Pargunde , et al, International Journal of Advanced Engineering Research and Studies E-ISSN2249–8974 Research Paper DEVELOPMENT OF ALUMINIUM BASED METAL MATRIX COMPOSITE (AlSiC) 1Dinesh M. Pargunde, 2Prof. Gajanan N. Thokal, 2Prof. Dhanraj P. Tambuskar, 3Mr. Swapnil S. Kulkarni Address for Correspondence 1M.E. Scholar, 2Assistant Professor, Mechanical Engineering Department, PIIT, New Panvel, Mumbai University 3Director-Able Technologies India Pvt. Ltd., Pune ABSTRACT There are several technical challenges existing for today’s casting technology. Achieving a uniform distribution of reinforcement within the matrix is one such challenge, which affects directly on the properties and quality of composite material. In the present study a modest attempt would be made to develop Aluminum based Silicon Carbide (AlSiC) with an objective to develop a conventional low cost method of producing Metal Matrix Composites (MMCs)..Two step-mixing method of stir casting technique has been proposed and subsequent property analysis has been made to develop the composite. Aluminium (98.41%) and SiC (360-grit) have been chosen as matrix and reinforcement material respectively. Experiments are planned for conducting varying weight fraction of SiC (in the steps of 5%)while keeping all other parameters like furnace temperatures, stirring speed & total mass of material mixture constant. The results were evaluated by Brinell Hardness Test, Charpy Impact Test (including micro-structure) and Corrosion Test The trend of hardness and impact strength with increase in weight percentage of SiC were observed and recommendation made for the potential applications accordingly. By this experimental analysis, it is observed that 25% SiC with Aluminum is the optimum mixture for the Metal Matrix Composites. KEYWORDS: Aluminium Alloy, Hardness, Impact Strength, MMCs(Metal Matrix Composites), SiC (Silicon Carbide/ Carborundum) 1. INTRODUCTION • Increase in creep resistance at higher A composite material (1) is a material consisting of temperatures compared to conventional alloys two or more physically and/or chemically distinct • Increase in fatigue strength, especially at higher phases. The composite generally has superior temperatures characteristics than those of each of the individual • Improvement of thermal shock resistance components. • Improvement of corrosion resistance Usually the reinforcing component is distributed in • Increase in Young’s modulus the continuous or matrix component. When the • Reduction of thermal elongation matrix is a metal, the composite is termed a metal- 2.2 Application of MMC: matrix composite (MMC). In MMCs, the Metal Matrix Composite (MMC) is rapidly becoming reinforcement usually takes the form of particles, prime candidates as structural materials in whiskers, short fibers, or continuous fibers. engineering as well as in electronic application. 2. COMPOSITE MATERIALS Aluminium (Al) and Copper (Cu) reinforced by SiC Composite are materials in which two phases are is used in various industries due to its excellent combined, usually with strong interfaces between the thermo-physical properties such as low coefficient base metal and reinforcement. They usually consist of thermal expansion (CTE), high thermal of a continuous phase called the matrix and conductivity and improved mechanical properties discontinuous phase in the form of fibers, whiskers or such as higher specific strength, better wear particles called the reinforcement.. Composite resistance and specific modulus. materials are gaining wide spread acceptance due to 3 LITERATURE SURVEY their characteristics of (MMCs) is due to the relation Vijayaram T.R. and Sulaiman S. (2005) define of structure to properties such as specific stiffness or Squeeze forming process is a special casting specific strength. Composites materials are high technique that combines the advantages of traditional stiffness and high strength, low density, high high pressure die casting, gravity permanent mold die temperature stability, high electrical and thermal casting and common forging technology. Saraev D. conductivity, adjustable coefficient of thermal (2001), Analyzes 3D Finite element calculations expansion, corrosion resistance, improved wear comparing to axisymmetric calculations have been resistance etc. the matrix holds the reinforcement to performed to predict quantitatively the tensile form the desired shape while the reinforcement behavior of composites reinforced with ceramic improves the overall mechanical properties of the particles aligned in stripes. The analyses are based on matrix. When designed properly, the new combined a unit cell model, which assumes the periodic material exhibits better strength than would each arrangement of reinforcements. The results are individual material. presented in such a manner that can be directly 2.1 Objectives for Development compared for all possible aspect ratios and inclusion The reinforcement of light metals opens up the volume fractions. Kaczmar J.W. and Pietrzak K. possibility of application of these materials in areas (2000), Studied the production methods and where weight reduction has first priority. The properties of metal matrix composite materials precondition here is the improvement of the reinforced with dispersion particles, platelets, non- component properties. The development objectives continuous (short) and continuous (long) fibers are for light metal composite materials are: discussed in this paper. J. Wannasin and M.C. • Increase in yield strength and tensile strength at Flemings, (2005), developed a new centrifugal room temperature and above while maintaining casting process capable of achieving high pressure the minimum ductility or rather toughness for fabrication of metal matrix composites.

Int. J. Adv. Engg. Res. Studies/III/I/Oct.-Dec.,2013/22-25 Pargunde , et al, International Journal of Advanced Engineering Research and Studies E -ISSN 2249–8974 4 PROBLEM DEFINITIONS Automatic stirring was carried out with the help of The problem for the proposed work is to evolve a radial drilling machine for about 10 minutes at development process for the best mix of the alloying stirring rate of 290 RPM. At this stage, the preheated elements for AlSiC for deriving optimal mechanical SiC particles were added manually to the vortex. In properties for a given hardness and impact strength of the final mixing process the furnace temperature was the material. controlled within 700+ 10 C. After stirring process 5 METHODOLOGY the mixture was pour in the other mould to get With the use of experimental set-up we can analyze desired shape. the data in a real time environment or verify the 5.3 Steps for Experimental methodology: actual results obtained by other methods. This Step 1: Preparation of sand mould method is simpler to visualize and understand but is Green sand or Molding sand as it is popularly known more challenging in terms of manipulation of the is used with binding material to form the cope and input data for finding the sensitivity associated with the drag or the cores of the mold . the output. Also, it is time consuming and expensive Step2: Preparation of Specimen of various to build a prototype and later engage the testing compositions. The alloying element SiC is mixed equipments for th is purpose. For our case, the proportionately by weight in the ratio of 5%, 10%, physical experimentation has been carried out under 15%, 20%, 25%, 30%. The percentage of alloying specified input conditions at the foundry; the details element to be u sed is determined by literature review of which are given below. and history for development of this work 5.1 Experimental set up used in Stir casting operation: 5.1 Steps involved in Stir Casting:

Figure No.5.3. Specimens for hardness test of Metal Matrix Composite Step 3: Machining of specimen for test . For Charpy/ Izod Impact test, the material needs to be sized as a square section with a notch as specified by the relevant IS standard

Figure No.5.4. Specimens for Impact test of Metal Matrix Composite Step 4: Checking Hardness over `Hardness testing machine’ Brinell Hardness Test is carried out over `Llyod’ Testing machine

Figure No.5.1. Flow Chart showing steps involved in Stir Casting 5.2 Experimental Procedure: Aluminium Alloy was melted in a crucible by heating Figure No.5.5. Specimens of hardness tested of Metal it in a muffle furnace at 800 C for three to four hours. Matrix Composite The silicon carbide particles were preheated at 1000 Step 5: Checking Impact Strength using `Charpy C for one to three hours to make their surfaces Impact testing machine’ oxidized. The furnace was first raised above the Test for Impact Strength is carried out using the setup liquid us temperature of Aluminium near about 750 C specified for Izod Impact Test to melt the alloy completely and was cooled down Step 6: Analysis and graphs Attached. just below the liquidus to keep slurry in Semi solid Various Experiments were conducted on fabricated state. MMCs samples by varying weight fraction of SiC (5%, 10%, 15%, 20 %, and so on ) and size of SiC particles (360 Grade ) to analyze the casting performance characteristics of Al/SiC -MMCs. 5.4. Hardness Hardness is the resistance of a material to localized deformation. The term can apply to deformation from indentation, scratching, cutt ing or bending. Hardness measurements are widely used for the quality control of materials 5.5. Impact Strength The impact toughness of a material can be Figure No.5.2. Flow Chart Experimental Techniques deter mined with a Charpy or Izod test. For both tests, followed the specimen is broken by a single overload event Int. J. Adv. Engg. Res. Studies/III/I/Oct.-Dec .,2013/ 22-25 Pargunde , et al, International Journal of Advanced Engineering Research and Studies E -ISSN 2249–8974 due to the impact of the pendulum. A stop pointer is (b) Hardness (BHN ) and Density (gm/cc) increases used to record how far the pendulum swings back with the increase in reinforced parti culate size (360 after fracturing the specimen. The impact toughness Grade) and weight fraction (5% , 10%, 15 %, and of a metal is determined by measurin g the energy 20%) of SiC particles. Maximum Hardness (BHN ) = absorbed in the fracture specimen. 44.8 and Maximum Density (gm/cc) = 2.8 52 gm/cc 5.6. Microstructure has been obtained at 25 % weight fraction of 360 Metallographic samples were sectioned from the Grade size of SiC partic les as shown in Table 6.1 & cylindrical cast bars. A 0.5 % HF solution was used Figure no. 6.1. to etch the samples wherever required (c) Impact Strength (NM) decreases with the 5.7. Corrosion increase in reinf orced particulate size (360 Grade) Corrosion is an irreversible interfacial reaction of a and increases with t he increase in weight fraction material (metal, ceramic, and polymer ) with its (5%, 10%, 15%, and 20 %) of SiC particles. environment which results in consumption of the Maximum Impact Strength = 35.33 N -m has been material or in dissolution into the material of a obtained at 25 % weight fraction of 360 Grade size of component of the environment high-strength steel SiC particles as shown in Table 6.1 & Figure no. 6.1. 6 RESULTS AND DISCUSSION (d) Corrosion Test is based on weight loss Trend of hardness and impact strength with increase determinations and provides a quantitative measure in weight percentage of SiC were observed and of the relative performance of the material evaluated. tabulated in Table 6.1. Also the results are shown Corrosion Test was carried out by ASTM 262 -A graphically in Figure 6.1. The experiment was Practice B and results are that the corrosion rate of conducted by varying weight fraction of SiC (in the Metal Matrix Composites is 4.88822 mm/month and steps of 5%) while keeping all other parameters like 2307.23 miles/year . From this we see that the furnace temperatures, stirring speed & total mass of corrosion rate is satisfactory. material mixture constant. Table 6.1: Strength Properties of MMC at Various SiC mixture

Figure No.7.1. Corrosion Test Specimen The silicon carbide reduces the density of the aluminium and improves its stiffness and wear resistance. The toughness and ductility are reduced by the ceramic. These alloys have found applications in advance bicycle frames, racing horse shoes and From the above graph, 25% SiC is the best mixture. formula one racing car brakes. But to confirm this, we took a trial for 23, 24, 26 and FUTURE SCOPE 27% SiC. The results are shown in table no.6.2 The scope of this work can be extended to the Table No.6.2 : Strength Properties of MMC at Optimum SiC Mixture following exercise: • Use of Pressure Die Casting process for higher rate of production • Use of Metal Injection Molding (MIM) for `Fe’ based alloys REFERENCES 1. T.R. Vijayaram, S. Sulaiman (2006), “Fabrication of fiber reinforced meta l matrix composites by squeeze casting technology” Department of Mechanical and Manufacturing Engineering, Faculty of Engineering, University Putra Malaysia, Journal of Materials Processing Technology (178), 34–38. 2. D. Saraev, S. Schmauder, (2003) “Finite element modeling of Al/SiC metal matrix composites with particles aligned in stripes—a 2D –3D comparison” Staatliche Materialpru¨fungsanstalt (MPA), University Figure No.6.2. Strength vs . Optimum SiC % of Stuttgart, Pfa ffenwaldring 32, D - 70569 Stuttgart, Since the results show a favorable mechanical Germany, International Journal of Plasticity (19) 733 – strength for the specimens at 25%SiC, this value 747. 3. J.W. Kaczmar, K. Pietrzak, (2000) “The production needs to be studied with peripheral values for and application of metal matrix composite materials” securing the best results. For this purpose, Institute of Mechanical Engineering and Automation, experiments are proposed for 23%, 24%, 26% & 27% Technical Univer sity of Wrocøaw, ul. èukasiewicza SiC. 3/5, 50-371 Wroclaw, Poland Institute of Electronic Materials Technology, Journal of Materials Processing CONCLUSION Technology (106) 58±67. The experimental study reveals following 4. J. Wannasin, M.C. Flemings, (2005) “Fabrication of conclusions: metal matrix composites by a high -pressure centrifugal (a) Microstructure: Optical micrographs showed infiltration process” Department of Materials Science and Engineering, Massachusetts Institute of reasonably uniform distribution of SiC particles and Technology, Cambridge, MA 02139, USA, Journal of this is good agreement with earlier work. Materials Processing Technology (169) 143 –149. Homogenous dispersion of SiC particles in the Al 5. Mohamed A. Taha, (2001) “Practicalization of cast matrix shown in figure no.5.17 an increasing trend in metal matrix composites MMCCs” Department of Design and Production Engineering, Faculty of the samples prepared by applying stirring casting Engineering, Ain-Shams University , P.O. Box 8022, technique. Massaken Nasr-City, Materials and Design (22) 431 441.

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