MALNAD COLLEGE OF ENGINEERING

HASSAN-573 202, KARNATAKA

(An Autonomous Institution under VTU, Belagavi)

Project Synopsis on

“EVALUATION OF MECHANICAL PROPERTIES OF

ALUMINIUM-7029 HYBRID COMPOSITE MATERIAL”

In partial fulfillment for the award of B.E degree in Mechanical Engineering

By

NAME USN
PRAJWAL V J 4MC14ME068
ANANDA K N 4MC15ME401
ARUNAKUMAR M K 4MC15ME402
LOHITH S R 4MC15ME411

7th semester. B.E (MECHANICAL)

Under the guidance of

HAREESHA M.,B.E.,M.Tech MADHU K S., B.E.,M.Tech

Associate Professor Assistant Professor

 CHAPTER – 1
INTRODUCTION

Metal Matrix Composites (MMCs) and Metal Matrix Hybrid Composites (MMHCs) have
emerged as advanced materials for several prospective applications. As they have high specific
strength and stiffness, superior wear and seizure resistance, they are used in automotive, aircraft
and other engineering industries. The reinforcement materials in aluminum alloy improve the
mechanical and wear properties irrespective of load and speed.
Aluminium alloys are widely used in automobile industries, Ship-yard and aerospace
applications due to their great mechanical properties, low density, low coefficient of thermal
expansion, better corrosion resistance and wear as compared with conventional metals and
alloys. The low production cost and better mechanical properties of composites makes them
very useful for various applications in many areas from technological point of view. The aim
involved in designing aluminium based metal matrix composite by combining different
percentage of particulates in the mixture. Present study is focused on the fabrication of zinc
based aluminium metal matrix composites reinforced with boron carbide, graphite by stir
casting technique to determine Hardness, impact test and tensile strength of metal matrix
composites was performed on the samples obtained by stir casting technique.

1.1 COMPOSITE MATERIALS

Composite is a combination of two or more dissimilar materials having a distinct

interface between them such that the properties of the resulting material are greater to the
specific constituting components. Metal Matrix Composite (MMC) consists of superior
properties like high strength, high stiffness, high elastic modulus, high electrical and thermal
conductivity, high thermal stability and exhibits greater resistances to corrosion, oxidation and
wear comparable to conventional material.
Composite material is composed of two or more constituent phase: Matrix phase and
Reinforcement phase. The discontinuous phase in composites is usually harder and stronger
than continuous phase and is called reinforcing agents. The continuous phase is called as the
matrix.
MMCs are broadly used in aerospace, automobile, marine and structural application, etc., due
to its outstanding mechanical properties. Strength of MMC is considerable better than the
strength of base metal. The super alloys and alloy of Al, Mg, Ti and Cu were working as metal
matrix material. The reinforcement can be in the form of particles, continuous and
discontinuous fibres. These MMC’s are very expensive, but many advantage over polymer
matrix composite such as higher operating temperature, non flammability and more resistance
to degradation of organic fluids.
The different reinforcing materials used in the development of Aluminium matrix Composites
(AMCs) can be classified into three broad groups, which are synthetic ceramic particulates,
industrial wastes and agro waste derivatives.
Depending upon the type, size and morphology of reinforcement particles, AMCs are
manufactured by different processes such as squeeze casting, stir casting, spray casting, powder
metallurgy, ball milling and friction stir processing. Among these manufacturing methods of
AMCs, conventional stir casting is one of the most commonly used processes with advantage
of low cost, wide range of material and processing conditions, can manufacture composites
with up to 30% volume fraction of reinforcement with better bonding of metal matrix with
reinforcement particles because of stirring action.
Zinc is the major alloying elements in Aluminium-7029 alloy. Zinc based aluminium alloy
was chosen because the addition of zinc to aluminum (in conjunction with some other elements,
primarily magnesium and/or copper) produces heat-treatable aluminum alloys of the highest
strength. The zinc substantially increases strength and permits precipitation hardening.

Matrix
The primary phase, having a continuous character, is called matrix. Matrix is usually more
ductile and less harder phase. It holds the dispersed phase and shares the load with it.

Dispersed (reinforcing) phase

The dispersed phase is a secondary phase that is embedded in the matrix in a discontinuous
form. Dispersed phase is usually stringer than the matrix, therefore it is sometimes called
reinforcing phase.
Concept of Composite: Fibers or particles embedded in matrix of another material are the best
example of modern-day composite materials, which are mostly structural.

Laminates are composite material where different layers of materials give them the specific
character of a composite material having a specific function to perform. Fabrics have no matrix
to fall back on, but in them, fibers of different compositions combine to give them a specific
character.

Reinforcing materials generally withstand maximum load and serve the desirable properties.
Further, though composite types are often distinguishable from one another, no clear
determination can be really made. To facilitate definition, the accent is often shifted to the
levels at which differentiation take place viz., microscopic or macroscopic.
In matrix-based structural composites, the matrix serves two paramount purposes viz., binding
the reinforcement phases in place and deforming to distribute the stresses among the constituent
reinforcement materials under an applied force.
The demands on matrices are many. They may need to temperature variations, be conductors
or resistors of electricity, have moisture sensitivity etc. This may offer weight advantages, ease
of handling and other merits which may also become applicable depending on the purpose for
which matrices are chosen.
Solids that accommodate stress to incorporate other constituents provide strong bonds for the
reinforcing phase are potential matrix materials. A few inorganic materials, polymers and
metals have found applications as matrix materials in the designing of structural composites,
with commendable success. These materials remain elastic till failure occurs and show
decreased failure strain, when loaded in tension and compression.

Composites cannot be made from constituents with divergent linear expansion characteristics.
The interface is the area of contact between the reinforcement and the matrix materials. In some
cases, the region is a distinct added phase. Whenever there is interphase, there has to be two
interphases between each side of the interphase and its adjoint constituent. Some composites
provide interphases when surfaces dissimilar constituents interact with each other. Choice of
fabrication method depends on matrix properties and the effect of matrix on properties of
reinforcements. One of the prime considerations in the selection and fabrication of composites
is that the constituents should be chemically inert non-reactive.
1.2 Classification of composites

BASED ON MATRIX

FIG 1.2 Classification based on matrix

Composite materials are commonly classified at following two distinct levels:

a) The first level of classification is usually made with respect to the matrix constituent.
The major composite classes include Organic Matrix Composites (OMCs), Metal
Matrix Composites (MMCs) and Ceramic Matrix Composites (CMCs). The term
organic matrix composite is generally assumed to include two classes of composites,
namely Polymer Matrix Composites (PMCs) and carbon matrix composites commonly
referred to as carbon-carbon composites.
b) The second level of classification refers to the reinforcement form - fibre reinforced
composites, laminar composites and particulate composites. Fibre Reinforced
composites (FRP) can be further divided into those containing discontinuous or
continuous fibres.
Fibre Reinforced Composites
These are composed of fibres embedded in matrix material. Such a composite is considered to
be a discontinuous fibre or short fibre composite if its properties vary with fibre length. On the
other hand, when the length of the fibre is such that any further increase in length does not
further increase, the elastic modulus of the composite, the composite is considered to be
continuous fibre reinforced. Fibres are small in diameter and when pushed axially, they bend
easily although they have very good tensile properties. These fibres must be supported to keep
individual fibres from bending and buckling.

Laminar Composites
These are composed of layers of materials held together by matrix. Sandwich structures fall
under this category.

Particulate Composites
These are composed of particles distributed or embedded in a matrix body. The particles may
be flakes or in powder form. Concrete and wood particle boards are examples of this category.
Dispersed phase of these materials consist of two dimensional flat platelets(flakes), laid parallel
to each other. Effect of the dispersed particles on the composite properties depends on the
particles dimensions. Very small particles ( 0-25microns) in diameters finally distributed in the
matrix impended movement of dislocation and deformation of the materials. Such
strengthening effect is similar to the preparation hardening. In the contrast to the preparation
hardening, which disappears at elevated temperatures where the precipitated particles dissolve
in the matrix, dispersed phase of the particulate particles (ceramic particles) is usually stable at
high temperatures, so the strengthening effect is retained, many of composite materials are
designed.

Polymer Matrix Composites

Polymers make ideal materials as they can be processed easily posses lightweight and desirable
mechanical properties. It follows, therefore, that high temperature resins are extensively used
in aeronautical applications.
Metal Matrix Composites (MMC)
Metal matrix composites, at present though generating a wide interest in research fraternity,
are not as widely in use as their plastic counterparts. High strength, fracture toughness and
stiffness are offered by metal matrices than those offered by their polymer counterparts. They
can withstand elevated temperature in corrosive environment than polymer composites. Most
metals and alloys could be used as matrices and they require reinforcement materials which
need to be stable over a range of temperature and non-reactive too. However the guiding aspect
for the choice depends essentially on the matrix material. Light metals form the matrix for
temperature application and the reinforcements in addition to the aforementioned reasons are
characterized by high moduli.

Most metals and alloys make good matrices. However, practically, the choices for low
temperature applications are not many. Only light metals are responsive, with their low density
proving an advantage. Titanium, Aluminium and magnesium are the popular matrix metals
currently in vogue, which are particularly useful for aircraft applications. If metallic matrix
materials have to offer high strength, they require high modulus reinforcements. The strength-
to-weight ratios of resulting composites can be higher than most alloys.

The melting point, physical and mechanical properties of the composite at various temperatures
determine the service temperature of composites. Most metals, ceramics and compounds can
be used with matrices of low melting point alloys. The choice of reinforcements becomes more
stunted with increase in the melting temperature of matrix materials.

Ceramic Matrix Materials (CMM)

Ceramics can be described as solid materials which exhibit very strong ionic bonding in general
and in few cases covalent bonding. High melting points, good corrosion resistance, stability at
elevated temperatures and high compressive strength, render ceramic-based matrix materials a
favourite for applications requiring a structural material that doesn’t give way at temperatures
BASED ON REINFORCEMENTS

Fig 1.2 Classification based on reinforcements

Reinforcing constituents in composites, as the word indicates, provide the strength that makes
the composite what it is. But they also serve certain additional purposes of heat resistance or
conduction, resistance to corrosion and provide rigidity. Reinforcement can be made to perform
all or one of these functions as per the requirements.
A reinforcement that embellishes the matrix strength must be stronger and stiffer than the
matrix and capable of changing failure mechanism to the advantage of the composite. This
means that the ductility should be minimal or even nil the composite must behave as brittle as
possible.

Fiber Reinforced Composites

Fibers are the important class of reinforcements, as they satisfy the desired conditions and
transfer strength to the matrix constituent influencing and enhancing their properties as desired.
Glass fibers are the earliest known fibers used to reinforce materials. Ceramic and metal fibers
were subsequently found out and put to extensive use, to render composites stiffer more
resistant to heat.
Fibers fall short of ideal performance due to several factors. The performance of a fiber
composite is judged by its length, shape, orientation, and composition of the fibers and the
mechanical properties of the matrix.
The orientation of the fiber in the matrix is an indication of the strength of the composite and
the strength is greatest along the longitudinal directional of fiber. This doesn’t mean the
longitudinal fibers can take the same quantum of load irrespective of the direction in which it
is applied. Optimum performance from longitudinal fibers can be obtained if the load is applied
along its direction. The slightest shift in the angle of loading may drastically reduce the strength
of the composite.

Laminar composites

These are found in as many combinations as the number of materials. They can be described
as materials comprising of layers of materials bonded together. These may be of several layers
of two or more metal materials occurring alternately or in a determined order more than once,
and in as many numbers as required for a specific purpose.

Particulate Reinforced Composites (PRC)

Microstructures of metal and ceramics composites, which show particles of one phase strewn
in the other, are known as particle reinforced composites. Square, triangular and round shapes
of reinforcement are known, but the dimensions of all their sides are observed to be more or
less equal. The size and volume concentration of the dispersoid distinguishes it from dispersion
hardened materials.

1.3 Examples for composite materials:

• Fibre reinforced plastics:
o Classified by type of fiber:
􀂃 Wood (cellulose fibers in a lignin and hemicellulose matrix)
􀂃 Carbon-fibre reinforced plastic (CRP)
􀂃 Glass-fibre reinforced plastic (GRP)
o Classified by matrix:
􀂃 Thermoplastic Composites
• short fiber thermoplastics
• long fiber thermoplastics or long fiber reinforced thermoplastics
• glass mat thermoplastics
• continuous fiber reinforced thermoplastics
• Reinforced carbon-carbon (carbon fibre in a graphite matrix)
• Metal matrix composites (MMCs):
o White cast iron
 o Hardmetal (carbide in metal matrix)
o Metal-intermetallic laminate
• Ceramic matrix composites:
o Bone (hydroxyapatite reinforced with collagen fibers)
o Cermet (ceramic and metal)
o Concrete
• Organic matrix/ceramic aggregate composites
o Asphalt concrete
o Dental composite
o Syntactic foam
o Mother of Pearl

1.4 Role of matrix materials

The choice of a matrix alloy for an MMC is dictated by several considerations. Of particular
importance is whether the composite is to be continuously or discontinuously reinforced. The
use of continuous fibers as reinforcements may result in transfer of most of the load to the
reinforcing filaments and hence composite strength will be governed primarily by the fiber
strength. The primary roles of the matrix alloy then are to provide efficient transfer of load to
the fibers and to blunt cracks in the event that fiber failure occurs and so the matrix alloy for
continuously reinforced composites may be chosen more for toughness than for strength. On
this basis, lower strength, more ductile, and tougher matrix alloys may be utilized in
continuously reinforced composites. For discontinuously reinforced composites, the matrix
may govern composite strength. Then, the choice of matrix will be influenced by consideration
of the required composite strength and higher strength matrix alloys may be required.

Additional considerations in the choice of the matrix include potential reinforcement/matrix

reactions, either during processing or in service, which might result in degraded composite
performance; thermal stresses due to thermal expansion mismatch between the reinforcements
and the matrix; and the influence of matrix fatigue behavior on the cyclic response of the
composite. Indeed, the behavior of composites under cyclic loading conditions is an area
requiring special consideration. In composites intended for use at elevated temperatures, an
additional consideration is the difference in melting temperatures between the matrix and the
reinforcements. A large melting temperature difference may result in matrix creep while the
reinforcements remain elastic, even at temperatures approaching the matrix melting point.
However, creep in both the matrix and reinforcement must be considered when there is a small
melting point difference in the composite.

1.5 Functions of a Matrix

In a composite material, the matrix material serves the following functions:

• Holds the fibres together.
• Protects the fibres from environment.
• Distributes the loads evenly between fibres so that all fibres are subjected to the same
amount of strain.
• Enhances transverse properties of a laminate.
• Improves impact and fracture resistance of a component.
• Helps to avoid propagation of crack growth through the fibres by providing alternate
failure path along the interface between the fibres and the matrix.
• Carry interlaminar shear.

The matrix plays a minor role in the tensile load-carrying capacity of a composite structure.
However, selection of a matrix has a major influence on the interlaminar shear as well as in-
plane shear properties of the composite material. The interlaminar shear strength is an
important design consideration for structures under bending loads, whereas the in-plane shear
strength is important under torsion loads. The matrix provides lateral support against the
possibility of fibre buckling under compression loading, thus influencing to some extent the
compressive strength of the composite material. The interaction between fibres and matrix is
also important in designing damage tolerant structures. Finally, the process ability and defects
in a composite material depend strongly on the physical and thermal characteristics, such as
viscosity, melting point, and curing temperature of the matrix.

1.6 Factors considered for Selection of Matrix

In selecting matrix material, following factors may be taken into consideration:

• The matrix must have a mechanical strength commensurate with that of the
reinforcement i.e. both should be compatible. Thus, if a high strength fibre is used
as the reinforcement, there is no point using a low strength matrix, which will not
transmit stresses efficiently to the reinforcement.
 • The matrix must stand up to the service conditions, viz., temperature, humidity,
exposure to ultra-violet environment, exposure to chemical atmosphere, abrasion
by dust particles, etc.
• The matrix must be easy to use in the selected fabrication process.
• Smoke requirements.
• Life expectancy.
• The resultant composite should be cost effective.

The fibres are saturated with a liquid resin before it cures to a solid. The solid resin is then said
to be the matrix for the fibres.

1.7 Advantages of Composites

• High resistance to fatigue and corrosion degradation.

• High ‘strength or stiffness to weight’ ratio. As enumerated above, weight savings are
significant ranging from 25-45% of the weight of conventional metallic designs.
• Due to greater reliability, there are fewer inspections and structural repairs.
• Directional tailoring capabilities to meet the design requirements. The fibre pattern can be
laid in a manner that will tailor the structure to efficiently sustain the applied loads.
• Fibre to fibre redundant load path.
• Improved dent resistance is normally achieved. Composite panels do not sustain damage as
easily as thin gage sheet metals.

1.8 Limitations of Composites

Some of the associated disadvantages of advanced composites are as follows:

• High cost of raw materials and fabrication.
• Composites are more brittle than wrought metals and thus are more easily damaged.
• Transverse properties may be weak.
• Matrix is weak, therefore, low toughness.
• Reuse and disposal may be difficult.
• Difficult to attach.
• Repair introduces new problems.
1.9 Application of Composite Material
 • In Aerospace- Approximately 50% component of the airspace is made from
composites. The primary benefits that composite components are reduced weight and
assembly simplification.
• In Automotive - Composites are being considered to make low weight, safer and more
fuel-efficient vehicles.
• In Medical- A composite is a nonviable material used in a medical device and intended
to interact with biological system.
• In Sports- Composite materials are used in sports equipment because they offer ease of
transport, resistance, low weight, low maintenance and durability.

1.10 Properties of matrix and reinforcement

Properties Aluminium Boron carbide Graphite

alloy

Density(g/cc) 2.77 2.52 2.26

Tensile 166 261 -

strength(MPa)

Shear 260 - 700

strength(MPa)

Poisson’s ratio 0.33 0.18

Thermal 140 30-42 25-470

conductivity(W/mK)

Elastic 72 460 8-15

modulus(GPa)

Melting point (˚C) 660 2763 4027

Table 1.10 properties of matrix material and reinforcements

 FIG 1.10 matrix and reinforcements

1.11 STIR CASTING

Stir casting is an economical process for the fabrication of aluminium matrix composites by
means of mechanical stirring. The liquid composite materials is then cast by conventional
casting methods and may also be processed by conventional metal forming technologies. In
preparing MMCs by stir casting method, some of the factors that needed considerable attention
are as follows.

• To achieve uniform distribution of the reinforcement material.

• To achieve wettability between the two main substances.
• To minimize the porosity in the cast metal matrix composites.
 Fig4(a): Stir casting block diagram

1.12 Process parameters :

A. Stirrer Design
It is very important parameter in stir casting process which is required for vortex
formation. The blade angle and number of blades decides the flow pattern of the liquid
metal. The stirrer is immersed till two-third depth of molten metal. All these are
required for uniform distribution of reinforcement in liquid metal, perfect interphase
bonding and to avoid clustering.

B. Stirrer Speed
The stirring speed is an Important parameter to promote binding between matrix and
reinforcement i.e, wettability. Stirring speed decides formation of vortex which is
responsible for dispersion of particulates in liquid metal. In our project, stirrin speed is
300 rpm.

C. Stirring Temperature
Aluminium melts around 650˚C, At this temperatures, semi solid stage of melt is
present. A particle distribution depends on change in viscosity. The viscosity of matrix
is mainly influenced by the processing temperature. The viscosity of the liquid is
decreased by increase in processing temperature with increase in holding time for
 stirring which also promote binding between matrix and reinforcement. Good
wettability is obtained by keeping temperature at 800˚C.

D. Stirring time
As stirring promote uniform distribution of reinforcement particles at interface bond
between matrix and reinforcement, stirring time plays a vital role in stir casting method.
Less stirring leads to non-uniform distribution of particles and excess stirring forms
clustering of particles at some places. Stirring time is 5 minutes in our case.

E. Preheat temperature of reinforcement

Casting process of AMCs is difficult due to very low wettability of aluminium particles
which results in non-uniform distribution and poor mechanical properties.
Reinforcement is heated to 500˚C for 40 minutes. It removes moisture as well as gas
present in reinforcement.

F. Preheat temperature of mould

Porosity is the major problem in casting. In order to avoid porosity, preheating of mould
is good solution. It helps in removing the entrapped gases from the slurry to go into the
mould. It also enhances the mechanical properties of the cast AMCs. Mould is heated
to 500˚c for 1hr.

G. Addition of Magnesium
Addition of magnesium enhances the wettability. However, increase in the content
above 1 wt % increases viscosity of slurry and hence uniform particle distribution
becomes difficult.

H. Reinforcement feed rate

Non-uniform feed rate promotes clustering of particles at some places which causes the
porosity defect and inclusion defect, so to have a good quality of casting, the feed rate
of powder particles must be uniform. The flow rate of reinforcements measured is
0.5 gm/sec.

I. Pouring of melt
Powering rate and powering temperature plays a significant role in quality of casting.
Powering rate of slurry must be uniform to avoid entrapping of gases. At this stage, the
temperature of melt is 800˚C. The distance between mould and crucible also plays vital
role in quality of casting. Apart from these size of reinforcement plays significant role
in quality of casting.
 CHAPTER – 2

LITERATURE REVIEW

A literature review carried out based on Aluminium Metal Matrix Composites are summarized
below

Ranganatha S R. et al [1] has investigated the mechanical properties of discontinuous fiber

composites for short fiber composites. He found that aluminium matrix is getting strengthened
when it is reinforced with SiC, B4C and Al2O3. Aluminium alloy gives more advantages
because of its low density. Also he found that as Al 2014 reinforced with short basalt fiber and
B4C by stir casting method. B4C and basalt fiber is a robust material having excellent chemical
and thermal stability, high hardness and low density. Results shows the increase in
reinforcement of small fiber and basalt fiber and B4C improves the impact strength and
hardness properties
S Venkatesan. et al [2] has concluded that the mechanical behaviour of aluminium metal matrix
reinforced with graphene particles in different weight fractions that were prepared by stir
casting method, one can obtain optimum results in increasing fracture toughness. Further
addition of graphene to aluminium increases crack resistance and electrical conductivity
G Pitchayyapillai et al [3] have found that the addition of molybdenum disulphide
reinforcement in composites as a hybrid reinforcement further increases wear resistance of the
composites. He produced Al6061 alloy with reinforcement of MoS2 and alumina by stir casting
method and he also observed that addition of alumina particles improves the tensile strength
and hardness of hybrid composites. Also, tensile strength and hardness decrease with increase
in MoS2 content.
Gopal Krishna U B, et al [4] has made an effort to enhance the mechanical properties like
tensile strength and hardness of AMCs by reinforcing Al 6061 matrix with B4C reinforcement
by stir casting route. He then found that tensile strength of AMCs was increased with increase
in particle size.
Anil Kumar Bodukuri. et al [5] have developed Al-SiC-B4C MMC which is prepared from
sintering of mechanically alloyed powder (ball milling) in powder metallurgy process. He has
chosen three different combinations of composition in volume fraction to study the
characteristics of developed MMC. Increase in B4C increases micro hardness of MMC. Effect
of SiC on Al matrix was also studied by varying weight fractions. The best result is obtained
at 25% where increase in hardness and impact strength is seen.
E.Mohammad Sharifi, et al [6] studied the effect bulk Al-B4C nanocomposites. B4C nano
particles were mixed with pure Al powder by ball milling to produce Al-B4C powder. Al-B4C
powders containing different amounts of B4C (5, 10, and 15 wt %) were subsequently hot
pressed to produce bulk nano composite sample. Consolidated samples were characterized by
hardness, compression and wear tests. Results showed that the sample with 15 wt% B4C had
the optimum properties. The wear resistance of the nano composites increased significantly by
increasing the B4C content.

K.M. Shorowordi.et al [7] has studied the effect of B4C, SiC and Al203(0-20 vol.%). The stir
casting manufacturing route followed by hot extrusion was utilized, being one of the cost -
effective industrial methods. Clear interfacial reaction product/layer was found at Al-SiC
interface for composites held for a relatively long processing time (>30 min). No reaction
product was observed at Al-B4C and Al- Al203 Interfaces at the resolutions limit of the SEM
used. On the other hand, two secondary phases (alumina and another phase containing
aluminium, boron and carbon) were found in the aluminium matrix away from the interface in
Al-B4C composites. From the fracture surface analysis, B4C reinforced Al composites seemed
to exhibit a better interfacial bonding compared to the other two composites.

T.Mohan, el al [8] have developed aluminium metal matrix composite (AMMC) material for
turbocharger components made by wrought aluminium alloy with various weight fractions of
aluminium oxide in the order to make five different forms of composites. They used stir casting
process and the fabricated composites are tested for their tensile and impact properties. The
results show that composites with higher percentage of aluminium oxide have high tensile
strength than other composites.

B.Vijaya Ramnath, et al [9] has developed an Accumulative Roll Bonding (ARB) process for
Al/B4C composites, in which the particles were distributed evenly throughout the matrix. The
mixed B4C nano particles with pure Al powder by ball milling to produce Al-B4C powder. Al-
B4C powders containing different amounts of B4C were subsequently hot pressed to produce
bulk nano composites samples. The hardness, ultimate compressive strength and wear
resistance, of the nano composites decrease in the reinforcement particle size to the nano meter
range can improve maechanical and tribological properties of the aluminium matrix
composites.
 CHAPTER - 3

FABRICATION OF COMPOSITES

3.1 SELECTION OF MATERIALS AND COMPOSITIONS

• The base metal is chosen as zinc based aluminium alloy

• The reinforcement is chosen as boron carbide particulates(B4C) and graphite
• With the base metal as zinc based aluminium alloy, the composite is fabricated with
0%, 2%, 4%, 6% volume of particulate reinforcement material.

3.2 MATRIX MATERIALS

Aluminium, the second most abundant metallic element on the earth, became an
economic competitor in engineering applications recently.

Zinc based Aluminium alloy Weight percentage

Silicon(Si) 0.10

Iron(Fe) 0.12

Copper(Cu) 0.5-0.9

Manganese(Mn) 0.03

Magnesium(Mg) 1.3-2.0

Zinc(Zn) 4.2-5.2

Titanium(Ti) 0.05

Vanadium(V) 0.05

Others 0.15

Aluminium(Al) Remaining

Table 3.2 Composition of Zinc based Aluminium alloy

This matrix was chosen since it provides excellent combination of strength and damage
tolerance at high strength applications like structural components and high strength. It also has
a high heat dissipation capacity due to it is high thermal conductivity.

3.2 REINFORCEMENT MATERIALS

Boron carbide particles are the most commonly used reinforcement materials in the
discontinuously reinforced metal matrix composite system. Aluminium matrix composites
reinforced with Boron carbide particulates provide for a low cost, high modulus of materials
that can be processed via conventional powder metallurgy techniques. With increased addition
of Boron carbide reinforcement, the modulus increases and losses in strength, ductility, and
toughness may occur. Also, the role of the interfacial bond between B4C particulates and the
aluminium matrix may further detract from the mechanical properties when the composite is
subjected to high temperatures. Particle shape and size are important factors in determining
materials properties. Fatigue strength is greatly improved with the use of fine particles. The
Boron carbide particles, which were used to fabricate the composite, add an average particle
size of 50microns and average density of 2.52g/cm3. The boiling and melting point is 3300˚C
and 2763˚C. With the addition of the Boron carbide, Graphite is also used as a reinforced
material for the fabrication of Al-7029 hybrid metal matrix composite because graphite has
high melting point, similar to that of diamond (4300˚C) and density of about 2.23g/cc and it
conducts the electricity.

3.4 FABRICATION METHOD

Since the Zinc based aluminium alloy is found in bulk quantities in the market it is
proposed to first fabricate the Zinc based aluminium alloy by using the typical composition as
shown in Table 1.2.1.
Stir casting technique was used to fabricate the composite specimen as it ensures a more
uniform distribution of the reinforcing particles. This method is most economical to fabricate
composites with discontinuous fibres or particulates. Zinc based aluminium alloy was in larger
sizes we cut that larger size into small piece of blocks. Exactly 300 rams of blocks of aluminium
alloy was placed in the mild steel crucible of electric furnace about 5KW. The furnace
temperature was raised to 790˚C. The furnace temperature maintained between 790˚C-810˚C
for about 120minutes to melt aluminium alloy blocks. The scum powder of cover all in small
quantity is added to the melt to remove the slag or flux which was floating on molten metal
and removed by a slag cleaning tool. The total melt is then degassed by adding dry
hexachloroethane tablet weighing 10gms (C2Cl6, 0.3% by weight). The boron carbide particles
(50microns grit size) were pre heated to 300˚C for 20minutes before adding to furnace,
Graphite is also preheated at a temperature of 450˚C for 25 minutes before adding to the furnace
which contain matrix material. Magnesium (chips) are added to increase the wettability. After
degassing, pre heated Boron carbide particles with different percentage by weight were added
to the vertex formed in the melt by stirring. The mild steel stirrer with vertical axis was used.
It has been used to obtain an output of 400rpm. The rpm of the stirrer was maintained at 130-
150rpm for 10-20minutes and stirring is continued for about 10minutes to allow for uniform
mixing of Boron carbide particles and Graphite with the molten metal, the melt temperature
maintain at 750˚C -800˚C during the addition of the particles.
The pouring temperature was kept at 800˚C and time of pouring was 5 minutes, the crucible
containing the melt mixture was then carefully taken out of furnace and poured into a specially
designed permanent mould. The melt was poured grey cast iron moulds. The mould was left to
cool and castings were ejected. The aluminium boron carbide and graphite composites were
produced by varying amount of boron carbide and graphite 2%, 4%, and 6% by weight. Here
0.75% of boron carbide and 0.25% of graphite is used for the fabrication of zinc based
aluminium alloy because boron carbide helps to increase the hardness of the material and also
provide good shielding properties against neutrons, stability to ionising radiation and most
chemicals. And graphite helps to improve the electrical and thermal properties of the material.

3.5 CALCULATION OF WEIGHT FRACTIONS

Sl no Reinforcements Matrix Boron carbide Graphite in
compositions compositions in in gms gms
% gms

1 0% 2000 0 0

2 2% 2009 30.75 10.25

3 4% 1968 61.5 20.5

4 6% 1974 94.5 31.5

Table 3.5: Variation of compositions

3.6 ADDITIVES USED DURING FABRICATION

• Magnesium (chips)

Magnesium is used during fabrication of Zinc based aluminium alloy to improve the
wettability. And also helps to developing defect free stir zone in stir casting process by
providing interfacial bond strength.

• Cover all

With the addition of the cover all to the mixing of matrix and reinforced mixture that
helps to separate the impurities present in the mixture and also helps to separation of slag
produced during fabrication process.

• Hexachloroethane

Hexachloroethane plays a very important role in fabrication process because it helps

to avoid oxidation and is used as a degassing agent, which removes gases from the casted part
that makes materials free from blow holes and other defects

Fig 3.6(a) Magnesium (chips) Fig 3.6(b) Cover all

 Fig 3.6(c) Hexachloroethane

3.7 STIR CASTING EQUIPEMENTS

Fig 3.7(a) Electric arc furnace Fig 3.7(b) Temperature indicator

Fig 3.7(c) Stirrer Fig 3.7(d) Stirrer attached to the furnace

3.8 FINISHED COMPONENT

Fig 3.8 Stir cast components after removal from mold

 CHAPTER - 4

PREPARATION OF SPECIMENS

A number of samples will be prepared from Zinc based aluminium alloy matrix, Boron carbide
and graphite composites. The samples prepared for hardness test, tensile test, and impact test
are according to the standards.

4.1 Hardness

Hardness is the measure of how resistant solid metal is to various kinds of permanent shape
change when force is applied. Macroscopic hardness is generally characterized by strong inter
molecular bonds. There are 3 types of tests used with accuracy by the metal industry, they are
the Brinell hardness test, Rockwell hardness test, and Vickers hardness test.

Hardness test specimen

Hardness test specimen will be prepared according to the ASTM standards E10 having
diameter 20 mm and length 25 mm. hardness test specimen geometry is as shown in the figure

25 mm

20 mm

Fig 4.1 Hardness test specimen geometry

4.2 IMPACT TEST

The purpose of impact testing is to measure an objects ability to resist high rate loading. It
is usually thought of in terms of two objects striking each other at high relative speeds. A part,
or materials ability to resist impact often is one of the determining factors is the service life of
a part, or in the suitability of a designated materials for a particular application. Impact
resistance can be one of the most difficult properties to quantify. The ability to quantify this
property is a great advantage in product liability and safety.

Impact Test specimen (Charpy)

The charpy impact test, also known as the charpy V-notch test, is a standardize high strain rate
test which determines the amount of energy absorbed by a material during fracture. Impact test
specimens will be prepared according to the ASTM standard E23 of 10 mm square rod and
length of 55 mm. impact test specimen geometry is shown in the Figure

55 mm

10mm
mmm
mm

0.25 mm
2 mm

45˚

Fig 4.2 Impact test specimen geometry

4.3 TENSILE TEST SPECIMEN

A tensile specimen is a standardized sample cross section. It has two shoulders and a gauge
in between. The shoulders are large so they can be readily gripped, where as the gauge section
as a smaller cross section so that the deformation and failure can occur in this area.

Tensile test specimens will be prepared according to the ASTM standard E8M having
diameter 12.5 mm and gauge length 62.5 mm. tensile test specimen geometry is as shown in
the figure.

145

75

62.5

27.2 27.2

Φ20

Φ12.5

Fig 4.3 Tensile test specimen geometry

Finished test specimens

Fig. 4.5 Hardness test specimen

Fig. 4.6 Impact test specimen(Charpy)

Fig. 4.7 Tensile test specimen

 CHAPTER - 5

RESULTS AND DISCUSSIONS

5.1 HARDNESS TEST

Sl No COMPOSITIONS HARDNESS(HRC)

1 Aluminium alloy 7029+0% reinforcement 30.46

(B4C and Gr)

2 Aluminium alloy 7029+2% reinforcement 34.73

(B4C and Gr)

3 Aluminium alloy 7029+4% reinforcement 45.13

(B4C and Gr)

4 Aluminium alloy 7029+6% reinforcement 58.93

(B4C and Gr)

Table 5.1 Test Result of Hardness

Hardness

60

50

40

30

20

10

0
Aluminium alloy Aluminium alloy Aluminium alloy Aluminium alloy
7029+0% B4C, Gr 7029+2% B4C, Gr 7029+4% B4C, Gr 7029+6% B4C, Gr

Graph 4.1 HRC Number v/s Composition

Discussion:
Experiment is conducted by varying weight fraction of B4C and Graphite (0%, 2%, 4%
and 6%) with zinc based aluminium alloy. For this work we considered Rockwell hardness
test. The Rockwell scale is a hardness scale based on the indentation hardness of a material
is calculated. Here we used 1/16” ball indentor and a force of 100Kgf. The Rockwell
hardness test determines the hardness by measuring the depth of penetration of an indentor
under a large load compared to the penetration made by a preload.

Hardness strength results are recorded and tabulated. Hardness is indented on each
specimen using a constant load of 100Kgf. From the graph 4.1 It is concluded that surface
hardness of zinc based aluminium alloy increases with increases of reinforments (B4C and
Gr) weight percentage. The specimen having highest hardness number exhibit better
hardness.
5.2 IMPACT TEST

Sl No COMPOSITIONS ENERGY ABSORBED (J)

Trial-1 Trial-2

1 Aluminium alloy 7029+0% reinforcement (B4C 1.942 1.942

and Gr)

2 Aluminium alloy 7029+2% reinforcement (B4C 2.966 2.966

and Gr)

3 Aluminium alloy 7029+4% reinforcement (B4C 3.944 3.944

and Gr)

4 Aluminium alloy 7029+6% reinforcement (B4C 4.926 4.926

and Gr)

Impact Test

250

200

150
Trial 1
100
Trial 2
50

0
Aluminium Aluminium Aluminium Aluminium
alloy 7029 + 0% alloy 7029 + 2% alloy 7029 + 4% alloy 7029 + 6%
B4C,Gr B4C,Gr B4C, Gr B4C, Gr

Graph 5.2 energy v/s composition

Discussion:
Experiment is conducted by varying weight fraction of B4C and Gr (0%, 2%, 4% and
6%) with zinc based aluminium alloy. Impact strength results are recorded and tabulated.
Here Charpy impact test is conducted at room temperature of 30˚C. At the beginning the
impact strength increased with increase in percentage composition of B4C an Gr, and then
maintain constant impact strength. From the graph it is concluded that highest impact
energy is for aluminium alloy with 2%, 4% and 6% of B4C and Gr. Maximum impact
energy shows maximum amount of energy absorbed by aluminium composite material
during fracture.
 5.3 TENSILE TEST

S Sl No TENSILE STRENGTH (N/mm2)

COMPOSITIONS Trial 1 Trial 2

1 Aluminium alloy 7029+0% 169.74 170.04

reinforcement(B4C and Gr)

2 Aluminium alloy 7029+2% 166.86 168.95

reinforcement(B4C and Gr)

3 Aluminium alloy 7029+4% 193.43 195.48

reinforcement(B4C and Gr)

4 Aluminium alloy 7029+6% 200.55 202.45

reinforcement(B4C and Gr)

Tensile Test

250

200

150

100

50

0
Aluminium alloy Aluminium alloy Aluminium alloy Aluminium alloy
7029 + 0% 7029 + 2% 7029 + 4% B4C, 7029 + 6% B4C,
B4C,Gr B4C,Gr Gr Gr

Tensile Trial 1 Tensile Trial 2

Graph.5.3. Tensile strength(N/mm2)V/s composition

DISCUSSION:
Experiment is conducted by varying weight fraction of B4C and Gr (0%, 2%,4% and 6%)
with zinc based aluminium alloy. Tensile strength results are recorded and tabulated.
Tensile test is conducted in Universal testing machine. The tensile strength of zinc based
aluminium alloy is highest for 6% of reinforcements (B4C and Gr). The highest value of
tensile strength shows the maximum capacity of an aluminium alloy composite material to
withstand loads while being stretched or pulled before failure.
 CHAPTER - 6

CONCLUSION

One of the simplest and economical way of fabrication of composites is Stir casting method.
Zinc based aluminium alloy with hybrid reinforcements (B4C and Gr) can be made in a
closed condition by Stir casting fabrication process derived from the literature review.

Zinc based aluminium alloy with hybrid reinforcements (B4C and Gr) with varying weight
fractions was prepared through stir casting process.

• It has been observed from the hardness test that the hardness value is increased with
increase of reinforcements (B4C and Gr) with zinc based aluminium alloy.
• The impact strength is the maximum amount of energy absorbed by aluminium
composite material during fracture. It increases with increase in percentage of
reinforcements (B4C and Gr)
• It is concluded from the tensile test that the strength of the composite increases with
increase in weight fraction of reinforcements (B4C and Gr). Tensile test is revealed
that ductility of the composites decreases with increasing weight fraction of
reinforcements (B4C and Gr) with zinc based aluminium alloy. The tensile strength
of zinc based aluminium alloy is highest for 6% of reinforcements (B4C and Gr).

SCOPE FOR FUTURE WORK

1. Tribological properties of the composite material can be studied.

2. Mechanical properties and characterisation can be studied for the heat treated composite
material.
3. Mechanical properties of the composite material can be studied for different particulate
reinforcement with different weight fractions.
4. Characterisation of the composite material can be studied at elevated temperature.
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[2] S Venkatesan - “Mechanical behaviour of aluminium metal matrix composite reinforced

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[3] G Pitchayyapillai- “Al 6061 hybrid metal matrix composite reinforced with alumina and
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boron carbide metal matrix composites”. Department of Mechanical Engineering, Sri Sai Ram
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GROUP MEMBERS

USN NAME SIGNATURE

4MC14ME068 PRAJWAL V J

4MC15ME401 ANANDA K N

4MC15ME402 ARUNAKUMAR M K

4MC15ME411 LOHITH S R

SIGNATURE OF GUIDES

Mr. HAREESHA M

Mr. MADHU K S