Chapter:-1: 1.1 Need For The Composite Material

STUDY OF MECHANICAL PROPERTIES OF AL6061 REINFORCED WITH INSITU
TIB2 METAL MATRIX COMPOSITES

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Chapter:- 1
INTRODUCTION
1.1 Need for the composite material
In the 21st century, high strength, lightweight and energy efficient materials have received
extensive attention, since the problems of environment and energy are major threshold areas. In
order to fulfill this requirement, engineers and researchers are striving to develop new and better
engineering materials.
The modern engineering material finds wide application in the aerospace, defense field,
engineering industry, automobile and leisure industry. The performance and efficiency for these
applications can be increased largely by the application of modern engineering materials
1.2 History of composites
Materials science has developed rapidly during the last century to meet the needs for better
materials which has tailored properties, enhanced performance and reliability in defense,
aerospace, engineering, structures and automobile application. But its main support has come from
the newer technologies associated with aircraft, automobile, missiles, space research and in the
engineering industry. The increasing demand for lightweight, a stiff and strong material to
withstand conditions not previously experienced by man-made components and to perform
functions have not been previously envisaged. Some of these requirements were able to be met by
improvements in existing methods of manufacture and treatment of well-tried materials.
The first major structural metal matrix composite material system was Boron/Aluminum (B/Al),
which was developed in the late 1960s. To date, the only production applications are the tubular
struts used in NASA's Space Shuttle Orbiter mid fuselage. However many airframe, engine
component and other items of B/Al have demonstrated the weight savings of 20 to 65 percent.
There is also considerable research in Boron/Titanium, Graphite/Aluminum and
Graphite/Magnesium systems which were developed show significant potential in
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structural applications. New fibers such as SiC were developed in the mid 1970s and coatings for
carbon, boron fibers were made as viable additives for metallic matrices. The addition of a ceramic
reinforcing phase such as SiC-fibers in a metal matrix such as aluminum produces a composite
with a coefficient of thermal expansion (CTE) below that of the matrix metal itself. In addition,
long, continuous fibers of SiC, carbon or boron can dramatically increase the modulus of the
component over that of the unreinforced matrix. Adding 30% continuous carbon fiber to aluminum
matrix will increase the modulus of the metal.
By the mid 1990s, a variety of MMCs was found in spacecraft applications: Carbon-reinforced
copper was used in the combustion chamber of rockets, SiC-reinforced copper was used in rocket
nozzles, Al2O3-reinforced aluminum composites were used in the fuselage and SiC- reinforced
aluminum composites were used for wings and blades. The antenna boom on the Hubble Space
Telescope was made of a graphite-aluminum composite. The cost of producing MMCs has
prevented them from entering into other marketplaces. A notable exception is again in the area of
sports equipment, where MMCs such as Duralcan (Al reinforced with 10% Al,O3 particulates)
and Al reinforced with 20 % SiC particulates were used in bicycle frames for lightweight, high
strength, very expensive mountain bikes. Honda has used aluminum metal matrix composite for
the cylinder liners in some of their engines; B21A1, H22A, H23A and C32B. Toyota has used
metal matrix composites in the Yamaha designed 2ZZ-GE engine which is used in Toyota car. All
major automotive components like space frames, exterior and interior body panels, instrument
panel assemblies, power plants, power trains, drive trains, brake and steering systems etc. are now
being fabricated with a wide variety of composites that include polymer, metal and ceramic matrix
composites.
Every industry is now vying with each other to make the best use of composites. The present trend
is to use composites in many disciplines starting from sports goods to space vehicles. This
worldwide interest during the last four decades has led to the prolific advancement in the field of
composite materials and structures.

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1.3 The definition of a composite.
The term composite means composed, therefore it should be material that is composed of
two or more components. However, this would mean that most natural and synthetic materials and
alloys belong to this category. The definition should be clarified.
Matrix + Reinforcement = Composite
1.4 Classification of composites,
Composites are classified based on matrix material as follows,
Figure No : 1

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Figure No : 2

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1.5 Metallic Matrix composites,

Metals are extremely versatile engineering materials. A metallic material can exhibit a wide
range of readily controllable properties through appropriate selection 0f alloy composition and
thermo mechanical processing method.
Metal matrix composites (MMCs) are materials, which combine a tough metallic matrix with a
hard ceramic reinforcement to produce composite materials with superior properties to
conventional alloys (Barnes et al. 1999).
Composites consist of one or more discontinuous phases embedded in a continuous phase. The
discontinuous phase is usually harder and stronger than the continuous phase and is called the
‘reinforcement’ or ‘reinforcing material’, where as the continuous phase is termed the ‘matrix’.
The metal matrix composite, on the other hand, has a series of advantages that are very important
in the utilization of structural materials. These advantages relate to the same metallic properties
that have led to the general primacy of metal alloys for use in dynamic engineering structures and
they include the combination of the
following properties:
1. High strength.
2. High modulus.
3. High toughness and impact properties.
4. Low sensitivity to changes in temperature or thermal shock.
5. High surface durability and low sensitivity to surface flaws.
6. High electrical and thermal conductivity.
7. Excellent reproducibility of conductivity.
8. Excellent technological background with respect to (a) Design, (b) Manufacture,
(c) Shaping and forming, (d) Joining, (e) Finishing and (f) Service durability information.
1.5.1 Matrix Phase
Matrix is a solid which can be processed so as to embed and adherently grip the reinforcement and
matrix should not react chemically or metallurgically with the reinforcement.

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The role of the matrix material comprises the following:
 Distributes the stress to the reinforcement material.

 Provides the final shape of the composite part.
 Binds the reinforcements (fibers/particulates) together.
 Mechanically supports the reinforcements.
 Protects the reinforcements from surface damage due to abrasion or chemical attacks.
1.5.2 Classification of metal matrix composites
Figure No : 3
1.6 Aluminium Matrix Composites (AMCs)
Many Al-MMCs are more suitable for higher temperature operations than un-reinforced alloys.
The aim is also to get improved strength, stiffness, fatigue strength, thermal conductivity, abrasion
resistance, creep resistance and dimensional stability. The reinforcement is typically a ceramic
material.
The Al-MMCs can be classified based on the structure of the reinforcements. There are continuous
fibers, short and particle strengthened materials. The particulate metal matrix composites can be
fabricated partly by the already existing production investments and can be produced at a lower
cost.

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Aluminium alloys have a high machinability index and have been enormously used in aerospace
and automobile industries due to their superior properties such as higher strength to weight ratio,
excellent low-temperature performance, exceptional corrosion resistance, chemical inertness to
commonly used cutting tools, etc. However, the main weaknesses of aluminium alloys are their
poor high-temperature performance and wear resistance. To overcome these problems, aluminium
alloys reinforced by ceramic particles, known as metal matrix composites (MMCs), have been
developed (Pramanik et al. 2008).
Aluminium is the most popular matrix for the metal matrix composites (MMCs). The Al alloys
are quite attractive due to their low density, their capability to be strengthened by precipitation,
their good corrosion resistance, high thermal and electrical conductivity, and their high damping
capacity. Aluminium Matrix Composites (AMCs) offer superior combination of properties (profile
of properties) in such a manner that today no existing monolithic material can be a rival. Over the
years, AMCs have been tried and used in numerous structural, non-structural and functional
applications in different engineering sectors.
The key benefits of AMCs in the transportation sector are lower fuel consumption, less noise and
lower airborne emissions. With increasing stringent environmental regulations and emphasis on
improved fuel economy, use of AMCs in transport sector will be inevitable and desirable in the
coming years. AMCs are intended to substitute monolithic materials including aluminium alloys,
ferrous alloys, titanium alloys and polymer based composites in several applications. It is now
recognized that in order that AMCs substitute for monolithic materials in engineering system to
be wide spread, there is a compelling need to redesign the whole system for weight reduction and
volume savings. Moreover, by utilizing near-net shape forming and selective-reinforcement
techniques AMCs can offer economically viable solutions for a wider variety of commercial
applications. Recent successes in commercial and military applications of AMCs are based partly
on such innovative changes made in the component design.
Composite materials should include component materials which complement each other and are
compatible. With these composites, the high-modulus reinforcement is combined with a matrix
that has been selected for its ease of fabrication into structural hardware. In addition, there is little
chemical or mechanical interaction between the two phases, which simplifies matrix

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reinforcement compatibility problem. With metal matrix composites, the temperature of composite
fabrication is generally much higher, and the composite has elastic modulus by one or two orders
of magnitude higher than those of the matrices.
Chemical compatibility has been solved in metal matrix composites in two ways: either by using
low temperature fabrication techniques or by selecting thermodynamically stable component
phases which are at equilibrium with each other. A corresponding thermal mechanical
compatibility problem has been solved either by using ductile matrix that yields and takes up all
the differential strain necessary in thermal cycling or by selecting a matrix and reinforcement that
have nearly matching thermal expansion coefficients.
1.7 Polymeric Matrices.
Polymeric matrices are the most common type in production. In comparison with metals they have
low weight, high strength, are corrosion resistant, do not require surface treatment, absorb
vibrations and have low thermal and electrical conductivity. The mechanical properties vary
according to the type of polymer, whether it is a thermoplastic, thermo set or elastomer. For the
production of composites all three types of polymers are used. Thermoplastics are mostly
chemically resistant and tougher than thermo sets, while for elastomers, the dominant feature is its
elongation.
Due to their low density, they are most widely used in aircraft design. The disadvantage is the low
thermal stability of polymers. The most important composites have a thermoset matrix.
1.8 Ceramic Matrices.
Ceramics is inorganic non-metallic heterogeneous material consisting of crystalline substances of

varying composition and configuration. Ceramic materials generally have good chemical
resistance, lows thermal conductivity, a high melting point, high hardness and compression
strength and are electrically non-conductive. The main disadvantage is the considerable brittleness,
poor workability, and high sensitivity to internal defects. They are suitable for use at high
temperatures.

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1.9 The composition of a composite.
A composite material is composed primarily of a matrix, i.e. a continuous phase, which is armored
with a reinforcement (reinforcement is a secondary phase), which is usually the discontinuous
phase.
1.9.1 The matrix.
The matrix combines the individual particles of reinforcement, protecting them against external
influences and prevents their violation. The basic function of the matrix is to transmit the external
load onto the reinforced phase. For the matrix, a good bond strength with the reinforcing phase
material (i.e. perfect wet ability without chemical interaction at the interface of the matrix and
reinforcement) is required. Among other requirements for the matrix, a low weight is commonly
included. In comparison with the reinforcement phase, a matrix has generally lower strength and
greater plasticity.
1.9.2 The reinforcement.
Reinforcement is the strong, stiff integral component which is incorporated into the matrix
to achieve desired properties. The term ‘reinforcement’ implies some property enhancement.
Reinforcement may be particle, whisker or fiber.
Reinforcement increases the strength, stiffness and the temperature resistance capacity and lowers
the density of MMC. In order to achieve these properties the selection depends on the type of
reinforcement, its method of production and chemical compatibility with the matrix and the
following aspects must be considered while selecting the reinforcement material.
 Size – diameter and aspect ratio

 Shape – Chopped fiber, whisker, spherical or irregular particulate, flake, etc
 Surface morphology – smooth or corrugated and rough
 Poly or single crystal
 Structural defects – voids, occluded material, second phases

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 Inherent properties – strength, modulus and density.
Even when a specific type has been selected, reinforcement inconsistency will persist
because many of the aspects cited above in addition to contamination from processing equipment
and feedstock may vary greatly.
Selection criteria for the ceramic reinforcement include
 Elastic modulus,
 Tensile strength,
 Density,
 Melting temperature,
 Thermal stability,
 Coefficient of thermal expansion,
 Size and shape,
 Compatibility with matrix material, and
 Cost
1.10 ALUMINUM ALLOY:
Aluminium alloys are alloys in which aluminium (Al) is the predominant metal. The typical
alloying elements are copper, magnesium, manganese, silicon and zinc. There are two principal
classifications, namely casting alloys and wrought alloys, both of which are further subdivided
into the categories heat-treatable and non-heat-treatable. Alloys composed mostly of the two
lightweight metals aluminium and magnesium have been very important in aerospace
manufacturing since somewhat before 1940. Aluminium-magnesium alloys are both lighter than
other aluminium alloys and much less flammable than alloys that contain a very high percentage
of Selecting the right alloy for a given application entails considerations of its tensile strength,
density, ductility, formability, workability, weld ability, and corrosion resistance. Aluminium
alloys typically have an elastic modulus of about 70 GPa, which is about one-third of the elastic
modulus of most kinds of steel and steel alloys. Therefore, for a given load, a component or unit
made of an aluminium alloy will experience a greater elastic deformation than a steel part of the

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identical size and shape. Though there are aluminium alloys with somewhat-higher tensile
strengths than the commonly used kinds of steel, simply replacing a steel part with an aluminium
alloy might lead to problems. Aluminium alloys are widely used in automotive engines,
particularly in cylinder blocks and crankcases due to the weight savings that are possible. Since
aluminium alloys are susceptible to warping at elevated temperatures, the cooling system of such
engines is critical.
1.10.1 WROUGHT ALLOYS
The International Alloy Designation System is the most widely accepted naming scheme for
wrought alloys. Each alloy is given a four-digit number, where the first digit indicates the major
alloying elements.
 1000 series are essentially pure aluminium with a minimum 99% aluminium content by weight
and can be work hardened.
 2000 series are alloyed with copper, can be precipitation hardened to strengths comparable to
steel. Formerly referred to as duralumin, they were once the most common aerospace alloys,
but were susceptible to stress corrosion cracking and are increasingly replaced by 7000 series
in new designs.
 3000 series are alloyed with manganese, and can be work hardened.
 4000 series are alloyed with silicon. They are also known as sliming.
 5000 series are alloyed with magnesium.
 6000 series are alloyed with magnesium and silicon, are easy to machine, and can be
precipitation hardened, but not to the high strengths that 2000 and 7000 can reach.
 7000 series are alloyed with zinc, and can be precipitation hardened to the highest strengths
of any aluminium alloy.
 8000 series is a category mainly used for lithium alloys.
1.11 The use of composites.
For fields such as rocketry and aviation, the automotive and chemical industries, electrical
constructions and many other areas, composites are indispensable in a variety of applications
today.

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1.11.1 Uses of 6000 series

 6061-T6 is one of the most commonly used 6000 series aluminum alloys (see 6061
aluminium alloy)
 6063 is an aluminium alloy, with magnesium and silicon as the alloying elements. The
standard controlling its co mposition is maintained by The Aluminum A sociation.
s It has
generally good mechanical properties and is heat treatable and wieldable. It is similar to the
British aluminium alloy HE9.

 6063 is mostly used in extruded
m shapes for architecture, particularly window frames, door
frames, roofs, and sign fra es. It is typically produced with very smooth surfaces fit for
anodizing.
1.12 Material Properties.
Base Matrix – Al6061
Properties of Al 6061
Density 2.7 g/cm3
Poisson’s ratio 0.33
Young’s modulus 68.9 GPa
Tensile strength 124-290 MPa
Melting point 585 0C

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Fig 4.Al6061 Table No : 1

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Reinforcement – KBF4
Properties of KBF4
Density 2.505 g/mL at 25

°C(lit.)
Assay 96%
Form Powder
Fig 5. KBF4 Table No : 2
Reinforcement – K2TiF6
Properties of K2TiF6
Density 300 g/cm3
Boiling point 235-237 0C
Form Powder
Fi Kg.6. K2TiF6 Table No : 3

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1.5 SUMMARY
We studied need for the composite material by studying this we known that people and industries
requires light weight and high strength material for different applications like in aerospace
industries, automobile industries etc. we studied history of composite, by studying this we known
that different technologies has been arrived, to enhance the strength of material with low weight.
We studied the definition of composite and their classification based on reinforcement and based
on metal matrix composites and then we studied definition of reinforcement, metal matrix with
their classification, in that we choose AMCs for our project concerned. We Al-alloy wrought alloy,
uses of composite, We choose base matrix as AL6061. Reinforcement as TiB2, halides as KBF4
and K2TiF6 for our project concerned.

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Chapter. 2
LITERATURE SURVEY
In the recent years the researcher have given more attention to in-situ composites mainly
because of its clean interface formed between the matrix with reinforcement , high bonding
strength , good interfacial integrity , uniform distribution in the matrix with high mechanical
properties and low fabrication costs. Because of its uniform distribution in the matrix , the in-situ
AMC are mainly used in structured application , when high strength to weight ratio is plays
important role in the aircraft industries and automotive chassis. In previous studies ultra-fined
ceramic reinforcement with the AMC have been report,
Title of the paper : Microstructure Evolution and Mechanical Properties of Al-TiB2/Tic In Situ
Aluminum-Based Composites during Accumulative Roll Bonding
(ARB) Process
Authors : Jinfeng Nie , Fang Wang , Yusheng Li , Yang Cao , Xiangfa Liu.
Material Used : Al-TiB2/Tic.
Methodology : Stir casting process.
Abstract : This kind of Al-TiB2/Tic in situ composite was successfully prepared
using the melt reaction method and the accumulative roll-bonding
(ARB) technique.
Conclusion : The fracture surface of Al-TiB2/Tic composites showed many
dimples, indicating ductile-type fracture. Most of the TiB2 and TiC
reinforcement particles were located in the centers of the dimples.

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Title of the paper : Analysis of Factors Influencing Hardness of Al-TiB2 Composites Using
Response Surface Methodology.
Authors : Jenarthanan M. P, Ramesh Kumar S, Pradeep M.
Material Used : Al-TiB2.
Methodology : Response Surface Methodology.
Abstract : Aluminium matrix reinforced with titanium diboride (TiB2) yield
superior properties than the aluminium alloy reinforced with other
particulates such as Al2O3, Sic, and Tic.
Conclusion : The value of hardness increases much as the composition of TiB2 increases
and the optimum hardness is obtain in stirrer speed 400rpm and 2%
composition of Mg.
Title of the paper : Al 6061-TiB2 Metal Matrix Composite Synthesized with Different Reaction
Holding Times by In-Situ Method
Authors : Lawrance C. A.1, P. Suresh Prabhu.
Material Used : Al 6061-TiB2.
Abstract : Al 6061 and TiB2 using in-situ technique where halide salts namely
potassium hexaflurotitanate (K2TiF6) and potassium tetrafluroborate
(KBF4) were introduced in the Al 6061 melt at 850°C.
Conclusion : AL 6061-TiBmetal matrix composites were synthesized successfully by
incorporating halide salts, K2TiF6 and KBF4 in the Al 6061 alloy at
850°C.

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Title of the paper : Study of Mechanical Properties and Microstructure of Aluminum Alloy
Reinforced with TiB2, by in Situ Technique.
Authors : Akshay Mohan Pujar and Chetan Kulkarni.
Material Used : Aluminum Alloy Reinforced with TiB2.
Abstract : In preparing the samples for microstructure, wear,hardness and tensile testing
a square plate of size (0.15 m / 0.15 m / 0.065 m)was cast using the sand
casting method.
Conclusion : The wear properties of the Al6061 alloy were improved by the addition
of TiB2 particulates, The wear resistance of composites increased with
decreasing particle size of TIB2 particulates.
Title of the paper : Corrosion Characterization of Al-Cu Reinforced

In-Situ TiB2.
Authors : R. Rosmamuhamadan,, S. Sulaiman, M.A. Azmah Hanim
M.I.S. Ismail.
Material Used : Al-Cu Reinforced TiB2.
Abstract : Aluminium-copper (Al-Cu) alloy was reinforced with 3 and 6wt.%
titanium diboride (TiB2). Al-MMCs has been fabricated with salt route
reaction process at 800 °C via potassium hexafluorotitanate
(K2TiF6) and potassium tetrafluoroborate (KBF4) salts.
Conclusion : The composition of 3wt.%TiB2 gave the best corrosion rate compare to
cast Al-Cualloy which were 16.15 and 22.50 x 10-3 mm/y.

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Title of the paper : A Comparative Study on the Microstructures and Mechanical Properties
of Al 6061 Alloy and the MMC Al 6061/TiB2/12P
Authors : T.V. Christy1, N. Morgan and S. Kumar.
Material Used : Al 6061/TiB2.
Abstract : Al 6061 alloy with Al–TiB2 metal matrix composite containing 12% by
weight TiB2 manufactured through the in-situ process was presented.
Conclusion : Strings as well as particulate agglomerates were present as distinct micro
structural features of the composite.
Title of the paper : Comparative Analysis Of Aluminium Metal Matrix Composites

Reinforced With Tic And TiB2 Using Stir Casting Process.
Authors : S. Venkatesan, M. Anthony Xavier.
Material Used : Al 6061-TiB2.
Methodology : Stir Casting Process.
Abstract : Influence of Titanium carbide and Titanium boride reinforcements in
different percentages with the aluminum composites were prepared by
stir casting process and analysed mechanical characterization and wear
characteristics.
Conclusion : A TiB2 particulate reinforced magnesium matrix composite was
successfully fabricated by adding a TiB2–Al alloy and using the stir
casting technique obtained uniform dispersion of reinforcement.

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Title of the paper : In-situ metal matrix composite steels: Effect of alloying and annealing
on morphology, structure and mechanical properties of TiB2 particle
containing high modulus steels.
Authors : R. Aparicio-Fernandez, H. Springer, A. Szczepaniak, H. Zhang,
D. Raabe.
Material Used : Al-TiB2
Methodology : Stir casting method.
Abstract : Morphology, size and dispersion of TiB2 particles formed in-situ from
FeTiB2 based melts, as well as their chemical composition, crystal
structure and mechanical properties.
Conclusion : Increase the stiffness/density ratio of steels, where found to be drastically
changed by the alloying additions andadditional annealing treatments.
Title of the paper : A study of microstructure and wear behavior of TiB2/Al metal
matrix composites.
Authors : A. Sreenivasan, S. Paul
Vizhianb, N.D. Shivakumar,
M. Muniraju, and
M. Raguraman
Abstract : Aluminium metal matrix composites (MMCs). Matrix alloys with 5,
10 and15% of TiB2 were made using stir casting technique.
Conclusion : The observed wear rate was higher for the unreinforced aluminum
alloy when compared to the Al/TiB2 reinforced composites.
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Title of the paper : Mach inability Study of Al-5Cu-TiB In-situ Metal Matrix
2
Composites Fabricated by Flux-assisted Synthesis.

Authors : A.Mahamani.
Abstract : This work is an attempt to understand the machinability behavior of
the Al-5Cu-TiB2 in-situ metal matrix composites .The focus of this
study is to investigate the effect of the cutting speed and feed rate on
flank wear, cutting force, and surface roughness.
Conclusion : The increase in cutting speed increased the flank wear, reduced the
cutting force, and minimized the surface roughness.
Title of the paper : Wear and Friction Behavior of Stir Cast Al-TiB2 Metal Matrix
Composites with Various Lubricants
Authors : S. Poria . Sutradhar, P. Sahoo.

Abstract : a multi-tribotester using block-on-roller configuration under 25-75 N
loads and 400-600 rpm rotational speeds. Four different weight
percentages of TiB2 are considered in this study.
Conclusion : during sliding against steel surface by higher weight percentage of TiB2-
composites. It leads to relatively smoother surface morphology of wear
tracks which is confirmed by SEM images. In case of lower weight
percentage of TiB2-composites.

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Title of the paper : Wear performance optimization of stir cast Al-TiB2 metal matrix
composites using Taguchi design of experiments.
Authors : Suswagata Poria,, Prasanta Sahoo, and Goutam Sutradhar
Abstract : Different weight percentages of micro-TiB2 powders with average sizes
of 5-40micron are incorporated into molten LM4 aluminium matrix by
stir casting method.
Conclusion : In comparison to conventional base alloys or metals, MMCs also able to
provide improved strength, high elasticity, high stiffness.
Title of the paper : Effect of TiB2 content on microstructure and mechanical properties of in-situ
fabricated TiB2/B4C composites.
Authors : WANG Yu-jin, PENG Hua-xin, YE Feng1, ZHOU Yu.
Material Used : TiB2/B4C.
Abstract : The fully dense boron carbide matrix composites containing 10%/40%
(volume fraction) TiB2(TiB2/B4C) were in-sit fabricated via chemical
reaction of B4C, TiO2 and graphite powders at 2050°C under a pressure
of 35MPa.
Conclusion : The fracture toughness increases steadily with increasing TiB2 content,
reaching the maximum value of8.2MPa/m1/2 at 40% (volume fraction).

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Title of the paper : Quantitative study of particle size distribution in an in-situ grown Al–TiB2
composite by synchrotron X-ray diffraction and electron microscopy.
Authors : Y. Tang , Z. Chen, A. Borbély, G. Ji , S.Y. Zhong , D. Schryvers , V. Ji ,
H.W.Wang.
Abstract : TiB2 particles are well crystallized and free of crystal defects. The average
particle size determined from different Bragg reflections by the restricted
moment method ranges between 25 and 55nm,where the smallest particle
size is determined using the 110 reflection .
Conclusion : TiB2 particles are well crystallized and have negligible dislocation
density. Good agreement was found between the results obtained from
the restricted moment and multiple whole profile fitting procedure.
Title of the Effect of cooling rate and other factors on size and pattern of distribution
Paper :
of TiB2 particles formed during solidification of the Al- TiB2 melt for
various pouring temperatures
Authors : P.Senthil Kumar, P.R.Lakshminarayanan, R.Varahamoorthi
Material Used : Al-TiB2
Abstract : Aluminium alloy is melt in a graphite crucible and two salts , potassium
hexaflour titanate and potassium tetra fluro borate are dropped at a slow
rate and mixed with aluminium melt, with the help of a hand held graphite
stirrer.
Conclusion : When fluidity is more the circulation will be more and at the same time if
the cooling rate is very high more number of TiB2 particles will be
trapped and observed in that location.

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Title of the paper : Effect on size and pattern of distribution of TiB2 particles formed during
solidification of the Al-TiB2 MMC.
Authors : P.Senthil Kumar , P.R.Lakshminarayanan
Abstract : aluminium (A356) alloy is melt in a graphite crucible and two halide salts (ie),
potassium hexa fluro titanate and potassium tetra fluroborate are dropped at
a slow rate and mixed with aluminium melt, with the help of a hand held
graphite stirrer.
Conclusion : When the cooling rate and local turbulence are very high at a particular location
of the casting the presence of the TiB2 particles are also found to be more.
Title of the paper : Production and Characterization of Al 6061–TiB2

In – situ Metal Matrix Composite.
Authors : Lawrance C.A1 and Dr. P. Suresh Prabhu.
Material Used : Al 6061–TiB2.
Abstract : Using halidesalts namely potassium hexafluro titanate (K2TiF6) and potassium
tetrafluro borate (KBF4) an attempt has been made to
investigate the degree of in-situ reaction in the synthesis of Al 6061 – TiB2
metal matrix composite.
Conclusion : Volume of cryolite slag increases with reaction holding time. Variation in the
weight percentage of TiB2 will take place because of change in the volume
of cryolite slag.

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Title of the paper : Analysis on Tensile Strength of Al/TiB2 MMCs in FEA for Different Mould
Conditions.
Authors : C. Rajaravi, P.R. Lakshminarayanan.
Abstract : Fabricated different pouring temperatures with permanent and sand mould
conditions through chemical reactions between Aluminium, Titanium and
Boron bearing salts and to test in terms of mechanical property.
Conclusion : The tensile strength of the Al 6% wt while the temperature poring temperature
increase tensile strength is also increase.
Title of the paper : Corrosion of Metal-Matrix Composites with Aluminium Alloy Substrate.
Authors : B. BOBIĆ, S. MITROVIĆ, M. BABIĆ, I. BOBIĆ
Material Used : Aluminium Alloy.
Abstract : The corrosion characteristics of boron-, graphite-, silicon carbide-, alumina-
and mica- reinforced aluminium MMCs were reviewed. The reinforcing
phase influence on MMCs corrosion rate as well as on various corrosion
forms was discussed.
Conclusion : light weight, environmental resistance and favorable mechanical
properties has made aluminium alloys very popular for use as a matrix metal
However, the addition of the reinforcement particles could significantly alter
the corrosion behavior of these materials.

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Title of the paper: Effect of Thermo-Mechanical Processing and Heat Treatment on

the Tribological Characteristics of Al Based MMC's.
Authors : R Keshavamurthy, J Madhu Sudhan, Narasimhe Gowda and R Ananda
Krishna.
Methodology : Thermo-Mechanical Processing and Heat Treatment.
Abstract : Cast aluminium alloy and composite were subjected to open die hot forging
process. Alloy and its composites were examined to characteristics hardness
and wear test under both primary and secondary processing conditions.
Conclusion : Aluminium alloy & its composite processed under forging conditions exhibit
higher wear resistance compared with cast conditions.
2.1 SUMMARY
we observed the some literature survey on composite material number of researchers are done
on tensile, compressive, impact and corrosion test. But we choose same topic because this is R&D
project, the outcomes value will be given in different some time. that’s way we are selecting
mechanical properties on AL-TIB2 composites many of them done research on mechanical
properties that’s way are doing project on mechanical properties of AL-TiB2.

2018
Chapter. 3
OBJECTIVES OF THE PRESENT WORK
The objective of the present work is as follows:
1) Al in-situ composite were fabricated with TiB2 reinforcement (1, 3 and 5 wt.%) via
exothermic chemical reaction between molten aluminium alloy and mixed halide salts
KBF4 and K2TiF6 at a temperature of 8000C by using stir casting route.
2) Micro structural characterization of Al-TiB2 composite by using Optical microscope or
Scanning Electron Microscopy equipped with Energy Dispersive Spectroscopy (SEM-
EDS).
3) Evaluation of various mechanical properties like tensile, hardness and izod and charpy test
of the prepared Al-TiB2insitu composites.
4) Evaluation of corrosion test of the prepared in-situ composites.
3.1 SUMMARY
Objectives of our project work is to Al in-situ composites can be fabricated TiB2 reinforcement
via exothermic chemical reaction. then Al-TiB2 composite can be characterized by microstructure
analysis by using techniques SEM, EDM, XRD, then evaluate mechanical properties of prepared
by AL-TiB2.

2018
Chapter. 4
PROPOSED METHODOLOGY
chemical reaction between KBF4 & K2TiF6 halide salt with Al6061 base matrix in an electrical
The present work involved preparing Al6061-TiB2 composites using stir casting method using
resistances furnace by using stir casting route( liquid metallurgy route).
In-situ process,
In-situ process, process the reinforcement is added internally and forms during the chemical
reaction.
Figure No : 4
In-situ fabrication of metal matrix composite is a process, in which dispersed(reinforcing) phase is

formed in the matrix as a result of precipitation from the melt during its cooling and solidification.
Ex-situ process,
Figure No : 5
In ex-situ Process reinforcement is added externally to the base matrix.

2018
REACTIONS
3Al+2KBF4 AlB2+2KAlF4
3K2TiF6 + 6KBF4+ 10Al 3TiB2+10AlF3+12KF
Molecular Weights.
Al - 26.982 g/mol F - 18.998 g/mol
K - 39.0983 g/mol B - 10.811 g/mol.
Ti - 47.867 g/mol
4.1 Stir casting
Figure : 6
In stir casting we use stirrer to agitate the molten metal matrix. The stirrer is generally made up of
a material which can withstand at a higher melting temperature than the matrix temperature.
Generally graphite stirrer is used in stir casting. The stirrer is consisting of mainly two components
cylindrical rod and impeller. The one end of rod is connected to impeller and other end is connected
to shaft of the motor. The stirrer is generally held in vertical position and is rotated by a motor at
various speeds. The resultant molten metal is then poured in die for casting.

2018
Stir casting is suitable for manufacturing composites with up to 30% volume fractions of
reinforcement.[1] A major concern in associated with the stir casting is segregation of
reinforcement particles due to various process parameters and material properties result in the non-
homogeneous metal distribution. The various process parameters are like wetting condition of metal
particles, relative density, settling velocity etc. The distribution of particle in the molten metal
matrix is also affected by the velocity of stirrer, angle of stirrer, vortices cone etc. In this method
first the matrix metal is heated above its liquid temperature so that it is completely in molten
state. After it is cooled down to temperature between liquid and solidus state means it is in a
semi-solid state. Then preheated reinforcement particles are added to molten matrix and again
heated to fully liquid state so that they mixed thoroughly each other.
Electric resistance furnace
In stir casting process during solidification of fabricated composite are depends on following
factors.
 Stirring speed and time
 Stirring blade angle
 Pouring temperature and solidification rate
 Reinforcement’s size, percentage and its relative density

2018
4.4 Electrical Resistance Furnace(ERF)

ERF uses principle of indirect heating. Refractory material tightly wounded by wire of metallic
alloy(i.e. Kanthal, Nikrothal). 2- AC supply is passed through the wire. Internal resistance opposes
the flow of current and hence heat is produced. Heat is passed Through refractory material and by
radiation as well as convection this heat is transferred to the charge.
Fig 7.Electrical Resistance Furnace
It is essentially requires for vortex formation for the uniform dispersion of particles. There is a
no uniform dispersion of particles in case of no vortex formation.
Fig 11. Aluminium Stir Casting Machine And Graphite stirrer

2018
4.5 UNIVERSAL TESTING MACHING
Figure No : 8
A universal testing machine (UST), also known as material testing machine or materials test
frame, is used to test the tensile strength and compressive strength of materials.
A tensile test also known as tension test, is probably the most fundamental type of mechanical
test we can perform on material. Tensile tests are simple, inexpansive, and fully standardized.as
the material is being pulled, I will find its strength along with how much it will elongate.
A compressive test measuring the maximum amount of compressive load a material can bear
before fracture. A test piece, usually in the form of a cube, prism, or cylinder.

2018
4.6 BRINELL HARDNESS TESTING MACHINE
Figure No : 9
4.7 Impact Testing Machine.
Fig 10

2018
4.7 Scanning Electron Microscope

A scanning electron microscope (SEM) is a type of electron microscope that produces images of
a sample by scanning the surface with a focused beam of electrons. The electrons interact
with atoms in the sample, producing various signals that contain information about the surface
topography and composition of the sample. The electron beam is scanned in a raster scan pattern,
and the position of the beam is combined with the detected signal to produce an
image. SEM can achieve resol u tion better than 1 nanometer. Specimens are observed in high
vacuum in conventional SEM, or in low vacuum or wet conditions in variable pressure or
environmental SEM, and at a wide range of cryogenic or elevated temperatures with specialized
instruments.
Fig11. Scanning Electron Microscope

2018
4.8 X-ray Diffraction (XRD)
The atomic planes of a crystal cause an incident beam of X-rays to interfere with one another as
they leave the crystal. The phenomenon is called X-ray diffraction.
Fig12. X-ray Diffraction

2018
4.9 Optical Microscope

The optical microscope, often referred to as the light microscope, is a type of microscope that
commonly uses visible light and a system of lenses to magnify images of small objects. Optical
microscopes are the oldest design of microscope and were possibly invented in their present
compound form in the 17th century
Fig 13. Optical Microscope
4.10 SUMMARY
In our proposed methodology we have to know in situ ex situ process to prepare TIB2 by using
AL6061 as base matrix and KBF4,K2TIF6 as halide salt in electrical resistance furnace using stir
casting rout molten TIB2 can be poured into desired shape of mould allow to solidified material
can be characterized by micro structure analysis using SEM, XRD, EDS. solidified material can
be machined with required dimension using lathe machine preferred specimen can be tested for
mechanical properties of different temperature.

2018
Chapter. 5
EXPECTED OUTCOMES
1. Microstructure analysis may reveal that fine and clean TiB2 particles distributed uniformly
with good interfacial bonding and dislocations was observed throughout the matrix.
2. The XRD patterns revealed the formation of TiB2 particulates without the presence of any
other compounds.
3. Mechanical properties may increases with the increase in the weight % of TiB2 content in
the base matrix.
4. Tensile strength may increase with increase in the weight % of reinforcement but the
ductility of the composites reduces with increasing the reinforcement.
5. Hardness BHN and impact strength may increases increase in the TiB2 reinforcement.
6. Corrosion resistance may increases with the increase in the weight % of TiB2
reinforcement.
5.1 SUMMARY
TiB2 distributed uniformly in the base matrix prepared composite can be tested for
mechanical properties at different temperature it may shows better performance with increase in
the ALB2 content.

2018
Chapter. 6
PROGRESS OF THE PROJECT WORK
Sl No Month Work Carried out
Recent projects Discussed with the guide on agricultural,

1 July month
composites and fabrication
2 August Literature survey on above topics
3 September Finalization of the project topic
4 October Literature survey on composite materials
Collected information about the Purchasing of the raw

5 Mid October
material required for preparing composites
6 November Casting preparation according to the methodology

2018
REFERENCES.
1. Jinfeng Nie, Fang Wang, H.W.; Le, Y.K.; Li, X.F. Damping capacity of in situ TiB2
particulates reinforcedaluminium composites with Ti addition. Mater. Des. 2007, 28, 628–
632.
2. Jenarthanan M.P, Ramesh Kumar S and Ranade R.S, Effect of KBF4 and K2TiF6 on
precipitation kinetics of TiB2 inaluminium matrix composite, Advanced material
letters,2011, 210-216.
3. Lawrance C.A. prabhu1,P. Suresh “An Introduction to Metal Matrix Composites”,
Cambridge University Press, Cambridge, pp 1-525, 1995.
4. Akshay Mohan Pujar and Chetan Kulkarni. : Investigation of the precipitation kinetics in
an Al6061/TiB2 metal matrix composite. Mater Sci Eng. A. 237, 12–23 (1997).
5. R. Rosmamuhamadan,, S. Sulaiman,M.A A., (2013). Influence of B4C on the tribological
and mechanical properties of Al7075–B4C composites. Composites Part B: Engineering
54(0): 146-152.
6. T.V. Christy1, N. Morgan and S. Kumar S. Kumar, M. Chakraborty, B.S. Murty, Wear,
265, 134 (2008)
7. Sharma, S.C., Girish,B., Kamath, R., and Sathish, B.M., (1999) Fractography, Fluidity
andTensile Properties of Aluminium/Hematile Particle Composite, Journal of Materials.
8. M.K. Surappa – Aluminium matrix composites: Challenges and opportunities. Sadhana
Vol 28, 2003.
9. M.F. Ashby, Materials Selection in Mechanical Design, Butterworth-Heinemann,
Burlington, MA, USA, 2005.
10. C.S. Ramesh, R. Keshavamurthy, B.H. Channabasappa, S. Pramod. "Friction and wear
Behavior of Ni–P coated Si3N4 reinforced Al6061 composites". Volume 43, Issue 3, March
2010, pp 623–634.
11. V. Basavarajappa, G. Chandramohan, R. Subramanian, and A. Chandrasekar. Dry sliding
wear behavior of Al2219/SiC metal matrix composites. Mat.Sci, 24:357–356,
12. C.S. Ramesh, R. Keshavamurthy, B.H. Channabasappa, Abrar Ahmed. "Microstructure
mechanical properties of Ni–P coated Si3N4 reinforced Al6061 composites". Materials
Scienc and Engineering A 502 (2009) pp 99–106.

2018
13. N. Kumar, G. Gautam, R. K. Gautam, A. Mohan and S. Mohan, ‘Synthesis and

Characterization of TiB2 Reinforced Aluminium Matrix Composites: A Review’, Journal
of Institute of Engineers India Series D, DOI 10.1007/s40033-015-0091-7.
14. M. Rosso, ‘Ceramic and Metal Matrix Composites: Routes and Properties’, Journal of
Material Processing Technology, vol. 175, pp. 364-375, 2006.
15. Y. Sahin, ‘Preparation and some properties of SiC particle reinforced aluminium alloy
composites’, Materials and Design, vol. 24, pp. 671- 679, 2003.
16. Suresh, S., N. Shenbag, and Vinayaga Moorthi. "Aluminium-titanium diboride (Al-TiB2)
metal matrix composites: challenges and opportunities." Procedia Engineering 38 (2012):
89-97.
17. M.K. Aghajanian, M.A. Rocazella, J.T. Burke, S.D.Keck The Fabrication of Metal Matrix
Composites by a Pressureless Infiltration Technique Journal of Material Science 26(1991)
447-454.
18. C.Rajaravi, P,R,Lakshminarayanan. The precipitation of TiB2 in aluminum alloy melts
from the exothermic reaction of K2TiF6 and KBF4 halide salts and evaluation of its
mechanical properties [C], World Congress on Engineering and Computer Science, San
Francisco, USA, 2007: 978−988.
19. B. BOBIĆ, S. MITROVIĆ, M. BABIĆ, I. BOBIĆ VIALA J C. Chemical reactivity of
aluminium with boron carbide [J]. J Mater Sci, 1997, 32: 4559/4573.
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method, Metall. Mater. Trans. A 31 (2000) 1959–1964.

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STUDY OF MECHANICAL PROPERTIES OF AL6061 REINFORCED WITH INSITU

TIB2 METAL MATRIX COMPOSITES

1.2 History of composites

DEPARTMENT OF MECHANICAL ENGINEERING Page 1

DEPARTMENT OF MECHANICAL ENGINEERING Page 2

1.3 The definition of a composite.

Matrix + Reinforcement = Composite

1.4 Classification of composites,

Composites are classified based on matrix material as follows,

DEPARTMENT OF MECHANICAL ENGINEERING Page 3

DEPARTMENT OF MECHANICAL ENGINEERING Page 4

1.5 Metallic Matrix composites,

1.5.1 Matrix Phase

DEPARTMENT OF MECHANICAL ENGINEERING Page 5

The role of the matrix material comprises the following:

 Distributes the stress to the reinforcement material.

1.5.2 Classification of metal matrix composites

1.6 Aluminium Matrix Composites (AMCs)

DEPARTMENT OF MECHANICAL ENGINEERING Page 6

DEPARTMENT OF MECHANICAL ENGINEERING Page 7

1.7 Polymeric Matrices.

1.8 Ceramic Matrices.

Ceramics is inorganic non-metallic heterogeneous material consisting of crystalline substances of

DEPARTMENT OF MECHANICAL ENGINEERING Page 8

1.9 The composition of a composite.

1.9.1 The matrix.

1.9.2 The reinforcement.

 Size – diameter and aspect ratio

DEPARTMENT OF MECHANICAL ENGINEERING Page 9

 Inherent properties – strength, modulus and density.

1.10 ALUMINUM ALLOY:

DEPARTMENT OF MECHANICAL ENGINEERING Page 10

1.10.1 WROUGHT ALLOYS

1.11 The use of composites.

DEPARTMENT OF MECHANICAL ENGINEERING Page 11

1.11.1 Uses of 6000 series

British aluminium alloy HE9.

1.12 Material Properties.

Base Matrix – Al6061

Density 2.7 g/cm3

Poisson’s ratio 0.33

Young’s modulus 68.9 GPa

Tensile strength 124-290 MPa

Melting point 585 0C

DEPARTMENT OF MECHANICAL ENGINEERING Page 12

DEPARTMENT OF MECHANICAL ENGINEERING Page 13

Density 2.505 g/mL at 25

Fig 5. KBF4 Table No : 2

Density 300 g/cm3

Melting point 780 0C

Boiling point 235-237 0C

Fi Kg.6. K2TiF6 Table No : 3

DEPARTMENT OF MECHANICAL ENGINEERING Page 14

DEPARTMENT OF MECHANICAL ENGINEERING Page 15

DEPARTMENT OF MECHANICAL ENGINEERING Page 16

DEPARTMENT OF MECHANICAL ENGINEERING Page 17

Title of the paper : Corrosion Characterization of Al-Cu Reinforced

DEPARTMENT OF MECHANICAL ENGINEERING Page 18