International Journal of Scientific Engineering and Applied Science (IJSEAS) - Volume-1, Issue-5, August 2015 ISSN: 2395-3470 www.ijseas.com

INVESTIGATION OF WEAR BEHAVIOUR OF Al 6061 ALLOY

REINFORCED WITH SiC, AlR2ROR3R AND E GLASS FIBER

1 2 3 R.SaravananP ,P K.VinodP ,P T.TamilarasanP P 1 Assistant Professor, Kalaignar Karunanidhi Institute of Technology, Coimbatore 2 P P Assistant Professor, Kalaignar Karunanidhi Institute of Technology, Coimbatore 3 P P Assistant Professor, Kalaignar Karunanidhi Institute of Technology, Coimbatore

Abstract compared to matrix phase it is stronger. So it is called Aluminium 6061 has been used as matrix material as reinforcement phase. In this work the various for its excellent mechanical properties coupled with aspects of the wear behavior of MMC’s have been good formability. Numerous technological challenges investigated. Metal Matrix Composites (MMCs) have present in casting techniques for obtaining a proper resistant with the ceramic particulates and tender to distribution of reinforcement in the matrix. In this the significant performance advantages over pure work Al 6061 alloy act as a matrix and AlR2ROR3R, SiC, E metals and alloys. MMC’s are adapt with the best glass fiber are used as reinforcement. Composites are properties of the two components, such as ductility fabricated by liquid metallurgy technique (stir casting) and toughness of the matrix. Generally aluminium for decreasing the castings fault and to improve the alloys are having low density and good adaptability, proper mixing of reinforcement and matrix. Al 6061 good corrosion resistance and high thermal and alloy is melted at 680° C and then preheated electrical conductivity. The objective of the present reinforcements are added to maintaining stirrer speed study is to investigate the wear behaviour of al 6061 around 180 RPM. The smallest amount of reinforced with AlR2ROR3R, SiC and E glass fiber. magnesium is added for enhancing usability and then 2. Literature survey molten metal is transferred into the mold cavity for Prashant Sharma, et.al.[1] have studied the properties machining composite as per the ASTM standards to of hybrid metal matrix composites containing conduct a tribological test in Pin on Disc apparatus. Al,SiC,E glass fiber. His experimental results, says The Sliding wear tests are conducted at various loads, when increasing the reinforcement compositions the Speeds, Sliding distances. Experimental results tells tensile, hardness are slightly increased. Satyappa the minimum wear is found in 10% wt of AlR ROR R, 6% 2 3 basavarajappa, et.al .[2] have studied the Dry Sliding wt of SiC and 4%wt of E glass fiber compared with Wear Behaviour of Hybrid Metal Matrix Al 6061 alloy. Composites.The experiment results, says the wear

Keywords: Al 6061, AlR2ROR3R, SiC, E glass fiber, Stir rate has been increased with the increasing load and casting, Pin on Disc. liquid metallurgy technique, decreased with increasing speed. Al-qutub, et.al [3] preheated reinforcements, Pin on Disc apparatus. has studied the Wear properties of 6061 aluminum alloy composite. This experiment results, says 1.Introduction depending on the load, the wear resistance increased Aluminium based metal matrix composites have by the reinforcement and also, the transition load evoked a keen interest in recent times for potential from mild to sever wear, was increased due to the applications in marines, aerospace and automotive addition of the reinforcement. S. Venkat Prasat, et.al. industries owing to their superior strength to weight [4] have investigated the Parameters on the Dry ratio, good wear and corrosion resistance. Composite Sliding Wear Behaviour of Aluminium/Fly materials are having their desirable properties, which ash/Graphite Hybrid Metal Matrix Composites. From include high specific stiffness, low density, his investigation results shows a at high sliding controlled co efficient of thermal expansion, high speeds, mechanically mixed layer (mml) and a specific strength, and superior dimensional stability lubricating film of graphite were formed between the at elevated temperatures. As the dispersed phase is composite pin and the steel counter face and they

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International Journal of Scientific Engineering and Applied Science (IJSEAS) - Volume-1, Issue-5, August 2015 ISSN: 2395-3470 www.ijseas.com reduced the chance of direct metallic contact, thereby small diameters owing to the poor wet ability lowered the wear rate. Ozben et.al [5] investigated between the matrix and reinforcement. about the Machinability of MMC and observed 4. Experimental setup MMC was very different from traditional materials because of abrasive reinforcement element. This was 4.1. Specimen preparation due to abrasive element causes more wear on cutting The MMC’s were prepared by using cast aluminium tools. Flank wear of cutting tool are also increased alloy Al 6061 as matrix and AlR2ROR3R, SiC, Eglass fiber with increase in reinforcement ratio. WANG et.al [6] as reinforced materials. In the hybrid MMC’s the investigated the wear performance of Hybrid metal reinforcement materials were used on different matrix composites using Aluminium oxide (AlR2ROR3R) proportions. Table 1 shows the percentage fibers and Silicon carbide particles as reinforcements composition of the materials. The ratios are randomly with aluminium cast alloy A536 as matrix and two selected to the field of casting process. different orientations of fibers, PR-orientation and N- orientation and three different ratios of reinforcements.. They observed that the wear resistance of the specimens with the N-orientation of the fibers is better than that with the PR-orientation for all the three hybrid ratios. The coefficient of friction decreases when the temperature increases. Furthermore, although the hybrid ratio has little effect on the coefficient of friction, the fiber orientation had a greater effect on this. SURESH et.al [7] investigated the wear behaviour of Al6061MMCs and its relation with Processing & microstructure. Fig 1 Al 6061 alloy Composite with 10%,20%,30% compositions They concluded the wear rate and coefficient of friction decreased linearly with increasing weight Table 1 composition of composite materials percentage of AlR ROR R. The wear rate increase as the 2 3 Al 6061(%) Al203(%) SiC(%) Eglass sliding speed increases. The best results of minimum fiber(%) wear have been obtained at 8% weight fraction of 90 5 3 2 AlR2ROR3R. Hariharan et.al [8] observed that the wear resistance of the composite is increased as the 80 10 6 4 percentage of the TiBR2 Rincreases. And also the increased volume fraction of the TiBR2R particles 70 15 9 6 contributed to increase the strength of composites.

R.L.Deius et.al [9] says the adhesive wear of Al-Si 4.2. Wear test machine alloy and aluminium composites containing The wear characteristics of casting Al alloy is tested discontinues reinforcement phases, such as the role using pin on disk apparatus. The pin specimen is held of reinforcement phase encountered by the material. strongly beside the rotating steel counter disk with

the help of an applied load. 3. Preparation of Al alloy

Generally The Al alloy is produced by various 4.3. Matrix material methods such as Stir casting, powder metallurgy, In this investigation 6061 aluminium alloy is used as squeeze casting process. Here, the stir casting process a matrix material for preparing the composites. is mostly used and most adaptable. And also the Table 2 shows the rate of chemical compositions of additional benefit of this process is the near net shape Al 6061 alloy. formation of the composites by conventional Table 2 chemical composition boundary process. Stir casting method is low cost and Element Mg Si Fe Cu Cr Mn Al easy to put the operation. The basic process is to put into the second phase of the melt via stirring. Weight % 1.0 0.8 0.7 0.3 0.2 0.15 Remainder Additionally it is difficult to allocate particles with

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International Journal of Scientific Engineering and Applied Science (IJSEAS) - Volume-1, Issue-5, August 2015 ISSN: 2395-3470 www.ijseas.com

5. Experimental Procedure 5.2.1Pin On Disc Apparatus Test

5.1.Stir Casting Process

Fig 3 Wear test – pin on disc machine

A pin-on-disc machine was used to investigate the dry sliding wear behavior of the aluminum alloy

6061 and AlR2R0R3R, SiC, E glass fiber composites as per ASTM standards. That the Sliding wear tests are conducted at various loads, Speeds, Sliding distances. It is noted that three samples were tested for each Fig 2 Stir casting machine conditions in the analysis. The matrix alloy was reinforced with 10% wt of The wear rate was determined using weight loss AlR2ROR3R, 6% wt of SiC and 4%wt of E glass fiber compared with Al 6061 alloy by stir casting process. method. The wear of the composite was studied as a The production process of matrix alloy and function of the applied load. In the wear test the pin composites is as follows: Al 6061 alloy is melted at (specimen) was pushed next to the counterpart 680° C and then preheated reinforcements are added rotating against EN 31 steel disc with hardness 56-58 to maintaining stirrer speed around 180 RPM. The HRC by applying the load. An around strain gauged smallest amount of magnesium is added for friction-detecting arm holds and loads the pin enhancing usability and then molten metal is specimen vertically into a rotating hardened steel transferred into the mold cavity for machining. disc. After running throughout the sliding distance of 5.2. Wear Test Machine 1884 m for 7 min 57 seconds, the specimen were The wear characteristics of casting Al alloy is tested removed, cleaned with acetone, dried and weighed to using pin on disk apparatus. The pin specimen is held find the weight loss due to wear. The difference in strongly beside the rotating steel counter disk with the weight measured before and after the test gives the help of an applied load. The pin Specimen is the wear of the specimen. The wear was calculated pressed against the disk at a specific load usually by using weight loss method. means of an arm or level and attached weights. The amount of wear is determined measuring appropriate 6. Results & Discussion linear dimensions of both specimens before and after 6.1. Sem micrographs of the mmc’s: test, or by weighing both specimens before and after The Scanning electron microscope images of the Cast test. Al6061 alloy with three different compositions are shown in figure 3a,b&c.The microscope clearly indicates the Wear portions of the material.

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International Journal of Scientific Engineering and Applied Science (IJSEAS) - Volume-1, Issue-5, August 2015 ISSN: 2395-3470 www.ijseas.com

6.2.Calculation of Wear rate

Table 3 Parameters of calculating wear rate LOAD SPEED DISTANCE

10 2 1000

20 3 1750

30 4 2500

Table 4 variation in wear rate for Al 6061 composite

alloy Fig 4a) SEM micrographs Al6061 10% composition. S.NO COMPOSITION TRIAL INITIAL FINAL WEIGHT WEAR WEIGHT WEIGHT LOSS RATE

3 (g) (g) (g) (mmP /km)P Al 6061 alloy 1 composite I 6.6 6.4 0.2 0.0002 with 10%

reinforcement II 6.4 6.1 0.3 0.0003

Al 6061 alloy 2 composite 5.3 5 0.3 0.0003 Fig 4b) SEM micrographs Al6061 20% I with 20% composition. reinforcement II 5 4.6 0.4 0.0004

Al 6061 alloy 3 composite I 3.8 3.4 0.4 0.0004 with 30%

reinforcement

II 3.4 3.1 0.3 0.0003 Fig 4c) SEM micrographs Al6061 30% composition. The above table shows the variation of wear rate with applied load for Al 6061 alloy composites. It can be observed from the figure that as the applied load increases the wear rate also increases. At the initial phase, little change in wear rate was observed for

trail 1 and 2 as the applied load increases more change in the wear was observed. The wear of the Al

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6061 alloy composite with 10% reinforcement is less tribology conference , ISSN – 1221 – 4590 than that of other compositions for all applied load. September 2013.

7.References 1. Prashant Sharma, A. Paul ; Properties of Hybrid MMCs containing Al as base material 10. T.Miyajima, Y.Iwai ; Effects of reinforcement and mixed with SiC and E-glass , International on sliding wear behavior of aluminium matrix Journal of Latest Trends in Engineering and composites , ISSN- 606-616 wear 205 (2003). Technology (IJLTET), Vol. 1 Issue 3 11. M K Surappa ; Aluminium matrix composites: September 2012. Challenges and opportunities , sadhana vol.28 , pp-319-324 april 2003. 2. basavarajappa, govindarajulu Satyappa 12. Prashant S N , Madeva nagaral, V Auradi ; chandramohan ; Dry Sliding Wear Behaviour Preparation and evaluation of mechanical and of Hybrid Metal Matrix Composites , ISSN wear properties of Al 6061 reinforced with 1392–1320 MATERIALS SCIENCE graphite particulate metal matrix composite , (MEDŽIAGOTYRA). VOL. 11, NO. 3. 2005. IIMMSE, ISSN-2278-2516, Vol. 2 Issue 3 3. Al-Qutub, A M 1 ; Allam, I M; Qureshi, T W ; September 2012. Wear properties of 10% sub-micron Al sub 2 O 13. Ashok K.Mishra, Rakesh sheokand ,Dr.R K sub3/ /6061 aluminum alloy composite , Srivatsava ; Tribological behavior of Al 6061 / Technical University of Zielona Gora, SiC Metal matrix composite by taguchi’s Department of Mechanics, ul. Szafrana 2, P.O. technique , International journal of scientific Box 47, Zielona Gora, 65-516, Poland, and research publications , ISSN- 2250- Volume: 7, ISSN: 1425-1655 Year: 2002. 3153Vol. 2 Issue 10 October 2012. 4. S. Venkat Prasat, R. Subramanian, N. Radhika, B. Anandavel, L. Arun, N. Praveen ; Influence of Parameters on the Dry Sliding Wear Behaviour of Aluminium/Fly ash/Graphite Hybrid Metal Matrix Composites , European Journal of Scientific Research ,ISSN 1450- 216X Vol.53 No.2 (2011), pp.280-290. 5. R.L.Deuis,C.subramanian,J.M.Yellup ;Dry sliding wear of Aluminium composites, composites science and technology 57 (1997) 415-435 printed in northern Ireland. PII: S 0266- 3538(96)-00167-4, Issue – October 1996. 6. WANG Yi-qi , SONG jung-il ; Dry sliding wear behavior of AlR2ROR3R fiber and SiC particle reinforced with aluminium based MMC’s fabricated by squeeze casting method ,Trans Non ferrousmet.soc.china 21 (2011) 1441- 1448 in August 2010. 7. Rabindra behera, Nihar ranjan mohanta, G.Sutradhar ; Distribution of SiC particles in Stir cast aluminium alloy metal matrix composites and its effect on mechanical properties , ISSN- 2249-6149, Issue 2 ,Vol 1 January 2012. 8. V.C.Uvaraja, N.Natarajan ; Tribological characterization of stir cast hybrid composite aluminium 6061 reinforced with SiC and B4C particulates , ISSN- 1450-216X ,Vol 76 No 4 (2012). 9. Mihaly cozma ; Friction and wear of aluminium matrix composites , in National

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