International Journal of Scientific Research and Innovative Technology ISSN: 2313-3759 Vol. 4 No. 8; August 2017
Review Article (2017)
Development and Characterization of Nanoparticle Metal Matrix Composites: A Review
Muhammad Arshad Chaudhry1, Liaqat Ali2, Khalid Mahmood Ghauri2
1Ph.D Research Scholar, Department of Metallurgical and Materials Engineering, University of Engineering & Technology, Lahore, Pakistan 2Professor Dr. Department of Metallurgical and Materials Engineering, University of Engineering & Technology, Lahore, Pakistan
Corresponding Author: [email protected]
Abstract:
A composite material consists of at least two or more physically and chemically separate phases, one being a metal and other may be a ceramic. In recent years, Al and its alloys based cast MMCs have gained a great importance in the fields of engineering and technology due to improved properties such as high strength, low CTE, good fatigue resistance and lower creep rate than unreinforced materials. The present research is aimed for Development of nano particle Metal Matrix Composites by using stir casting process and subsequent characterization for analyzing the microstructure and mechanical properties.
MMCs play a vital role in the present day industrial and engineering sectors like Automotive, Aerospace, Defense and Industrial Infrastructure. Al alloy / SiC nano particle composites using stir casting method are light weight along with high strength and toughness. It has various advantages such as simple, flexible and could be made economical if applicable to large quantity production with enhanced efficiency of the engineering systems.
Nano Composite has nano particles with average particle size of 45-55nm. Its properties include mechanical, electrical and thermal which depends upon the materials composition used. The properties and microstructures are governed by type and size of reinforcement, nature of bonding and process of production. Recent focus is on reinforcing aluminum matrix with much smaller particles, submicron or nano sized range, is one of the key factor in producing high performance composites with enhanced mechanical properties.
Keywords: Al-Cu alloy, SiCnp, Stir Casting, Characterization.
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1. Introduction in Sequence of Events having 50% improvement with 2.0 wt% nano particle [10]. MMC is produced using Stir Casting by selecting metal Al is widely used because of its easy availability, high matrix of required grade and the dispersion of the strength to weight ratio, easy machinablity, durability, reinforcement material. In order to form a vortex, stirring ductility and malleability [11]. Stir casting is the type of is carried out vigorously in which reinforcing materials are vortex heating with stirring method in which the raw inserted from the vortex side. The reinforcement particles material gets homogeneously mixed with each other at along with all impurities drag to form the vortex. The air is controlled temperature rate [12]. It is well known that entrapped by the vortex into the melt. Due to increased MMCs being light weight, hard and abrasion resistant are viscosity of the slurry, it is difficult to remove the air from widely used for high temperature and speed parts such the melt [1]. The Particle distribution in the melt depends as pistons, axles, high speed wheels and so on [13]. upon the viscosity of the slurry, particle wetting, particle
settling rate, effective mixing, agglomeration breakup and Decrease in the reinforcement particle size from micron minimum gas entrapment [2]. The Metal matrices have a to nano sized increases the tendency of particles useful combination of properties such as high strength, clustering and agglomeration but having good strength. ductility and high temperature resistance but sometimes Homogenous particle distribution improves mechanical have low stiffness, whereas ceramics are stiff and properties [14]. Al Metal Matrix Nano Composites strong though brittle [3]. (AMMNCs) have gained considered importance because
It is well known fact that Liquid phase process has of dispersion of nano particles in the host matrix to achieve superior mechanical properties [15]. capability to develop producing of intricate profiles having
light weight [4]. Al and its alloys have preferable dispersing Al alloys having light weight, good stiffness, corrosion of SiC due to its high melting point (23000C), high stiffness resistance and improved mechanical properties etc [16]. (480 GPa), good thermal stability, high hardness (9.7 Mohs), Al alloys are mostly attractive due to their low density, great resistance to chemical attack at room temperature, good thermal & electrical properties and having good low density (3.21 gm/cm3) and low thermal coefficient of damping capacity [17]. Stir casting method is used to expansion (4.7 x 10-6 K-1). That’s why, SiC has proved achieve a suitable dispersion. It has some advantages competitive reinforcing material with wider applications in such as simple, flexible, economical and applicable to industries [5]. large quantity production [18]. Al alloy reinforced with
particulates composites are achieving great importance Al Metal Matrix Composites (AMMCs) are produced by dispersing SiC, Al 203 and B4C having micron or nano sized due to their low cost, isotropic in nature and useful into Al alloy matrix. [6]. Al Metal Matrix Nano Composites for secondary processing [19].
(AMMNCs) reinforced by nano scale particulates are widely The development of Al alloy / Al2O3 reinforced used in industry such as automotive and aerospace [7]. Stir (MMNCs) is important for such applications in casting method has some limitations of poor wettability aerospace, jet engine exit vanes, blade sleeves of which enhances the tendency of agglomeration of helicopters, parts of space shuttle, piston and cylinder reinforcement material. The wettability of SiC and Al2O3 liners, brake drums and discs [20]. Cast Al alloy matrices may be improved by adding Si or Mg [8]. have higher specific strength, specific modulus and
The objective of the present study was to investigate the good wear resistance [21]. Al alloys are preferred influence of the stir casting process parameters like heating engineering materials in automobile and aviation temperature with holding time for uniform distribution of industries for various high performance components [22]. SiC particles and obtain mechanical properties such as TS, Al alloys reinforced with Al2O3 have been used in ductility, impact and hardness behavior [9]. automobile, aerospace, aircraft etc. due to their high Current researches reveal that the dispersing of strength- to-weight ratio, good cast ability and better nanoparitcles into the Al matrix improve the hardness, tribological properties [23]. The dispersion of SiC into yield and UTS substantially whereas the ductility is retained. It was observed that yield strength of A356 alloy
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Al matrix is constrained due to more %age of Si. It is casting method is most suitable for large quantity noted that viscosity of the molten metal increases because production of composite [40]. The development of of the addition of nano SiC particles [24]. Stir Casting is one Aluminum Metal Matrix Nano Composites (AMMNCs) is of the most economical, simple casting route for the most considered material for high temperature production of AMMCs [25]. Composite materials have more applications, due to their excellent mechanical properties, potential for replacing of widely used steel and Al. They increased performance and weight saving for more have many times better performance [26]. reduction of fuel consumption [41].
Al matrix composites reinforced with SiC have structural Stir casting process has certain characterized features and non-structural applications both at room and high such as simple and low cost technology, dispersion phase temperatures. [27]. A MMC is an engineered material by may not more than 30 vol %, inhomogenous distribution combining the metal (matrix) and ceramic hard particles of reinforced particles, might be clusters of dispersed (reinforcement) in order to obtain required properties [28]. particles and possibility of gravity segregation of Al metal matrix composites have specific use due to low dispersed phase because of difference in the densities of cost, ease in fabrication, recyclability and isotropic matrix and dispersed phases. Rheocasting / characteristics [29]. Al alloys are used for engineering compocasting is the method in which matrix in semi applications at moderate temperature [30]. solid state is used to improve the distribution of dispersed phase [42]. There are various factors such as In the production of composite with desired properties, the nature and type of reinforcement material, its important factors like nature of metal matrix and choice, particle size and weight or volume fraction, the the kind of reinforced particulates and the process involve, processing conditions, secondary forming and heat must be standardized [31]. By using casting method, the treatment processes, which affect the properties of cost of composite production is about 1/3 to 1/2 and for MMCs. [43]. high volume production, it falls to 1/10 [32]. Normally, Al and its alloys solidify in columnar structure having In order to obtain optimum mechanical properties of large grain size with less mechanical properties. The composite material, high level of homogenous addition of Cu in Al alloy, there is a substantial distribution is required. Therefore, the important improvement in mechanical properties and microstructure parameters controlling the process must be identified [33]. There is a dire need of modern development of and corrected so as to attain a better quality composite advanced engineering materials for various engineering [44]. There has been emerging a huge demand from applications. [34]. automotive sector due to light weight with reduced fuel consumption [45]. In order to obtain better properties, hybrid MMCs have more than one type, shape and size of reinforcement are There can be further enhanced the properties of MMCs by utilized. Hybrid MMCs possess better and improved adding the nano sized reinforcement particles. The properties being, combined advantages of their uniform distribution of nano particles in the molten metal constituent reinforcements [35]. During the last three is entirely difficult. It is because of high viscosity, poor decades, Al based composite has been creating an wettability and large surface to volume ratio. These interest in materials science and engineering sector for the factors create clustering and agglomeration which may development of high performance components in the fields be overcomed by using the ultrasonic cavitations to of automobile, medical, aerospace, defense, marine, sports breakup the clustered fine particles and disperse more and recreation [36]. uniformly in liquids. It enhances the wettability between
the alloy melts and reinforcement particles [46]. Al and its alloys in the form of MMCs are widely used in aircraft, aerospace, automobiles and various other fields [37]. It is desirable that the composite material be The advantages of stir casting lies in its simplicity, economical for the mass production [38]. Aluminum MMC flexibility and applicability on large scale production. [47]. exhibits better mechanical properties than unreinforced Al Application of nano sized ceramic particles strengthens alloys. Al is only second to steel, when it comes to automobile the MMCs while maintain good ductility, high temperature body frame, with 5xxx and 6xxx series on the lead [39]. Stir creep resistance and better fatigue strength [48]. During 92 International Journal of Scientific Research and Innovative Technology ISSN: 2313-3759 Vol. 4 No. 8; August 2017 the last three decades, MMCs have improved specific alloy having properties like high strength, ductility and strength, stiffness, wear, fatigue and creep properties than high temperature resistance and SiC ceramic materials to conventional engineering materials [49]. MMC with less which are stiff and strong, though brittle [58]. Al than 100 nm size, it can be termed as Metal Matrix Nano metal matrix composites are low density having Composite (MMNC) and it shows far superior mechanical improved mechanical properties like high strength properties than conventional MMC. The grain refinement toughness, fatigue and wear resistance. It is an ideal increases the ductility, weight %age elongation, UTS, material for automotive and aerospace sectors for the impact strength and hardness [50]. construction of light weight structures and engine parts which enhances the fuel efficiency of the systems [59]. In The operational parameters of stir casting process such as order to enhance the mechanical properties of Al metal mold preheating temperature, stirring speed, pouring matrix nano composites, hybridization technique is temperature and stirring time are optimized to obtain better used which improves the ultimate efficiency and properties [51]. With the development of MMC, It is possible performance of the nanocomposites [60]. to produce large volume of complex shape components at high production rates along with producing near net shapes 2. Comparison of Experimental by the foundry techniques [52]. For the investigation on the Techniques and Findings effects of coating on particles, there were considered main J. Hashim (2001) studied by using A359, SiC and Mg. parameters of stirring like stirring speed and temperature to Placed A359 & SiC and Mg particles in a graphite produce the composite. The objective of the present study crucible. Heated in an inert atmosphere of N gas at a rate was to fabricate Al 2024 / SiC nano composite with Al and of 3 cc / min. inside the rig, controlled temperature Cu pure coating using stir casting process and the effects of inside the rig was kept below 750 0C to minimize the coating on microstructure. [53]. chemical reactions between substances. Stirring in two
steps process was used. Firstly it took place in semi solid In order to develop light weight high performance Al state while secondly, when the slurry was remelted at composite materials should have combined metallic 50-70 0C above liquidus to form full liquid. It was properties such as ductility and toughness with ceramic stirred at 100 rpm with placement of stirrer at 20% properties of high strength and modulus. The final from the bottom of the rig. Poured the full liquid slurry properties depend on interface strength between the matrix into the mold die of graphite having cavity of dia 20 mm and reinforced particles. There are various manufacturing and length 150 mm. variables which affect the final properties including matrix alloy, particle volume fraction, its size and heat treatment It was concluded that main problem of low wettability be [54]. Because of the attractive properties, MMCs are being enhanced by heat treating of SiC particles and can be considered for a wide range of applications in shuttles, ensured uniform distribution of particles by re-stirring commercials airlines, electronic substrates, automobiles and process to disperse the SiC particles [1]. golf clubs [55]. S. Naher et al. (2004) studied by using A356 and SiC The various reinforced materials used as nanocomposite are particles. A356 and SiC particles were placed in the Al203, illmenite, SiC, etc. Al is widely used as matrix material crucible under N gas in a furnace in order to reduce the due to its high wear resistance and high strength to weight oxidation problem at high temperature. The crucible ratio [56]. During these days with the modern was heated above liquidus to 630 0C for 130 min till it development, an application for the composites goes on becomes complete liquid. Stirring was started at semi- increasing for various engineering materials. To meet such solid state during cooling till it was stabilized with an demand, MMC is one of the dependable source. Al is appropriate stirring level. The full liquid slurry was then important not only because of its availability but also of its poured into mold to cast test sample. immense properties. The reinforcement used such as SiC, composites have become as a class of materials suitable for It was concluded that full dispersion of SiC particles into various applications. [57]. the Al matrix was achieved in the semi solid state [2].
Al metal matrix composite is a combination of Al metal S. B. Prabu et al. (2006) studied by using A384 and SiC 93 International Journal of Scientific Research and Innovative Technology ISSN: 2313-3759 Vol. 4 No. 8; August 2017 powder (60 µm). Melted weighed quantity of A384 in a using pure Argon gas. Thereafter slurry was slowly cool graphite crucible at 100 0C above liquidus to get full down at 4.2 0C per min to 650 0C (full liquid) and then liquid which was stirred at 500-700 rpm to form the vortex. to 607 0C (semi-solid). Added 1 wt% Mg to the melt to MS impeller coated with Zircon was used to minimize the increase the wettability between the matrix and the dissolution of blades in molten metal. A mechanical stirrer reinforcement particles. Poured the composite melt in was used to agitate the molten metal to create turbulence the steel die for sample casting. motion. The stirring speed was maintained at 500-600-700 rpm. The preheated SiC powder (60 µm) at 800 0C for 2 hrs, It was concluded that by using semisolid state was then dispersed at a constant rate into the route of the (compocasting) with 8 to 3 um particle size. Porosity vortex. content was also decreased considerably [5].
M. H. Zamani and H. Baharvandi (2011) studied by using On oxidation of SiCp, SiO2 layer improve the incorporation A356, Al203, 10% volume ZrO2 nano particles. Smelted of SiCp into the molten Al / SiC slurry. Stirring was Al356 ingot and added 3 gm keryolite to the molten continusely made for different combination of processing metal in an electric resistance furnace having the conditions by varying the stirring time and stirring speed at graphite crucible. . Stirred molten metal at 420 rpm for 5, 10, 15 min at 500, 600, 700 rpm respectively. Then poured 14 min and added nano particles (80 nm) wrapped in Al the molten metal into MS steel die (preheated to foils at 850 0C. Test specimens were cast in preheated 300 0C. steel mold to avoid temperature drop. Prepared test
samples for microstrucctural and mechanical analysis. It was concluded that at lower speed and lower stir time, clustering was accord at some sites. Similarly, it was found It was concluded that by increasing the reinforcement better distribution of SiC particles at higher speed of 600 content, density decreased while yield, UTS and rpm and stirrer time of 10 min. it was found that better compressive strength increased. Ductility of the hardness was at 600 rpm and 10 min [3]. composite was low because of high porosity content [6].
S. D & N. Nageswara (2010) investigated by using A356 and SiC particles (34 nm). A356 alloy was melted in an electric E. S. Y. El-Kady et al. (2011) studied by using A356 and Al2O3 (200 & 60 nm). A356 alloy was melted at 680 0C resistance furnace at 700 0C. Added preheated SiC (34 nm in a graphite crucible in an electric resistance furnace. size) particles into the melt from the top which was After complete melting and degassing by Argon gas of the protected by argon gas. A stirrer was used at 750 rpm for 3 alloy, allowed the alloy to cool to the semisolid state min. composites with different wt% of 0.1, 0.2, 0.3, 0.4 & at 602 0C. Started stirring at 1000 rpm. Before stirring 0.5 nano sized were fabricated. Processed the melts for 6 the nanoparticles (200 and 60 nm) after heating to 400 min for every 0.1 wt% increment. The composite melt 0C for 2 hrs, added into the vortex (upto 5 wt was poured into MS permanent mold for casting of test %). After complete addition of SiCnp, stop the stirring and poured into preheated tool steel mold. Before testing, samples. composite melt was poured into MS permanent MMC heat treated at T6 (solution treated) at 540 0C for 3 mold for casting of test samples. hrs. Then quenched in cold water and aged at 160 0C for 11 hrs. It was concluded that tensile strength, hardness increased by increasing wt% of nano particles and decreased in It was concluded that Al 356/Al2O3 MMNC, containing ductility. The use of nanoparticles by top-down approach is upto 3 wt% of 60 nm Al2O 3 showed better thermal permissible. However, it is advised to use nano particles conductivity than the MMNCs containing 200 nm nano produced by bottom- up approach for fabrication of nano particles [7]. particles in view of ductility retention with the uniform increase of tensile properties [4]. A. R. I Kheder et al. (2011) studied by using Al and SiC (50 um), Al2O3 (60 um) & MgO (50 um). Melted Al in a S. Amirkhanlou and N. B. Niroumand (2011) studied graphite crucible to 900 0C. Pre heated ceramic particles by using A356 and Sip (8, 80 & 40 µm). A356 alloy was (SiC 50 um, Al 2 O 3 60 um, MgO 50 um) to 300 0C before melted in a graphite crucible to 700 0C for 2 min. Melt adding into the molten Al. Added different wt% of was stirred at 500 rpm and SiC particles were injected particles to the melt and stirred. Then continuous stirring 94 International Journal of Scientific Research and Innovative Technology ISSN: 2313-3759 Vol. 4 No. 8; August 2017 at 400-500 rpm for 15 to 20 min to achieve uniform It was concluded that with the addition of hybrid distribution of particles until 700 0C. After degassing, reinforcement instead of single reinforcement the poured the melt into preheated mold die for sample casting hardness, toughness, strength, corrosion resistance and of size 15 x 8 x 1 cm. Opened cooled mold after 10 min. wear resistance of the composite is increased Prepared tensile test samples as per ASTM-E8-95a and impact test samples as per ASTM E23. considerably [11].
A. D. Sable and Dr. S. Deshmukh (2012) studied by using It was concluded that by adding SiC, Al 2 O 3 and MgO particles significantly increased the YS, UTS & hardness and decreased Al and SiCp. Preheated the scrap of Al (99.41%) for elongation (ductility) of composites. Improved mechanical 3-4 hrs at 450 0C and SiC powder (320 grit size) at properties by increasing wt% of particles increases, but 900 0C. Mixed both and placed in graphite crucible and decreases ductility and toughness [8]. put into the coal fired furnace at 760 0C. Stirred the mixture to form slurry for casting of molds and solidified G.G Sozhamannan etl (2012) investigated the effect of into bars. Prepared the test samples by varying the processing parameters on MMCs by stir casting process. Al- SiC 5%, 10%, 15%, 20%, 25% & 30%. 0 11Si-Mg alloy was heated in a graphite crucible at 700 C, 0 0 0 0 750 C, 800 C, 850 C and 900 C. Preheated SiC (40 um) It was concluded that hardness, impact strength 0 particles at 1000 C for 2 hours. 10 vol % SiC was dispersed improved by increasing SiC particle at 25 w% of 320 in the melt. The designed 4 blade stirrer was used for grit size [12]. continuous stirring to obtain homogenous distribution. Stirring was carried out at 450 rpm for 10, 20 & 30 min by A. D. Sable and Dr. S. Deshmukh (2012) studied by using using argon gas to avoid oxidation of metal matrix. After Al and SiCp. Preheated scrap of Al (99.41%) for 3 to 4 completion the stirring process, the melt was poured in the hours at 450 0C and SiC powder (320 grit) at 900 0C. 0 preheated (300 C) mold die for sample casting. Mechanically mixed both the preheated mixtures with
each other. This metal matrix Al-SiC is then poured into It was concluded that because of homogenous distribution of the graphite crucible and put into the coal fired furnace reinforced SiC particles, there was an increase of TS, impact at 760 0C. Increased the furnace temperature above the strength and hardness [9]. composites completely melt the Al scrap and then cooled
down just below the components temperature and keep it B. S. Kumar and L. Ramesh (2012) studied by using A357 and SiCnp (18 µm & 50 nm). Heated SiCnp (50 nm) to in a semi-solid state. Added at this stage the preheated 1000 0C. Placed weighed quantity of A357 alloy (Al/SiC= SiC p with manually mixed with each other. On 1.66) in the crucible to 740 0C (above liquidus temp.) and completion of manual mixing then carried out added 1 wt% Mg in powder form as wetting agent. automatic stirring for 10 min with normal 400 rpm. Supplied N gas in the crucible. Connected Shaft to stir the Controlled temperature rate of coal fired furnace at 750 slurry. Poured and allowed the slurry to flow into a mold. 0C in final mixing process. After completion of the Ensured non-mixing of composites floating on the surface of the melt. Inserted powder mixture into an Al foil by process, the slurry is taken into the sand mold within 30 forming of a packet and added into molten metal of crucible. sec allow it to solidify for sampling. Melted packet of powder mixture and particles started to distribute around the sample. It was concluded that these metal matrices are very popular with improved mechanical properties, economical It was concluded that the addition of 3.5 vol. % of nano and beneficial for the modern engineering fields [13]. particle resulted in significant improvement in hardness, YS & UTS of composites [10]. A. Mazahery et al. (2012) studied by using A356 (16 µm) and SiC (50 nm). Melting of Al alloy and additions J. J. Rino et al. (2012) reviewed on the stir casting which is a of particulates were performed in a resistance heating liquid state method of fabrication for composite materials. furnace. Placed the Al ingot in a graphite crucible and In this method a dispersed phase (ceramic particles) is heated to 750 0C. Protected the melt by N gas poured mixed with a molten metal matrix by using mechanical composite slurry into preheated die cavity. Preheated the stirring. The liquid composite material is then cast by graphite lubricated die and rams to 350 0C to avoid conventional casting methods. premature chilling.
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Microstructural characterization was carried out using and Grp [17]. optical microscope. Brinell hardness of the sample was measured on the polished samples. [14]. K. L. Meena et al. (2013) analyzed by using Al 6063 and SiCp. Preheated Al 6063 to 450 0C before melting for 2 S. Chatterjee and A. B. Mallick (2013) studied by using Al, hrs. Melted Al 6063 in clay-graphite crucible. TiO2 (20 nm) & Mg. Prepared Al3Ti reinforced Al based Preheated SiC particles at 1100 0C for 1.5 hrs to MMNCs. Used TiO2 powder, Al (99.5% pure) and Mg as improve wetting properties. Melted the matrix at 750 starting material. The tubes (filled up Al tubes of length 4 0C, cooled down below the melting temperature to keep cm) were preheated at 500 0C and immersed into molten Al the slurry in semi solid state. Added the preheated SiC (containing 2wt% Mg) at 900 OC. stirrer the melt vigorously particles and mixed mechanically. Reheated the and poured into cast iron metal molds of size 200 mm x 10 composite slurry to full liquid state and carried out mm x 30 mm. mechanical mixing for 20 min at 200 rpm. Mixed in the final stage at 760 0C to control at 740 0C. Poured It was concluded that the strength and hardness of the the melt into the preheated molds (size 40 mm dia x composite is controlled by the degree of grain refinement 170 mm long). [15]. It was concluded that by increasing reinforced particulates increased homogeneous distribution of SiC A. Jailani and S. M. Tajuddin (2013) studied by using Al particle and also increased UTS, YS, hardness and alloy and SiCp. Set the impeller at the angle of 30 0 and speed decreased elongation% (ductility) and impact strength of 50 rpm. Melted Al alloy in induction furnace then mixed with maximum value at 20% wt of 400 mesh 10 wt% SiC reinforcements. Stirred SiC reinforced Al alloys size [18]. for 15-20 min. Poured the composite melt into the mold to prepare test specimens. D. Singla and S. R. Mediratta (2013) evaluated by using Al
It was concluded that during lower speed and lower stir 7075, Fly Ash & Mg. Fly ash is heat treated in the 0 time particle clustering occurred in some sites and some induction furnace at 600 C. Ethanol solution is also added 0 sites were without SiC inclusion. It was found that better at 50 C and stir for some time. Melted Al 7075 in an homogenous distribution of SiC (10 wt%) in the Al matrix electric resistance furnace. Added preheated fly ash into it. was because of increased stirring speed at 100 rpm and Added Mg to increase the wettability. A stirrer is used for stirring time for 10% found that better mechanical better mixing of all materials. Also used hexachloroethane properties of composite was obtained from 10% SiC, 100 tablets as solid degasser. Poured the molten composite material into the preheated sand mold for casting the rpm and 30 0 blade angle [16]. test samples. B. M. Viswanatha et al. (2013) studied by using A356 and SiCp & Grp. Preheated SiCp and Graphite for 2hrs to oxidize It was concluded that TS, hardness and toughness the surfaces. Melted A356 alloy in graphite crucible using increased with increasing as fly ash contents and showed electric resistance furnace. Then added slowly the best results with 30 wt% content. Density is decreased reinforcements into the crucible. Mixed Mg 1 wt% to with increasing fly ash contents [19]. enhance the wettability between reinforcement and V. Kumar et al. (2013) studied by using AA 2218 and matrix alloy. Added hexachloroethane (C 2 Cl 6 ) tablets Al2O3. Melted Al alloy 2218 at 850 0C by adding which decompose to form AlCl 3 gas bubbles. After Al2O3 using stirrer at different speed in the preheated sufficient mixing by stirrer, stirred at speed of 500-600 solid state. Addition of Al2O3 is used to increase the rpm for 10 min. Poured the slurry into preheated mold to mechanical strength, hardness and toughness. avoid the formation of porosity.
It was concluded that the distribution of Al2O3 is It was concluded that A356 hybrid composites have been uniform and non-uniform also at the different speeds and successfully fabricated by stir casting route with uniform there is the change in the mechanical properties [20]. distribution of SiCp and graphite. Hardness increased significantly with addition of SiCp by 9% while tensile Gopi K. R. et al. (2013) studied by using Al 6061 and strength improved by 5% with an addition of 3 wt% of SiCp 96 International Journal of Scientific Research and Innovative Technology ISSN: 2313-3759 Vol. 4 No. 8; August 2017
ZrO2 / Grp. Melted Al 6061 alloy in a graphite crucible at plates (solutionized at 560 0C for 1hr) and aged at 160 0C 756 0C using hexachloroethane degassing tablets. Stirring for 12 hrs. Prepared tensile specimens as per ASTM-E8 device having SS rod with 4 blades (1mm thick) mounted standards. Processed heat treated plates through rolling radial on the rotating rod at 50 angled to the radial to remove the casting defects & porosity. horizontal rotational plane. Added Zircon sand & graphite particles on %age weight of Al alloy from 2-10% (with It was concluded that MMNCs have fine and more increment of 2%). Stirred molten alloy at 400 rpm for 1 homogeneous microstructure with increase of wt% of min. Added preheated nanoparticles (ZrO2 & graphite B4Cnp. Hardness, UTS, YS increased by 14%, 6% & 11% particles) at 200 0C for 3-5 min. to ensure complete insersion respectively. Ultrasonic nonlinear affects efficiently of particles. Poured molten metal into preheated mold die. disperse nanoparticles into molten alloy by enhancing their wettability [24]. It was concluded that there was an average of 35% L. Rasidhar et al. (2013) studied by using Al alloy and improvement in the wear resistance at 400 rpm and 30% FeTiO3 nano particles (57 nm). Melted weighed amount at 800 rpm [21]. 0 of alloy to 750 C. Added weighed % of FeTiO 3 nano P. Phutane et al. (2013) studied by using Al alloy and SiCp particles 57 nm (1, 2, 3, 4 & 5 %) to the melt. Packed the (25 um). Superheated Al-HE-30 over its melting powder in Al foil as a packet. Melted packets of nano temperature and then lowering of temperature below the particles and distributed around the molten alloy. Stirred liquidus temperature to keep the matrix alloy in the melt at 650-700 rpm for 10-15 min. Maintained the temp semisolid state. Introduced the preheated SiC particles (25 at 850 0C during stirring and supplied Argon gas to the um) at 800 0C into the slurry and mixed with 3% and 5%. crucible. Al alloy reinforced melt with nano particles is Increased the composite slurry temperature to obtain full poured into a preheated permanent MS mold. liquid state. Continued the stirring for 10 min at 500 rpm. Superheated the melt above 760 0C and poured at 700 0C It was concluded that nano particles were evenly into preheated permanent metallic molds. distributed. TS & hardness increased maximum at 5wt% [25]. It was concluded that by increasing wt% of SiC particles J. Shree P. K et al. (2013) reviewed by using A6061 and increased TS, YS & hardness while decreased ductility. Also SiCp. Charged A6061 alloy billet into the furnace to 750 0C showed fairly uniform distribution of SiC particles [22]. & degassed by passing hexachloroethane (C 2 Cl 6 ) solid D. K. Koli et al. (2013) reviewed by using A356 and Al2O3 degasser. Allowed melt to cool to 600 0C to a semisolid (50 nm). Melted matrix Al 356 in an electric resistance state. Added preheated SiC particles at 600-800 0C for 2 furnace above its liquidus temp 750 0C. Stirred the molten hrs to the melt and performed manual stirring of slurry metal thoroughly to form a vortex. Added preheated for 20 min. Reheated composite slurry and maintained at O reinforcement particles Al 2 O 3 with 1.5 vol. % to 800 C. a temp of 750-760 0C. Performed mechanical stirring for Poured the melt for casting of test samples. 10 min at 400 rpm. Casted samples at a pouring temp of 720 0C. After degassing the molten metal, poured It was concluded that porosity increased with increasing into permanent molds. particle content at both casting temp (800 & 900 0C.) Increased nearly 92% in hardness, 57% in TS as compared It was concluded that 20% improvement in yield strength, to commercially pure Al [23]. low CTE, high modulus of elasticity and more wear resistance [26]. Dr. G. Nandipati et al. (2013) investigated by using Al 2024 and B4Cnp (50 nm). Melted Al 2024 alloy in an EN-8 steel N. S. Abtan (2013) investigated by using Al and SiCp 0 crucible placed in an electric resistance furnace at 638 0C. (63 um). Preheated Si particles to 700 C before Added B4C nano particles (50 nm) at various wt% (0.1, 0.2, adding to melt to avoid high drop of Al melt temp. Melted 0.3, 0.4, 0.5, 1.0, 1.5, 2.0 %) to the melt during stirring Al at 900 0C and added preheated SiC (63 um) with 0, 5, 10, 15, 20 wt% & Si element 10 wt% to overcome process. Added Argon gas during melting to protect molten problem of poor wettability of SiCp. Stirred the melt to metal from atmospheric air. Poured melt in a mold die of form vortex until the particles were completely wetted. size 200 x 130 x 9 mm3 to cast plates. Heat treated as-cast Reheated the composite slurry to 750 0C by electrical 97 International Journal of Scientific Research and Innovative Technology ISSN: 2313-3759 Vol. 4 No. 8; August 2017 resistance furnace. Poured the composite slurry in metal to the Al alloy enhances its properties. Increased mold of dimension dia15 x 100 mm long. Prepared test stirring time reduces agglomeration of added particles. specimens of dia 10 x 10 mm for micro structure, and Heat treatment refines grain size and consequently hardness and dia 10 x 20 mm for impact and resistance enhances mechanical properties. Increasing wt% tests. increases mechanical properties for certain limit and drop down. Reducing capsule particle content and It was concluded that addition of Si to Al improved the increasing its thickness lead to reduction in particles wettability between SiCp and Al. Also TS, YS and agglomerations [30]. hardness increased but decreased impact strength due to decrease of ductility by added SiCp [27]. B. P. Samal et al. (2013) studied by using Al and SiCp. 0 Melted Al ingot at 800 C. Charged the capsule/ bullet with pieces of Mg chips or SiC particulates. Mixed at stirring A. Kumar et al. (2013) studied by using A359 & Al2O3. speed of 500 rpm. Charged the bullet prepared by SiC Melted A359 to 730 -750 0C. Stirred the melt and added particulates (10 wt%) into the alloy melt Poured the preheated-Al2O3 particles at about 800 0C. Stirring uniform mixed melt of MMC into preheated mold of fire speed of stirrer kept at 300 rpm. Performed experiments bricks. Prepared the test sample. with varying wt% from 2% to 8 % in steps of 2%. It was concluded that by adding reinforcement particles,
YS, UTS and elastic modulus increased by 49%, 31% & It was concluded that tensile strength and hardness 24% respectively. The % of elongation decreased by 68%. increases with increase in weight fraction of Al203. Higher ductility is possibly due to finer grains [31]. Microstructural observation indicates good particle matrix interface bonding with smaller grain size [28]. S. Mathur and A. Baranawal (2013) studied by using
Al alloy and SiCp. Preheated base Al metal at 450 0C for 3 R. S Rana et al. (2013) studied by using A5083 & SiCnp. hrs in an electric resistance muffle furnace. Melted Al-4 % Placed small pieces of Al ingot into a graphite Cu in a graphite crucible. Mixed preheated SiC particles at crucible. Melted the A5083 alloy to 760 0C, added flux 1100 0C for 2 hrs at stirring rate of 600 rpm for 3 min in coveral 11 and degassed with dry N gas of grade 1. Added an electrical resistance furnace. Poured and casted molten preheated SiC nano particles (40 nm) with different wt% composite at 700-725 0C into molds. in the melt. Stirred the alloy melt and prepared different wt% of SiC particles such as 1, 2, 3, 4 & 5%. Poured melt into It was concluded that TS, hardness and impact strength preheated MS die in the form of cylindrical rod (20mm dia increased with increasing grit size of SiC. [32]. & 200 mm length). Prepared standard samples for tensile strength, compressive strength, hardness & microstructural A. Mittal and R. Muni (2013) studied by using Al6061 and analysis. RHA / Cu. Put Al 6061 into graphite crucible to melt to 750 0C. Prepared RHA as reinforcement (preheated to 850 It was concluded that porosity could be decreased 0C for 1 hr before mixing). Added at the same time 3wt% significantly by ultrasonic treatment and N degassing. TS, CS of Mg to improve wettability. Melted Cu metal cuttings & hardness increased with increase in wt% of SiC nano to 1100 0C. Stirred the melt at 600 rpm. Added slowly particles. It is maximum at 4% nano particles while preheated RHA particles at constant rate of elongation of MMC remains almost same [29]. 5gm/sec for 5 min. Poured composite melt into preheated
molds (550 0C for 20 min) to obtain uniform solidification. A. R. N. Abed and I. R. Ibrahim (2013) studied by using Al Produced samples of composites with 8, 16, 24 & 32 wt% 7075 and Al203 nano particles. Charged RHA with Cu and without copper particles. 500 gm of Al7075 alloy into the graphite crucible and
0 melted to 650 C. Cleaned the melt from the slag by It was concluded that strength and hardness increased by 0 overheating of the melt 50 C above the liquidus increasing RHA and Cu contents can lead to production temperature. Mixed by an impeller with a speed about 300 of economic composites [33]. rpm at 650 0C in semi-solid condition. Stirred the slurry for 20 min. Poured in a 100 x 120 x 14 mm steel mold. R. G. Bhandare and N. P. M. Sonawane (2013) studied by using Al alloy and Al2O3 / SiC / Graphite. Placed empty It was concluded that the addition of ceramic nanoparticles crucible in the muffle to set at temp of 5000C and then 98 International Journal of Scientific Research and Innovative Technology ISSN: 2313-3759 Vol. 4 No. 8; August 2017 upto 900 0C. Put cleanedrequired quantity of Al alloy in the toughness of the hybrid composites was observed to be crucible for melting. N gas is used as inert gas. Used powder superior to that of the single reinforced Al-10 wt% SiC mixture of Al 2 O 3 , SiC & graphite (320 mesh) and 1wt% composite. [36]. of Mg. Heated reinforcements at a temperature of 500 0C for ½ hr. Started stirring after 2 min from 0-300 rpm B. V. Ramnath et al. (2014) reviewed by using Al-Si alloy at a temp of 630 OC to achieve semi solid which is below the and Al2O3p. Preheated Al 2 O 3 reinforcement particles. melting temp of the matrix. Poured preheated Melted Al-Si alloy at 700 0C. In a graphite crucible using 0 reinforcements in semi solid stage to enhance wettability & an electric resistance furnace at 700 C. Mixed the Al 2 reduces the particle settling. Maintained flow rate of O 3 reinforcing particles in molten Al melt and stirred at reinforcements at 0.5 gm /sec with dispersion time of 5 min. 900 rpm, stirring time 5 min and particle addition rate 5 Stirred semi solid slurry for 5 min and reheated to hold at gm/min at pressure of 6 MPa. Poured the composite 900 0C to make sure full liquid slurry. Poured molten melt to 700 0C into preheated mold at 550 0C. Solidified composite slurry in the preheated metallic mold (500 0C) the molds to room temp to get test specimens. keeping uniform flow of slurry. It was concluded that SiC reinforced Al MMCs have higher It was concluded that uniform dispersion of reinforcement wear resistance than Al 2 O 3 & B4C are most suitable for particles achieved at 450 or 600 blade angle with 4 brake drums. Addition of ZrO 2 and fly ash reinforcement blades. Achieved good wettability at operating temperature increases wear resistance and compressive strength. of 6300C semi solid stage. Preheated molds helped in Found that Al MMCs reinforced with Diamond Fiber reducing porosity and increased mechanical properties [34]. exhibited high thermal conductivity and a low thermal expansion co-efficient [37]. T. Rajmoham et al. (2013) Evaluated by using aluminum Raghavendra N. and V S Ramamurthy (2014) studied by alloy, Al 356 and SiC particles with size of 25 um and mica using Al 7075 and Al2O3p. Cut sizeable pieces of Al 7075 with average size of 45 um. Melted Al alloy in an electric and placed inside the graphite crucible. Collected Al 2 O 3 furnace. Preheated Mica and SiC to 620 0C and were added powder in sieve size to the molten metal at 750 0C and stirred continuously. 100 mesh (149 u), 140 mesh Performed the stirring at 500 rpm for 5-7 min. Added Mg (105 u) & 200 mesh (74 u). Weighed quantity of Al 0 during stirring to increase the wetting. Poured the melt into 7075 is heated to 720 C. Al03 powder is also heated to 0 mold for casting of samples. 350 C and added to the melt. Stirred the melt for 5 min. Poured the melt into the sand mold. Cast the rods of It was concluded that the stir casting method is found to be dia 20 X 200 mm long. suitable to fabricate the hybrid aluminum–mica reinforced metal matrix composites. The strength and hardness is It was concluded that mechanical properties are found maximum with Al/10 SiC-3 mica composites [35]. controlled by the parameters such as processing route, reinforcement size, weight fraction and temp of melt. The K. K. Alaneme et al. (2013) studied by using aluminum temp of 700-720 OC be maintained to avoid matrix reinforced with SiC and BLA. Two steps stir casting agglomeration and clustering. Hardness and wear rate process was adopted by charging the determined amount of increases with reduced particle size [38]. BLA and SiC. Preheated separately the BLA and SiC particles at a temperature of 250 0C. Charged Al alloy and heated to P. O. Babalola et al. (2014) reviewed by using Al 6061 750 0C. Allowed the melt to cool to semi solid state at 600 0C. and SiCp. Melted Al 6061 alloy in a graphite crucible to Charged preheated BLA and SiCp with 0.1 wt% Mg and 670 0C and then stirred at 500 rpm. Added SiCp of 10 stirred for 5-10 min. Superheated the composite slurry to vol.% to the matrix alloy. Argon was used as a carrier gas. Slurry was cast into a steel die placed below the 600 0C. Performed second stirring at 400 rpm for 10 min. furnace. Poured the melt for casting of samples.
It was concluded that stir casting process is predominant It was concluded that the hardness, ultimate tensile strength because it is cost effective and processing parameters (UTS), and percent elongation of the hybrid composites could be readily varied and monitored. Specimens from decreased with increase in BLA content. The fracture stir casting showed high hardness and fine grains in the 99 International Journal of Scientific Research and Innovative Technology ISSN: 2313-3759 Vol. 4 No. 8; August 2017 microstructures [39]. 850-900 0C. and added to the melt and mechanically stirred at 750 0C at 400-500 rpm. Poured the melt at S. Haque et al. (2014) studied by using Al 6061-Cu and SiCp. 745 0C for test samples. Preheated billet of Al-Cu alloy at 450 0C for 40 min. Also preheated SiC particles at 1100 0C for 2 hrs. Melted Al 6061- It was concluded that TS, impact strength and hardness Cu alloy in a graphite crucible. Furnace temp was first raised increases with increase in reinforcement ratio whereas above the liquidus to melt. Cooled down the slurry to semi elongation decreases with increase of particle wt%age. solid state. Added the preheated SiCp and mixed manually [43]. and the slurry was reheated to a fully liquid state. Then automatic mechanical stirring was carried out for 10 min at B. V. Ramnath et al. (2014) evaluated by using Al alloy 200-600 rpm. Maintain the final mixing furnace temperature matrix with Al2O3 and B4C. Melted the Al alloy (95%) within 800 0C. Poured composite slurry in a sand mold to get ingot in the graphite crucible. Preheated the ingot for 3-4 standard test specimens. hr at 550 0C. Also preheated the B4C and Al2 O3 powders to 400 0C in the respective containers. Heated the crucible It was concluded that wear rates are high at high stirring with Al alloy to 830 0C. Stirred vigorously at 550 rpm for speed above 600 rpm. Also high wear at high pouring temp 10 min resulted to obtain uniform distribution of 775 0C for Al 6061-4% Cu and 5% SiC MMC. [40]. reinforcements at 830 0C. Poured the melt for sample casting. Vinoth M. A. et al. (2014) studied by using Al-Si alloy and SiCp / Cenosphere. Melted weighed quantity of Al-Si alloy It was concluded that the tensile strength, flexural in clay-graphite crucible at 750-800 0C. Added strength, impact strength and hardness of the MMCs hexachloroethane pallets to has improved values than that of Al alloy (LM 25) [44]. remove the atmosphere gases particularly H. Preheated Mr. Praveen. G et al. (2014) studied by using Al alloy measured quantity of SiC and cenosphere at 450 0C for matrix reinforced with MgO nano particles. Reinforced Al 3-4 hrs to remove gases and moisture. Added preheated alloy with MgO was stirred at 100 rpm for 15-30 particles at 10-30 gm/min into the melt. Stirred the mix min. Poured the melt at 850 0C for casting of samples into with speed range of 350-890 rpm for 8-10 min. Preheated the MS mold die. the mold and applied choco powder in mold to avoid shrinkage of casting material. Poured and casted the It was concluded that hardness and wear resistance required samples. increases with increase in wt% of nano particles. [45].
It was concluded that TS, CS & hardness increased with L. Poovazhagan et al. (2014) studied by using SiC increasing reinforced particles. Best TS obtained at 15% wt nano particulates reinforced Al matrix nano composites. of cenophere and 3% wt of SiC. [41]. Melted AA6061 at 680 0C for 10 min. Stirred
Tony Thomas. A et al. (2014) developed the feeding and mechanically alloy melt and added slowly SICnp to the 0 stirring mechanism for AMCs. Preheated Al alloy was molten metal. Poured the melt at v 800 C into melted in a crucible at 900 0C for 2.5 hrs. Preheated SiC preheated steel die. Prepared the sample of dia 20 mm particles were dispersed in the matrix at 600 rpm for 10 and 120 mm length. min. The molten MMC was poured in the mold for sample It was concluded that tensile strength and hardness casting. increases with increase of values %age of SiC nano particle [46]. It was concluded that by using modified feeding and stirring mechanism, homogenous distribution of SiC M. T. Alam and A. H. Ansari (2014) studied by using Al particles was ensured. There was an increase of about 34 % matrix reinforced with SiC particles. The side- blow elongation %age and 31% BHN. [42]. converted furnace was used to melt Al at 680 0C. A digital thermocouple was used to measure G. Sutradhar et al. (2014) studied by using LM 6 aluminum temperature of molten metal directly in the graphite alloy reinforced with SiC particles. Melted the LM 6 in a crucible. Added silicon carbide particles in the molten resistance furnace. Added 3 wt% Mg to the melt because metal and mixed by stirring at 300 rpm for 30 seconds. Mg forms strong bonding. Preheated SiC particles at 100 International Journal of Scientific Research and Innovative Technology ISSN: 2313-3759 Vol. 4 No. 8; August 2017
Prepared the MS steel die as per ASTM standard. Die is stirring at 300 rpm for 17 min. Preheated the cuboids in shape which is in 2 pieces of sizes 7 in. x 7 in. x reinforcements to a temperature of 500 0C for 1 hr to 1.5 in. and 7 in. x 7 in. x 0.75 in. oxidize and to prevent the decrease in temperature of the molten metal during addition of reinforcements. It was concluded that the hardness improves with an Poured the molten composite into preheated cast iron increase of SiC upto 30% and then it decreases with the mold at 400 0C. further increase in the %age of SiC [47]. It was concluded that tensile strength of the composite H. R Ezatpour et al. (2014) investigated by using Al alloy increases linearly with the addition of both SiC and 6061(50 um) and Al203 nanoparticles (40 nm). graphite reinforcements, whereas hardness improves with Melted Al alloy at 750 0C. Injection time of nanoparticles the SiC addition and shows decreasing trend with the was 10-30 min. Stirred the melt at 450 rpm for 15 min to graphite particle reinforcement. Wear rate of the produce homogenous mixture. Poured at 700 0C for casting developed HMMC has decreased with the addition of both of samples. SiC and graphite reinforcement [51].
It was concluded that mechanical properties shows greater Phaniphushana M. V et al. (2015) evaluated by using strength and hardness for four blade stirrer than two blade Al 6061 matrix reinforced with Fe2O3 particles. Melted and fine blade [48]. the matrix material Al 6061 alloy to 750 0C in a graphite crucible. Stirred the molten metal at 300-350 rpm. Added T. Q. Hashmi (2014) reviewed by using reference of scum powder (Alkaline powder) to the crucible to Sozhamannan et al [7]. Produced the samples at 600 0C, remove the slag and flux. Added preheated Fe203 750 0C and 800 0C and found uniform distribution of particles and dendritic structure with no large pores. powder to the melt slowly. Continued the stirring for 5-10 min and added degassing tablet (C2 Cl6) to remove the It was also observed that increasing temperature to 850 0C gasses. Poured the melt into the preheated die for sample to 900 0C, there were enhanced pores and particles casting. clustering. Hardness increased with increase in temperature of 750 0C 800 0C at 20 min holding time [49]. It was concluded that microstructure reveals uniform
distribution of the reinforcement particles. The hardness A. Kumar et al. (2015) studied by using Al matrix reinforced and tensile strength increases with increase of %age of with Al2O3 nano composites. Melted the pure Al in the reinforcement [52]. furnace to 700 0C. Removed the slag with the help of slick and then graphite rod was taken out so that molten metal P. Melali et al. (2015) fabricated high strength Al base flow towards the mold. Casting was also made without alloy composites reinforced with SiC nanoparticles coated ultrasonic vibration to compare the results of castings with with Al and Cu. Two types of powders of pure Al (type A) ultrasonic vibration. and pure Cu (type B) were produced by mechanical
milling process with size of 60 um each. SiC nano powder It was concluded that ultrasonic mold vibration has a good of size 50 nm was used in 1 weight % as reinforcement. effect on the microstructure and properties of casting being Mechanical milling was made at 900 rpm for 1 hr with fine grain than casting without ultrasonic vibration. Casting steel ball of 10 mm dia. Al 2024 alloy of about 450 gm with ultrasonic vibration has microhardness value 48.21 Hv with 18 gm of Al and Cu powders were added separately and ultimate tensile strength 68.01 MPa [50]. to the melt. To separate molds were used for each B. Pavithran et al. (2015) studied by using Al alloy matrix composite. The melt temperature was 750 0C and stirred reinforced with SiC (50 um) and graphite particles (60 um). at 512 rpm for 6 min. Poured the melt to MS mold for Melted Al 6061 in a furnace and stirred vigorously, after sample casting. It is to be noted that each stir casting effective degassing with solid C2 Cl6. Addition of wetting process be held under inert atmosphere. promoters into the melt enhances the particle distribution It was concluded that Al coated particles because of their and its bonding with the matrix. Carried out the lower melting point causes higher wettability and uniform hybridization by simultaneously introducing both the distribution of particles in the matrix. Also the dispersed reinforcements into the matrix alloy while stirring. Added particles act as grain refiner results in fine grain. As a the reinforcements at 700 0C in semi molten state while 101 International Journal of Scientific Research and Innovative Technology ISSN: 2313-3759 Vol. 4 No. 8; August 2017 result of high temperature difference between master powder and melt, there occurs high nucleation rate in melt. K. K. Paul and Sijo MT (2015) studied by using Aluminum This form spherical and rosset-shaped grains. This LM6 and SiC (20 um). Al alloy was preheated at 450 0C for phenomena can reduce the viscosity of melt during casting 3 to 4 hours. Preheated SiC at 900 0C for 2 hrs. Set the process [53]. temperature of furnace to 620 0C. Added preheated SiC particles. SS stirrer with 4 blades was used for stirring S. Dhanasekaran et al. (2015) investigated by using Al 356 operation. Achieved uniform semi solid stage by alloy, SiC (15-20 um) and Al203 (15-20 um). Melted Al356 stirring at 600 rpm. Pouring of preheated 0 in an electric resistance furnace at 800 C. Preheated SiC reinforcement at the semi solid stage of the matrix 0 and Al203 particles to 250 C for 30 min. Liquid metal was enhances the wettability of reinforcements, reduces the degassed by C2Cl6 and the temperature was maintained at particles settling at the bottom of the crucible. After 0 750 C. The melt was stirred at 200 rpm for 5 min. Also Mg 1 stirring for 10 min at semi solid stage, reheated the slurry % was added to improve the wettability of the particles. In and hold at 900 0C to make slurry in liquid state. Lowered order to ensure proper mixing, stirring at 200 rpm for the stirrer rpm gradually to the zero. Poured the molten another 10 min was maintained and then poured into the composite slurry into the metallic mold which was mold for casting of samples. preheated at 500 0C to ensure the molten slurry state
throughout the pouring. It was concluded that TS, YS increases with increase in vol fraction of SiC and Al203 particles. It was investigated The test specimens required for analysis were machined that 20 % SiC increases 16 % increase in TS while 10 % Al to cylindrical specimens and were then ground in 203 increases 19 % increase in TS [54]. successive steps using SiC abrasive papers of various grit
sizes. The micro structures of the samples were observed S. K. Thandalam et al. (2015) reviewed the research to study the particle distribution. A section was cut from investigated by Das et al. who reported the incorporation of the castings for microstructure analysis. The specimens zircon particles of different sizes and amount into Al-4.5 were ground thoroughly by using emery papers for certain wt% Cu alloy melt using stir casting process. time by using 300, 600, 900 grit papers and then polishing
it with applying a paste. The samples were then It was observed that courser particles of sizes 90 and 135 mechanically polished and etched by Kaller’s reagent to um were dispersed up to 30 wt% while finer particles of obtain the accurate contrast structure. The casting sizes 15 and 65 um could be dispersed upto 20 wt% [55]. procedure was examined under the light optical M. Vykuntarao et al. (2015) reviewed the research/ microscope under 100 X resolution to determine the investigation of Haisu (16) et al. how fabricated nano sized reinforcement pattern and cast structure. Tensile Test ceramic particles reinforced Al matrix composites. In samples were prepared according to ASTM E 08. Hardness Al2024/Al203 nano particle prepared by solid-liquid mixed Test was conducted with 250 kg load and 5 mm dia steel casting combined with ultrasonic treatment. Supersaturated ball indenter [57]. the matrix at 750 0C and held for 15 min. Added powdered Al / Al203 particles to the melt and stirrered. Dipped an Jamaluddin Hindi et al. (2015) studied by using Al ultrasonic probe in the melt and sonicated for 5 min. Solid- 6063 and SiC particles using stir casting process. Al 6063 liquid casting method decreased the agglomeration of was melted in an electric resistance furnace and SiC Al203 nano particles whereas ultrasonic treatment improved the distribution of particle and refined the grain (200-300 mesh) with 2, 4 & 6 wt% reinforcement structure. There was an increase in the UTS and YS of nano dispersed to produce homogenous slurry by using composites. mechanical stirrer. Poured the composite melt into the metallic mold die for casting of samples. Factors affecting the composites fabricated by stir casting are uniform distribution of reinforcement materials It was concluded that TS & hardness increases with wettability, porosity and chemical reactions between matrix increase of SiC wt% whereas ductility decreases. Impact and reinforcement particles. Process parameters are stirring strength initially increases and then decrease with the speed, stirring temperature, reinforcement preheat addition of SiC. The microstructure indicates better temperature, stirring time, preheated temperature of the distribution of SiC in the matrix [58]. mold and powder feed rate [56]. 102 International Journal of Scientific Research and Innovative Technology ISSN: 2313-3759 Vol. 4 No. 8; August 2017
S.B. Rayjadhav and Dr. V. R. Naik (2016) developed and ‹ Clean the melt from the slag by overheating of the characterized Al 6061-SiC MMCs by stir casting process. Al melt 50 0C above the liquidus temperature 6061 was melted at 820 0C in an electric resistance furnace. The preheated SiC (60-90 um) at 800 0C for 1 hr was ‹ Maintain furnace temperature at 800 0C and degas the added in the melt. The stirring of the melt was continued melt by passing hexachloroethane (C 2 Cl 6 ) solid for 20-40 sec. The melt was maintained at 750 0C and degasser poured in the mold for sample casting. ‹ Allow melt to cool to 700 0C to a semi solid state It was concluded that hardness increases with increase in SiC particles. The microstructure indicates uniform ‹ Add preheated SiC Nano particles at 700 0C to the distribution of SiC particles [59]. melt and perform stirring at 300 rpm for 20 minutes.
Kalidindi Sita Rama Raju et al. (2016) studied mechanical ‹ Add Mg 1 wt% as wetting agent in the melt properties of Al metal matrix nanocomposites by ‹ Reheat the composite slurry and maintain at a temp of hybridization technique. Al-4 % Cu alloy was melted at 750-760 0C 700 0C. Al powder (75 um) and CNTs (9 nm in dia and 5 um in length) as primary and secondary launching vehicles ‹ Perform mechanical stirring for 10 minutes at 400 respectively, were preheated to 200 0C. The mixtures were rpm then stirred at 200 rpm for 4 min in a two-step stirrer. The B. Sample Casting whole setup was maintained under an argon gas environment. A Boron Nitrate coating was used to all the 0 surfaces exposing to the casting environment to avoid iron ‹ Preheat steel mold die (En 31) at 550 C for 20 minutes contamination. 1.5 wt% Al203 (13 nm) is used as ultra-fine reinforced nano particles.
‹ Cast test sample bars of dia 20 mm and length 180 mm at pouring temperature of 750 0C It was concluded that launching vehicles methodology significantly enhances the distribution of reinforcements C. Machining of Test Samples and ultimately the strength of the composite by using the secondary launching vehicle CNTs, the strengthening of ‹ Machine the test samples to perform tensile test as composite is observed as better technique with improvement per ASTM-E 8-95a, brinell hardness test, charpy of ductility [60]. impact test, density measurement, metallographic test Muhammad Arshad Chaudhry et al. (2017) reviewed on Development and Characterization of nano Particle Metal D. Heat Treatment Matrix Composites (Stir Casting) and prepared a standard ‹ Heat treat the machined test samples at 530 0C for operating procedure for development and characterization of 3 hours nano particle metal matrix composites [61].
‹ Quench the test samples in H2 O at room The designed SOP is being described here under: temperature ‹ Age at 180 0C for 5 hours and then air cool at room A. Development temperature
‹ Preheat the Al Alloy at 450 0C for 3-4 hours and E. Sample Preparation SiC Nano Particles at 800-900 0C for 2 hours before melting ‹ Prepare heat treated specimens for microstructural observation by grinding using emery paper # ‹ Charge 1500 gm of Al Alloy into the stainless steel 0, 400, 600, 1000, 1500 crucible and melting in an electric resistance furnace ‹ Polish the ground samples using diamond paste # by heating upto 700 0C 6 micron and 1 micron ‹ Etch the polished test samples using keller’s reagent 103 International Journal of Scientific Research and Innovative Technology ISSN: 2313-3759 Vol. 4 No. 8; August 2017
for 10-30 second ‹ Prepare test samples of size dia 20 mm and height 20 mm for microstructural evaluation and hardness Experimental Procedure for Testing of samples
‹ Prepare test samples of size 10 mm x 10 mm x 55 mm with V-notch 2 mm deep at 450 for charpy impact test as per ASTM-E 23 Discussion on test Results and Conclusions
‹ Prepare tensile test samples of gauge dia 6 mm, gauge length 32 mm and shoulder dia 10 mm G. Characterization F. Flow chart showing experimental At the end, the samples so obtained would be procedure characterized using relevant characterization tools / physical facilities.
Weigh Al Alloy 2024 and preheat at 450 0C for 3-4 hours. Weigh SiCp and preheat at 800-900 0C for 2 hours before melting
Start melting Al 2024 in an electric resistance furnace and maintain melt at 800 0C
Degas the melt by solid degasser C2Cl6 to remove gasses. Set the melt at 700 0C to achieve semi solid state
Add preheated SiCp and 1 wt% Mg in the melt. Mechanical stirring at 300 rpm for 15 min for primary dispersion of SiCp.
Set the melt at 760 0C. Again mechanical stirring at 400 rpm for 10 min at 750 0C
Pour at 750 0C the molten melt into preheated mold die. Solidification of cast samples.
Machine cast samples for microstructure analysis, tensile strength, hardness, impact test and density measurement.
Heat treatment of machined test samples.
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3. Experimental Setups Used by Various Researchers
1. DC Motor 2. Kaowool Insulator 3. Heater Band 4. Nitrogen Gas 5. Graphite Crucible 6. Mould
Figure: Schematic of the experimental set-up to produce cast MMC [1]
1. Stirrer 2. Stopper 3. Thermocouple 4. Powder 5. Argon Gas 6. Valve 7. Coated injector 8. Graphite Crucible 9. Resistance Furnace 10. Mold
Figure: Schematic of the Experimental Setup to produce cast MMC [5] 105 International Journal of Scientific Research and Innovative Technology ISSN: 2313-3759 Vol. 4 No. 8; August 2017
Figure : Schemetic View of Set-up for fabrication of Composite [11]
1. Transformer-dimmer
2. Injection Hopper
3. Four Blade Stirrer
4. Graphite Crucible
5. Molten Aluminum
6. Coal Fired Furnace
Figure: Schemetic of Stir Casting Process [13]
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Figure: Schemetic diagram for Stir Casting Technique [15]
Figure: (a), (b) Induction resistance furnaces with temperature regulator cum indicator and (c) Melt-Stirring setup utilized for casting of composites [17]
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Figure: Experimental Setup used to produce MMC [20]
Figure: Stir Casting Setup [21]
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1. Ultrasonic Transducer
2. Ultrasonic Power Supply
3. Control System
4. Heat Jacket and Crucible
5. Temperature Sensor
6. Heat Jacket Power Switch
7. Argon Gas
8. To wall outlet
Figure: Schemetic of Experimental Setup [23]
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Figure: Metal Matrix Composites by Stir Casting Method [25]
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Figure: Stir Cast Apparatus [33]
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Figure: Schemetic Illustration of the Mixing Equipment used for (a) the distributive mixing Process and (b) the Rheo-Process [36]
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Figure: Experimental Setup and with Stirring Speed Controller [37]
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Figure: Stir Casting Setup [38]
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Figure: Experimental Setup used for Stir Casting [40]
Figure: Stir Casting Experimental Setup [42]
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Figure: Fabrication of MMC using Stir Casting Method [43]
Figure: Schematic diagram of Stir Casting Technique [44]
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Figure: Ultrasonic Cavitations Based Dispersion Experimental Setup [45]
Figure: Schematic Sketch of Ultrasonic Stir Casting [48]
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Figure: stir Casting Furnace [49]
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Figure: Stirring of Molten Metal in the Furnace, Slag Produce during Casting Process,
Preheating of Die and Casting of Al 6061+Fe2 O2 [50]
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Fig 1 Stir Casting Experimental Rig
Fig 2 Power Control Panel
Fig 3 Mechanical Stirrer Assembly
Fig 4 Electric Resistance Furnace
Fig 5 Crucible Lid
Fig 6 Sample Mold Die
Figure 1: Stir Casting Experimental Rig Figure 2: Power Control Panel [Top Loaded Electric Resistance Furnace with Mechanical Stirrer Assembly]
Figure 5: Crucible Lid
Figure 3: Mechanical Stirrer Figure 4: Electric Resistance Figure 6: Sample Assembly with lifting / lowering Furnace with Stainless Steel Mold Die Mechanism with Variable Speed Crucible and Stainless Steel Electric Motor [1 HP] Stirrer Rod Figure: Stir Casting Experimental Rig with Sub Assemblies [61] 120 International Journal of Scientific Research and Innovative Technology ISSN: 2313-3759 Vol. 4 No. 8; August 2017
4. Comparison of Process Parameters of Stir Casting Techniques
Character- Development of Al Metal Matrix Composites
ization
Melting Reinforcement, Matrix / Inert Speed Temp 0C Preheat Temp 0C Ref.# Researcher Year Technique Preheat gas rpm, Time Techniques / Time / Time
1 J. Hashim 2001 Stir Casting A359 750 N @ SiCp + Mg 100 TS, HV OM 3 cc/ min 2 S.Naher 2004 Stir Casting A356 630 N SiCp 200-500 - 130 min 900 0C for 4 hrs 2 min OM
3 S.B.Prabu 2006 Stir Casting A384 Super- - SiCp (60 um) 600 – 700 BHN 0 heated 800 C for 2 hrs 10-15 min OM, SEM
4 S. D. N. 2010 Ultrasonic A356 700 Argon SiCnp (34 nm) 750, TS, BHN, HV Nageswara Stir Casting 2 min 0.1-0.5 wt% 3 min OM, SEM
5 S. A. 2011 Stir Casting A356 700 Argon SiCp (8,80,40 um) 500 TS Amirkhan 2 min Mg 1 wt% OM, SEM
6 M. H. Zamani 2011 Stir Casting A356 850 - 1% Al2O3 (80 nm) 420, TS, BHN 10% ZrO2 14 min SEM (0.5,1,1.5,2.0 wt%) 7 E. S. Y. El- 2011 Stir Casting A356 680 Argon Al2O3 (200,60nm) 1000 - Kady 15 vol. %, 400 0C OM, XRD, for 2 hrs SEM 8 A. R. I. 2011 Stir Casting Al 700-900 - SiC, Al2O3, MgO 400-500 TS, BHN, Kheder (50,60,50 um) 15-20 min Impact 5-20 wt% OM, SEM 9 G.G. 2012 Stir Casting Al-11 Si- 700,750,8 Argon SiC (40 um) 450 TS, BHN, TS, Sozhamanna Mg 00, 850, 10 vol % - BHN, n 900 1000 0C IMPACT
10 B. S. Kumar 2012 Stir Casting A357 740 N SiCnp (50,18nm) - TS, BHN Mg 1 wt% OM, SEM, (10000C) (0, 0.5, TEM, EDS 1.5, 2.5, 3.5, 4.5 wt%)
11 J. J. Rino 2012 Stir Casting Al-4.5 - - SiC & Zircon Sand - TS, H, Charpy wt% Cu
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12 A. D. Sable 2012 Stir Casting Al 760 - SiCp (320 400, TS, BHN, 0 0 (450 C) grit) (900 C) 10 min Charpy 3-4 hrs (5, 10, 15, 20, 25, OM 30 %) 13 A. D. Sable 2012 Stir Casting Al 760 - SiCp (320 400, TS, BHN, 0 (4500C) grit) (900 C) 10 min Charpy 3-4 hrs (5, 10, 15, 20, 25, OM 30 %) 14 A. Mazahery 2012 Stir Casting Al 356 750 N SiC (50 nm) - TS, BHN (16um (0,0.5, 1.5, 2.5, 3.5, OM, EDS ) 4.5wt%) Mg 1wt%
15 S. Chatterjee 2013 Stir Casting Al 900 - TiO2 (20 nm) - TS Mg 2 wt% OM, SEM, EDS 16 A. Jailani 2013 Stir Casting Al - - SiC (10%) 100, TS, HV, 15-20 min Charpy OM, SEM 17 B. M. Viswa 2013 Stir Casting A356 - C2Cl6 SiC (25 um-0,3,6,9 500-600, TS, HV - wt%) +grp (44 um - 10 min OM, SEM 3 wt%)+Mg 1wt%
18 K. L. Meena 2013 Stir Casting Al6063 750 - SiCp (400 mesh- 200, TS, HRB, 5,10,15,20 wt%) 20 min Izod, 0 1100 C for 1.5 hrs OM 0 19 D. Singla 2013 Stir Casting Al 7075 1000 C2C16 Flyash 600 C + Mg, TS, BHN, Charpy XRD 20 V. Kumar 2013 Stir Casting AA 2218 850 - Al2O3 - TS, HV, Charpy OM 21 Gopi K. R. 2013 Stir Casting Al 6061 756 C2Cl ZrO2 400, BHN OM 6 (2,4,6,8, 1 min 10 wt%) + Grp 200 0C
22 P. Phutane 2013 Stir Casting Al-HE-30 800 - SiC (25 um) 500, TS, BHN OM 10 min
23 D. K. Koli 2013 Stir Casting A356 750 - Al2O3 (50nm) -
24 Dr. G. 2013 Stir Casting Al 2024 638 Argon B4C (50nm) - TS, HV OM, Nandipati (0.1, 0.2, 0.3, 0.4, SEM 0.5, 1.0, 1.5, 2.0, wt%)
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25 L. Rasidhar 2013 Stir Casting Al 730-750 Argon FeTiO3 650-700 TS, HV OM, (99.7%) (57nm) (1-5 10-15 min XRD, SEM, wt%) EDS
26 J. Shree 2013 Stir Casting Al 6061 750-760 C2Cl6 SiCp 400, 600-800 0C for 2 10 min hrs 27 N. S. Abtan 2013 Stir Al 750-900 - SiCp (63 um) TS, BHN, Casting (5,10,15,20 Charpy wt%) OM 700 0C 28 A. Kumar 2013 Stir Casting A359 730-750 - Al2O3 (30 300 TS, HRC OM um) (2,4,6,8 wt%) 800 0C
29 R. S. Rana 2013 Ultrasonic A 5083 760 N SiCnp (40nm) TS, BHN SEM, Stir Casting (1,2,3,4 wt%) TEM Sip (35 um) (3,5,8,10 wt%)
30 A. R. N. Abed 2013 Stir Casting A 7075 650 - Al2O3np 300, TS, HV (1,2.5wt%) 20min OM, XRD, SEM, AFM
31 B. P. Samal 2013 Stir Casting Al 800 - SiCp (10 wt%) 500 TS, OM, XRD
32 S. Mathur 2013 Stir Casting Al-4Cu 700-725 - SiCp (400 grit) 600, TS, BHN IZOD 450,3hr 5 wt% 3min 1100 0C for 2 hr
33 A. Mittal 2013 Stir Casting Al 6061 750, 1100 RHA (8,16,24 wt%) 600 HV 200 0C for 1 hr XRD, SEM, EDS +Cu (3wt%) 1100 0C + Mg (3wt%) 850 0C for 1hr
34 R. G. 2013 Stir Casting Al 6061 500-900 N Al2O3 (320 mesh) 300-600 Bhandare (5000C for 30 min) 2min SiC/Grp Mg 1wt %
35 T. Rajmohan 2013 Stir Casting Al 356 750 - SiC (25 um) Mica 500 TS, BHN / (45 um) 5-7 min HRB 620 0C, Mg SEM, EDS
36 K. K. Alaneme 2013 Stir Casting Al-Mg- 750-800 - SiC (30 um) 10 400 TS, H Si alloy wt% BLA (50um) 10 min OM, SEM 250 0C, Mg 0.1 wt%
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37 B.V. Ramnath 2014 Stir Casting Al-Si 700 Al2O3 900, 5min
38 Raghavendra 2014 Stir Casting Al 7075 700-720 - Al2O3 (149,105,74 5min TS, N. um) (100, 140, 200 BHN / mesh)(3,6,9,12 HV OM wt%) 350 0C
39 P. O. Babalola 2014 Stir Casting Al 6061 670 Argon SiCp (10 vol .%) 500
40 S. Haque 2014 Stir CastingAl 6061- 800 - SiCp 1100,2hrs 200-600, SEM Cu 450,40 10min min
41 Vinoth M. A. 2014 Stir Casting Al-Si 750-800 C2Cl6 SiCp (3 wt%) / 350-890 TS, BHN Cenosphere (5, 10, 8-10 min 15, wt%) 450,3-4hrs 10-30 gm/min (feed rate)
42 Tony Thomas 2014 Stir Casting Al LM6 800 - SiC 600 TS, BHN 10 min
43 `G. Sutradhar 2014 Stir Casting LM6 alloy 750 - SiCp (5-12.5 400-500 TS, HV, wt%) Mg 3wt% Impact 0 850-900 C OM, XRD
44 B. V. 2014 Stir Casting Al alloy 830 - Al2 O3 550 TS, BHN, Ramanath (95 %) 550, 3- B4C 10 min Charpy 0 4 hrs 400 C OM
45 Mr. Praveen. 2014 Stir Casting Al alloy 850 - MgO (80 nm) 100 BHN G 0.5,1, 1.5, 2.0 wt% 15-30 min XRD , SEM
46 L. 2014 Stir Casting AA 6061 680-800 Argon SiC (45-65 nm) (0.3, 2 kW TS, BHN Poovazhagan (Ultrasonic 0.5, 0.8, 1.0, 20 kHz OM, SEM, ) 1.25, 1.5 vol%) EDS
47 M. T. Alam 2014 Stir Casting Al alloy 680 - SiC (10, 20, 30, 40, 300 HRA 50 wt%) 30 seconds SEM, EDX
48 H. R. 2014 Stir CastingAl 6061 750 - Al203 (40 nm) (0.5, 450 - Ezatpour (50 um) 1, 1.5,wt%) 15 min OM, SEM
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49 T. Q. Hashimi 2014 Stir Casting Al alloy 700-800 - SiC 600-700 10 min
50 K. Kumar 2015Stir Casting Pure 700 - Al 2O3 np 20-30 kHz TS, HV (Ultrasonic) Al (0.5, 1 wt%) SEM alloy
51 B. P. 2015 Stir Casting Al 6061 700 C2 Cl6 SiC (50 um) 300 TS, BHN Pavithran Graphite (60 um) 17 min 500 0C for 1 hr
52 Phaniphusha 2015 Stir Casting Al 6061 750 C2 Cl6 Fe2 O3 (2,4,6,8 300-350 TS, BHN na wt%) 5-10 min OM
53 P. Melali 2015 Stir Casting Al 2024 750 - SiC (50 nm) 512 - Al & Cu (60 um) 6 min OM 1 wt% each
54 S. 2015 Stir Casting A 356 800 - SiC (5-20 um) 250 TS, HV, OM Thanesekara 20 vol % 30 min n Al203 (15-20 um) 200 10 vol % Mg 1% 10 min
55 S. K. 2015 Stir Casting LM 13 - - ZrSiO4-90 & 135um - TS, BHN Thandalam (Al-4.5 15 & 65um OM, SEM % Cu) 30 wt% & 20 wt%
56 M. 2015 Stir Casting Al 2024 750 - Al203 nanparticles Sonication Vykuntarao 15 min 5 min
57 K. K. Paul 2015 Stir CastingAl LM6 620-900 - SiC (20um) 20 600 TS, BHN OM 450 0C for vol% 0 3 to 4 900 C hours
58 Jamaluddin 2015 Stir Casting Al6063 - - SiC (200-300 mesh) - TS, HV, Hindi 2,4,6 wt % Charpy OM
59 S.B. 2016 Stir Casting Al 6061 820 - SiC (60-90 um) - BHN OM Rayjadhav 0,5,10 wt% 20- 40 sec 800 0C for 1 hr
60 V.R. Raju 2016 Stir Casting Al-4Cu 700 Argon Al powder 75 um 300 TS, BHN Al203 13 nm 2 hrs OM, XRD, C NT 9 nm SEM, TEM
61 Muhammad 2017 Stir Casting Al 2024 750-760 C2 Cl6 SiC (45-55 nm) 400 , TS, BHN, Arshad (0.3, 0.6, 0.9, 10 min Charpy Chaudhry 1.2, OM, XRD, et al. 1.5, 1.8 wt%) SEM, EDX
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5. Scope of Future Work ‹ To ensure uniform distribution of nano particles, restirring process can help to disperse the SiC nano Metal matrix composites with micron size reinforcements particles. have been used with great success in the automotive, ‹ A full incorporation of SiC nano particles into the aerospace, defense, sports and industrial applications. Al alloy matrix can be obtained in the semi solid state without any addition of a wetting agent. ‹ In case of MMNCs, incorporation of as little as one volume percentage of nano size ceramic particles has led ‹ Strength and hardness of the AMMNCs is governed to a much greater increase in the strength of aluminum. by the degree of grain refinement.
‹ Such potential improvements have great implication for ‹ By increasing the stirring speed and stirring the automotive, aerospace and in particular, defense time, homogeneous distribution of SiC nano particles industries due to the drastic weight savings and superior in the Al matrix is expected. properties that can be achieved.
‹ The addition of Si to Al matrix improves the 6. Challenges wettability among SiC nano particles and Al.
‹ Research on structure-property correlations in nano ‹ There are exciting opportunities for producing composites, new challenges in the development of extraordinary strong, light weight, wear resistant suitable fabrication techniques for nano composites, AMMNCs with adequate ductility by stir casting to be their characterization and mechanics, in order to easily adoptable by the automotive engineering understand interactions at much smaller sizes. industry locally and globally.
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