electrons interact with atoms in the sample, producing various signals that contain information about the surface topography and composition of the sample. The electron beam is scanned in a raster scan pattern, and the position of the beam is combined with the detected signal to produce an image. SEM can achieve resolution better than 1 nanometer. Specimens are observed in high vacuum in conventional SEM, or in low vacuum or wet conditions in variable pressure or environmental SEM, and at a wide range of cryogenic or elevated temperatures with specialized instruments. The most common SEM mode is the detection of secondary electrons emitted by atoms excited by the electron beam. The number of secondary electrons that can be detected depends, among other things, on specimen topography. By scanning the sample and collecting the secondary electrons that are emitted using a special detector, an image displaying the topography of the surface is created.

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Fig.1) Scanning electron microscope (SEM)

Transmission electron microscopy (TEM, also sometimes conventional transmission electron microscopy or CTEM) is a microscopy technique in which a beam of electrons is transmitted through a specimen to form an image. The specimen is most often an ultrathin section less than 100 nm thick or a suspension on a grid. An image is formed from the interaction of the electrons with the sample as the beam is transmitted through the specimen. The image is then magnified and focused onto an imaging device, such as a fluorescent screen, a layer of photographic film, or a sensor such as a charge-coupled device. Transmission electron microscopes are capable of imaging at a significantly higher resolution than light microscopes, owing to the smaller de Broglie wavelength of electrons. This enables the instrument to capture fine detail—even as small as a single column of atoms, which is thousands of times smaller than a resolvable object seen in a light microscope. Transmission electron microscopy is a major analytical method in the physical, chemical and biological sciences. TEMs find application in cancer research, virology, and materials science as well as pollution, nanotechnology and semiconductor research.

X-ray Powder Diffraction (XRD) X-ray powder diffraction (XRD) is a rapid analytical technique primarily used for phase identification of a crystalline material and can provide information on unit cell dimensions. The analyzed material is finely ground, homogenized, and average bulk composition is determined. Fundamental Principles of X-ray Powder Diffraction (XRD). All diffraction methods are based on generation of X-rays in an X- ray tube. These X-rays are directed at the sample, and the diffracted rays are collected. A key component of all diffraction is the angle between the incident and diffracted rays. Powder and single crystal diffraction vary in instrumentation beyond this.

B. Mechanical Testing Mechanical testing is an umbrella term that covers a wide range of tests, which can be divided broadly into two types: those that aim to determine amaterial's mechanical properties, independent of geometry.

Tensile testing, also known as tension testing, is a fundamental materials science and engineering test in which a sample is subjected to a controlled tension until failure. Properties that are directly measured via a tensile test are ultimate tensile strength, breaking strength, maximum elongation and reduction in area. From these measurements the following properties can also be determined: Young's modulus, Poisson's ratio, yield strength, and strain-hardening characteristics. Uniaxial tensile testing is the most commonly used for obtaining the mechanical characteristics of isotropic materials. Some materials use biaxial tensile testing.

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Fig.2) Tensile testing

Hardness Tests - The ability of a material to resist permanent indentation is known as hardness. It is an empirical test, rather than material property. In order to define different hardness values for the same piece of material, there are several types of hardness tests. The outcome of each test should have a label identifying the method used, as it is dependent on it. There is no intrinsic significance of hardness value or number; hence it cannot be used directly like tensile test value. The value is only useful for comparing different treatments or materials.

Testing is widely employed for process control and inspection, and the outcome is used in estimating mechanical properties like tensile strength. It is usually done using testing machines fitted with an indenter that is enforced into test matter over a period of time. The indentor’s shape varies by the hardness test type, and includes pyramid, ball and cone shapes. Each machine also makes use of different load or force application system, while recording a hardness value in kg-force as per the individual scales.

Fig.3) Tensile testing

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VI. CONCLUSION The aluminium matrix composites (AMCs) are low-weight and high-performance materials that have potential to replace conventional materials in many advanced applications. These materials can provide excellent combination of properties such as high specific strength, high specific stiffness, low density, improved dimensional stability and greater wear resistance. We can expect superior capacities and remarkable enhancement in various properties in nanocomposites, as compared to traditional materials.

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