Anitha 2022 IOP Conf. Ser. Mater. Sci. Eng. 1248 012093

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To cite this article: P Anitha and M Srinivas Rao 2022 IOP Conf. Ser.: Mater. Sci. Eng. 1248 012093 tribological behavior of Al-TiB2-nano Gr
hybrid composites
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Prasanta Sahoo
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International Conference on Materials Science and Engineering (ICMSE 2022) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1248 (2022) 012093 doi:10.1088/1757-899X/1248/1/012093
An investigation on microstructure and mechanical behaviour

of aluminium hybrid metal matrix nanocomposite fabricated
through electromagnetic stir casting process
Anitha P1, 3*, Srinivas Rao M2

1
Department of Mechanical Engineering, Kakatiya Institute of Technology & Science,
Warangal, Telangana, India.
2
Department of Mechanical Engineering, Jawaharlal Nehru Technological University,
Hyderabad, Telangana, India.
3
E-mail: [email protected]
Abstract. This study focuses on the microstructure characteristics and mechanical properties of
unreinforced and reinforced ceramic materials titanium diboride (TiB 2) and graphite (Gr).
Aluminium hybrid metal matrix nanocomposites reinforced with varying weight percentage of
nano TiB2 (0-12.5 wt. %) and nano Gr (4wt %) via electromagnetic stir casting process to
produce hybrid nanocomposites samples. Identification of phases and microstructure analysis
are performed through X-ray diffraction, Optical Microscope and Scanning Electron
Microscope with Energy Dispersion X-ray Spectrum. Mechanical properties such as hardness,
tensile, compression and flexural strength were investigated on the prepared hybrid
nanocomposites samples. Microstructure images of the samples reveals uniform dissemination
of reinforced TiB2 and Gr nanoparticles in Aluminium base matrix and X-ray diffraction
confirms the presence of reinforced particles TiB2 and Gr in Aluminium base matrix. Concluded
from the consolidated samples, mechanical properties of the reinforced samples improved as
compared to the matrix material.
1. Introduction
Aluminium Metal Matrix Composites (AMMCs) was traditionally being chosen for several engineering
industrial applications in automobile, space and mineral processing owed their lightweight, high
corrosion resistance accompanying with remarkable thermal properties, specific strength and better
formability. Further enhance of the existing properties of AMMCs were achieved on adding different
ceramic reinforcements [1, 2, 3, 4]. The advantages of AMMCs is that the tailored properties can be
sintered by using amalgamation of various inclusions in the base matrix [5]. The most common ceramic
reinforcement particles generally used are SiC [6, 7], Al2O3 [7, 8], TiO2 [9], TiC [10] and Gr [7, 10, 11]
were amalgamated in base aluminium matrix as particles or whiskers. Further, with the increase of
prerequisite the requirement of the material, Aluminium hybrid composites were developed. Further,
comparing single reinforced composites and hybrid reinforced composites possess superior physical
and mechanical properties [12, 13]. Addition of single reinforced materials improve the basic properties,
while two or more reinforced materials acquires the preferred composite properties [14]. Depends on
the reinforced materials amount and particles size of reinforced materials with aluminium matrix alloy,
combination of numerous reinforced materials results in aluminium metal matrix hybrid composites
advantages [15]. As a result, aluminium metal matrix hybrid composites replaces single reinforced
composites owing to their enhanced properties in a variety of industrial applications [16].A novel
category of Metal matrix hybrid nanocomposites, where the range of nanometer size reinforcements are
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being used increasingly in MMCs production since they provide enhanced properties [17]. Whereas,
the hybrid cermets overall properties were also influenced with the fabrication methods allied by the
alloys [18, 19, 20]. Numerous casting techniques like stir casting, squeeze casting, compo casting, etc.,
are more usually used for the production of hybrid cermets which involves the molten base metal as
intermediate [21,22]. The amalgamation of oxide particles into molten base metals causes nonuniform
dispersion, aggregation, and formation of cluster powders on surfaces [23].To overcome this problem
electromagnetic stirrers were further utilized. M. Shamsipour et al. [24] fabricated aluminium matrix
nanocomposites by electromagnetic stirrers via optimizing the parameters that leads to superior wear
behavior. M.O. Shabani et al. [25] revealed the uniformly distributed of intermetallic particles with
inferior points of stress concentration all over the Al-Si metal matrix by means of electromagnetic
stirrers. Kumar et al. [26] reported that increase of SiC/TiC reinforced hybrid metal composite enhances
their hardness and wear resistance which decreases density. Feldshtein et al. [27] showed that depends
on the volume and composition of WC, SiC and Gr reinforcements, the properties of MMCs base matrix
properties can be increased or decreased. Karthick et al. [28] studied the effect of Al2O3 and SiC addition
increases microhardness and density compared to the base material owing presence of silicon carbide
with supporting of Al2O3. Raturi et al. [29] fabricated Aluminum alloy with Al2O3 nanoparticulates with
different weight percentages and demonstrated that tested properties are superior has micro particulates
are added compared to composites. They have observed that when the content of Al2O3 nanoparticles
increases, further agglomeration is developed and residual porosity was increased. Ashwath et al. [30]
evaluated microstructural and mechanical behaviour of Aluminium matrix, silicon carbide and Alumina
and observed that characteristics of base matrix gives the best effect and also noticed that with lower
composition of the reinforcement, agglomeration of ceramic particles and density decreases.
Mechanical properties of Al7075 reinforced with B4C and MoS2 were studied by Shoufa Liu et al. [31].
They discovered that adding more B4C and MoS2 to the mix improves mechanical properties while
adding B4C reinforcing elements raises coefficient of friction. Kumar G. M [32] discovered that has
reinforcing material weight fraction increases in matrix alloy improves strength and wear resistance. It
was also discovered that hybrid metal composites had better improvement in properties compare to
single reinforced metal composites, and that reinforced hybrid composites and reinforced single
composites had superior properties than matrix alloy. Manikandan. R et al. [33] have observed that
mechanical behaviour and tribological properties increases with adding reinforcements of B4C and
CDA, seen slight decrease in impact strength. A. Baradeswaran et al. [34] fabricated aluminium hybrid
composites with 5wt% graphite and 10wt % boron carbide using liquid casting methods examined
mechanical and tribological properties of enhanced the mechanical properties and wear resistance
compared to matrix base alloys. Michael Rajanet al. [35] produced AA7075 with TiB2 via in-situ
reaction of KBF4 and K2TiF6 to salt molten aluminium then stated that there is a substantial
improvement in mechanical properties with increasing weight percentage of (0-9 wt. %) TiB2 particle.
Summarizing the detailed literatures, it was claimed that utilization of reinforced hybrid
nanoparticles improves significantly the mechanical properties of matrix base alloy. Yet, no practical
evidence is noticed the effectiveness use of hard ceramic nanoparticles, such as TiB2 and Gr. In the
present study fabrication of Al7075 as the matrix with different weight percentage of TiB2 and Gr
nanoparticles are fabricated by electromagnetic stir casting process. The presence of compounds,
elements and distribution of hybrid reinforcement nanoparticles in base matrix alloy are characterized
by means of optical images, Scanning Electron Micrographs (SEM) with Energy Dispersive X-ray
Spectrum (EDAS) and X-ray Diffraction (XRD). Mechanical behaviour such as hardness, tensile
strength, compression strength and flexural strength of fabricated nanocomposites were investigated.
2. Experimental Details
2.1. Material Selection

In present study, Al7075 ingot chosen as matrix base material to produce reinforced aluminium hybrid
nanocomposites. The reinforcements used in the current study are titanium diboride and graphite
nanoparticles. The nanoparticle size of titanium diboride and graphite ranging from 90-100nm are
procured from Otto chemicals Ltd., Mumbai. Al7075, titanium diborides and graphite chemical
composition are mentioned in Table 1-3 respectively.
2
Table 1. Chemical composition with weight percentage of Al7075
Elements Mg Fe Si Cu Mn Zn Ti Cr Al
wt% 2.6 0.5 0.4 1.6 0.3 6.1 0.2 0.15 Balance
Table 2. Chemical composition with weight

percentage of TiB2 powder
Elements Ti B O N C Fe
wt% 67.6 31.03 0.44 0.26 0.25 0.99
Table 3. Chemical composition with weight

percentage of Gr powder
Elements Carbon Sulfur Iron

wt% < 95.0 > 0.1 > 0.5
2.2. Fabrication process

Table 4 illustrate various nanoparticles reinforcements with varying compositions of hybrid cermet’s
of Al7075 fabricated through electromagnetic stir casting process. The experimental setup of
electromagnetic stir casting is shown in figure 1, which consists of a furnace and a stirring assembly.
The electromagnetic stirrer works on the linear motor principle, stands diverse to that of conventional
mechanical, decompression types as noncontact stirrer parts has no contact with the molten base metal.
The motor receives a three-phase AC voltage, which causes the magnetic coil to create a moving
magnetic field. Electric power produced in molten base metal due to the act of the magnetic field or
flux results in the flow of induction current [35,36]. This current takes the magnetic field to influence
electromagnetic force (F) of molten metal. As stir moves along magnetic field direction, this thrust stirs
the molten base metal. Further, when this thrust takes components along vertical and horizontal
directions, the molten base metal moves upwards diagonally in directions that results uniform
temperature in both top layer and also bottom layer of the base metal [37, 38]. The major advantage of
electromagnetic stir casting process over other casting process are where nanoparticles were spread all
over the matrix to acquire uniform dispersal of reinforcements. Here, Al7075 matrix was liquefied in
crucible using muffle furnace inside the three-phase induction motor stator, where magnetic field rotates
the molten metal Al7075 with reinforced TiB2 and Gr nanoparticles which produce vortex leads to
homogenous composite materials. This procedure is considered for other percentages of TiB2 and Gr
nanoparticles. Then poured the molten metal into rectangular slabs of 200×120×150mm3 mould and
allowed to solidify. As per ASTM standards specimens were machined for the study of microstructure
and mechanical behavior. The parameter of selected process were shown in Table 5.
2.3. Microstructural analysis

Specimens of unreinforced and reinforced hybrid nanocomposites were cut form the rectangular slabs,
prepared for metallographic study as per required dimensions and the specimens to be tested are
flattened using polisher. The specimens were polished using abrasive papers of 1/0, 2/0, 3/0 and 4/0 of
emery papers to achieve scratch free and clear surface by rotating on disk cloth polishing. Finally, as
per standard metallographic procedure the polished prepared specimens were etched by Keller’s reagent
for better reveal of the microstructure features. The microstructure of hybrid nanocomposites were
studied by means of an optical microscope. Scanning Electron Microscope with Energy Dispersion X-
ray Spectrum and X-ray diffraction analyzer were used to study microstructure of hybrid
nanocomposites.
3
Table 4. Composition of samples and its notation
Sl. No Sample notations Composition

1 A Al7075
2 ATG1 Al7075+2.5%TiB2+4%Gr
3 ATG2 Al7075+5%TiB2+4%Gr
4 ATG3 Al7075+7.5%TiB2+4%Gr
5 ATG4 Al7075+10%TiB2+4%Gr
6 ATG5 Al7075+12.5%TiB2+4%Gr
Figure 1. Electromagnetic stir casting experimental setup.
Table 5. Parameters of EMSC process for AMNCs preparation
Sl. No Parameter Value Units

1 Current 30-40 Amp
2 Voltage supply 250-410 V
3 Temperature of melt charge 780-800 ˚C
4 Preheated temperature of Gr particles 400 ˚C
5 Preheated temperature of TiB2 particles 2970 ˚C
6 Preheated temperature of mould 350-375 ˚C
7 Temperature during stirring 670-700 ˚C
8 Stirring time 4-5 min
2.4. Mechanical properties

The hardness has been performed using Brinell hardness tester with a specified load. Five different
locations on the samples were tested and average are taken to reveal the hardness of the aluminium
4
hybrid nanocomposites. The tensile strength of aluminium hybrid nanocomposites has been performed
as per ASTM E08-08 standards. The Compression test on the prepared samples has been done as per
ASTM E09-09 standards. The Flexural test has been performed using three-point bending method at
room temperature as per ASTM C1161 standards. These tests are carried by Universal Testing Machine
and to acquire the results four samples were prepared and average of all these reading were reported.
3. Results and discussion
3.1. Evaluation of microstructural analysis

Optical micrographs of unreinforced and reinforced hybrid nano composites were shown in Figure 2(a-
f). The micrographs reveal that the casting flaws as cracks, shrinkages cavity, porosity and slag
inclusion present in unreinforced Al7075 alloy. Since, casting defects reduces the mechanical
properties, incremental addition of the TiB2 and Gr nanoparticles into the matrix reduces these defects
and enhances the properties. From Figure 2, it was noticed that the sample A has larger grain size
compare to the samples ATG1, ATG2, ATG3, ATG4 and ATG5. This was found that as content of
TiB2 and Gr nanoparticles increases fine structured grains with admirable bonded strength and
homogeneous distributed hybrid nano particels over the matrix. Generally, it was observed that
increasing content TiB2 with 4wt% Gr nanoparticles there was decrease in grain size till 10wt% of TiB2
nanoparticles which enhances the mechanical particles. It was also observed that 12.5wt% of TiB 2
nanoparticles, nonuniform distribution of reinforced nanoparticles and agglomeration formation.
Comparable fine grains size structured and homogeneous dissemination of TiB2 and Gr nanoparticles
reinforced with in base matrix were reported [39, 40].
The particle dissemination in unreinforced matrix alloy and nano size particle hybrid composites
was evaluated using Scanning Electron Microscope (SEM) images with Energy Dispersion X-ray
Spectrum EDAS) patterns. The topographic SEM picture with EDAS of unreinforced base alloy and
hybrid reinforced nanocomposites are shown in Figure 3. The topographic SEM picture and EDAS of
an Al7075 alloy are shown in Figure 3(a). Elements like aluminum (Al), zinc (Zn), magnesium (Mg),
silicon (Si) with high intensity peaks as well as carbon (c), nitrogen (N) with low intensity peaks are
seen in Figure 3 (b-f). Nano particles were found to be evenly spread throughout the matrix, indicating
the presence of reinforcements. This form of nanoparticle distribution is required to provide improved
mechanical properties in aluminium-based hybrid nanocomposites. The interface among reinforced
TiB2 and Gr nanoparticles, and base matrix had a range of morphologies, including flat, spherical, cubic,
irregular and hexagonal with of TiB2 nanoparticles well bound over base alloy. Suresh et al., Sharma.
et al. [41, 42] found that the of TiB2, Gr and Aluminum composites nanoparticles had similar intensity
peaks. X-ray diffraction were used for the detection of the reinforced particles and matrix presence in
the cast composites. X-ray diffraction analysis of Aluminium composites with varying amounts of TiB2
and Gr in Al7075 alloy displayed in Figure. 4. The presence of Al, TiB2 and Gr in the form of carbon
are conformed by their respective peaks. Al shows the higher peaks owing to the presence of large
amount of Al followed by the TiB2 and Gr.
3.2. Evaluation of mechanical properties

Figure 5 shows the hardness tests results performed on prepared samples of unreinforced alloy and
reinforced hybrid nanocomposites with varying wt% of TiB2 and 4wt% of Gr. It was observed that the
hardness of ATG4 sample is more than compare to the other samples. Further, observing the results the
reinforced hybrid nanocomposites samples ATG1, ATG2, ATG3, ATG4 and ATG5 are higher than
unreinforced alloy sample A. The hardness of reinforced hybrid nanocomposite seems to be improved
about 10wt% of TiB2 then and there is a significant reduce at 12.5wt% of TiB2 with 4wt% of Gr. The
addition of hard TiB2 nanoparticles increases the hardness. As a result, the addition of TiB2 nanoparticle
above 12.5wt% not recommended for further investigation. Figure.5 illustrates, sample ATG4 exhibits
increased hardness when compared to other samples, as well as improved hardness above unreinforced
alloy. These findings were in line with what some researchers had discovered. Similar findings were
reported by Kumar G.M, Ramkumar et al. and Kannan. C. et al., [31, 40, 44].
5
Figure 2. Optical micrographs for samples (a) A (b) ATG1 (c) ATG2 (d) ATG3 (e)ATG4 (f)ATG5.
6
Figure 3. SEM images and EDAS for samples (a)A(b)ATG1 (c)ATG2(d)ATG3(e)ATG4 (f) ATG5.
7
Figure 4. XRD results for the prepared composites
Figure 5. Brinell hardness of prepared samples
Figure 6 clearly indicates the Tensile strength for various samples. The incorporation of
ceramic hard particles over base matrix alloy boosts strength because ceramic hard nanoparticles
take away the majority of exterior load, according to the literature. As a result, including nano
TiB2 particles with 4wt% Gr into the matrix alloy boosts the hybrid nanocomposites' tensile
strength. The sample ATG4 strength is higher than the other manufactured composites. It's worth
noting that ATG4 is higher than Al7075alloy. When the wt percent TiB2 is increased by 10%,
the strength achieves its maximum value, and then drops suddenly when the wt percent TiB 2 is
increased by 12.5 percent. Furthermore, results demonstrate the reinforced hybrid
nanocomposites have higher tensile strength compare to unreinforced Aluminum alloys, and a
previous study [31, 32] found comparable results.
8
Figure 6. Tensile strength of prepared samples
The hybrid reinforced nanocomposites along with unreinforced base alloy flexural strength is shown
in figure 7. In comparison to matrix alloy, the inclusion of reinforcement consistently increased flexural
strength [9, 20, 22]. The addition of variable weight percent of nano TiB2 particles and nano Gr particles
to matrix base alloy by avoiding dislocation improves the flexural strength. The homogenous
embedding of reinforced nanoparticles over the base matrix results in a significant increase in flexural
strength with 10wt% TiB2 and 4wt% Gr nanoparticles. At 12.5wt% TiB2 and 4wt% Gr nanoparticles,
the flexural strength began to decline as the addition of TiB2 nanoparticles increased. Due, to the
nonuniform dispersion of TiB2 nanoparticles throughout the matrix, this is expected.
Figure 7. Flexural strength of prepared samples
Compressive strength of matrix alloy illustrated in figure 8 increases as the wt% TiB2 and 4wt% Gr
increases. It was observed, with the addition of TiB2, the compressive strength of reinforced hybrid
nanocomposites samples ATG1, ATG2, AGT3, AGT4, AGT5 increases and is superior to the
unreinforced matrix alloy sample A. When compared to other samples, sample TiB2, AGT4 has the
highest compressive strength. In general, adding Gr nanoparticles reduces strength, but adding hard
9
ceramic nanoparticle TiB2, to the matrix base alloy improves the strength. Other researchers [21, 25]
have observed that these hard ceramic nanoparticles controls movement of obstacles dislocation in
matrix base alloy and which leave loop of dislocation around the particles in base alloy.
Figure 8. Compressive strength of prepared samples
4. Conclusion
In this work, the samples of unreinforced and reinforced hybrid nanocomposites have effectively
fabricated through electromagnetic stir casting technique. The microstructure characteristics and also
mechanical behaviour of Al7075 alloy matrix and hybrid Al7075 nanocomposites were examined,
yielding the following conclusions:
• Optical pictures and SEM indicate the inclusion of nanoparticles and their homogenous
implanting of hybrid reinforced nanocomposites on unreinforced base alloy defined via Optical
microscope, Scanning Electron Microscope. Here interfaced hybrid nanoparticles was clear
without the presence of casting defects. Uniform dissemination of nanoparticles can led to the
enhanced mechanical properties.
 XRD patterns analyse, Al, TiB2 and Gr peaks presence. To ensure, presence of elements in
matrix base alloy and hybrid nanocomposites EDAS study was performed.
• Hybrid nanocomposites increases hardness as the wt%TiB2 increases, compared to base matrix
alloy. The Hardness exhibited higher value for sample ATG4 compare to the other samples. In
comparison to matrix base alloy, the adding of wt%TiB2 and 4wt% Gr enhances flexural,
tensile, compression strength of hybrid nanocomposites owing to amalgamation of hard
ceramic nanoparticles in matrix alloy, which removes a large portion of external stresses. As
non-uniform dispersion of TiB2 nanoparticles over matrix alloy, the strength of sample ATG5
reduced with the addition of 12.5wt%TiB2 and 4wt% Gr.
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13

Anitha 2022 IOP Conf. Ser. Mater. Sci. Eng. 1248 012093

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This content was downloaded from IP address 49.47.130.238 on 23/05/2024 at 18:31

An investigation on microstructure and mechanical behaviour

Anitha P1, 3*, Srinivas Rao M2

2.1. Material Selection

Table 1. Chemical composition with weight percentage of Al7075

Table 2. Chemical composition with weight

Table 3. Chemical composition with weight

Elements Carbon Sulfur Iron

2.2. Fabrication process

2.3. Microstructural analysis

Table 4. Composition of samples and its notation

Sl. No Sample notations Composition

Figure 1. Electromagnetic stir casting experimental setup.

Table 5. Parameters of EMSC process for AMNCs preparation

Sl. No Parameter Value Units

2.4. Mechanical properties

3. Results and discussion

3.1. Evaluation of microstructural analysis

3.2. Evaluation of mechanical properties

Figure 4. XRD results for the prepared composites

Figure 5. Brinell hardness of prepared samples

Figure 6. Tensile strength of prepared samples

Figure 7. Flexural strength of prepared samples

Figure 8. Compressive strength of prepared samples

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