EXPERIMENTAL INVESTIGATIONS ON

TRIBOLOGICAL BEHAVIOUR OF ZrO2

REINFORCED ALUMINIUM MATRIX

COMPOSITES

PHASE I REPORT

Submitted by

JOSEPH D
(REG.NO: 911222408003)

in partial fulfillment for the award of

the degree of

MASTER OF
ENGINEERING IN
ENGINEERING DESIGN

MAHATH AMMA INSTITUTE OF ENGINEERING

AND TECHNOLOGY
PUDUKKOTTAI-622101

DEPARTMENT OF MECHANICAL ENGINEERING

ANNA UNIVERSITY, CHENNAI

DECEMBER 2023
 EXPERIMENTAL INVESTIGATIONS ON

TRIBOLOGICAL BEHAVIOUR OF ZrO2 REINFORCED

ALUMINIUM MATRIX COMPOSITES

PHASE I REPORT

Submitted by

JOSEPH D
(REG.NO: 911222408003)

in partial fulfillment for the award of

the degree of

MASTER OF
ENGINEERING IN
ENGINEERING DESIGN

MAHATH AMMA INSTITUTE OF ENGINEERING

AND TECHNOLOGY
PUDUKKOTTAI-622101

DEPARTMENT OF MECHANICAL ENGINEERING

ANNA UNIVERSITY, CHENNAI.

DECEMBER 2023
i
 BONAFIDE CERTIFICATE

Certified that this project report EXPERIMENTAL

INVESTIGATIONS ON TRIBOLOGICAL BEHAVIOUR OF ZrO2
REINFORCED ALUMINIUM MATRIX COMPOSITES” is the Bonafide work
of " JOSEPH D (91222408003)” who carried out the project work under my
supervision.

SIGNATURE SIGNATURE

Mr.H.Saravanan M.E, (Ph.D) Dr.C.Gopikrishnan M.E, Ph.D

HEAD OF THE DEPARTMENT SUPERVISOR
Assistant Professor, Assistant Professor,
Department of Mechanical Engineering, Department of Mechanical Engineering
Mahathamma Inst. of Engg & Tech Mahath Amma Inst. of Engg & Tech

Pudukkottai. Pudukkottai.

Submitted for the Project viva-voce examination held

on……………

INTERNAL EXAMINER EXTERNAL EXAMINER

ii
4
 ABSTRACT
Aluminium metal matrix composites (AMMCs) is an aluminium alloy. It is
strong, with strength comparable to many steels, and has good fatigue strength and
average machinability. It has lower resistance to wear than many other aluminium
alloys, but it has significantly better wear resistance than the 2000 aluminium
alloys. AMMCs are potential materials for various applications due to their good
physical and mechanical properties. This work aluminum metal matrix
composite
(AA8050) reinforced with Zirconium di oxide (ZrO2) by using the stir
casting
techniques. This serves as an additive to aluminum metal matrix composites,
wear resistant alloy. To fabricate the (AA8050) aluminum metal matrix composites
reinforced with Zirconium di oxide (ZrO2). To determine the mechanical properties
such as tensile strength and hardness.

5
 LIST OF CONTENTS
CHAPTER. TITLE PAGE.
NO NO

ABSTRACT
INTRODUCTIO 1
N

1
1.1 COMPOSITE MATERIALS 1
1.2 DEFINITION OF COMPOSITE 3
1.3 CLASSIFICATION OF COMPOSITES 3
1.3.1 Types of Matrix Material 4
1.3.2 Type of Reinforcing Materials Composite 5
1.4 METAL MATIX COMPOSITE 6
1.4.1 Fabrication Techniques for metal matrix 8
composites
1.4.2 Solidification processing of MMC’s 10
1.4.3 MMC Properties Compared to Other Structural 10
Materials
2 LITERATURE REVIEW 14

3 EXPERIMENTAL DETAILS 19

3.1 STIR CASTING PROCESS 19

3.2 HARDNESS TEST 21
3.2.1 Brinell Hardness Test 22
3.2 COMPOSITION 39
3.3 UNIVERSAL TESTING MACHINE 24

6
 3.4 WEAR TEST 27
4 RESULT AND DISCUSSION 28

4.1 BRINELL HARDNESS TEST 28

4.2 TENSILE TEST 29

5 CONCLUSIO 32
6 N 33
REFERENCE

vii
 LIST OF FIGURES
CHAPTER. FIGURE. TITLE PAGE.
NO NO NO

3 3.1 Casting Rod 20

3.2 Casting Plate 21
3.3 Brinell Hardness Testing Machine 23
3.4 Tensile Testing Machine (UTM) 25
3.5 Tensile Specimen before Testing 25
3.6 Tensile Specimen after Testing 26
3.7 SEM Image of Fracture Surface 27
4 4.1 AA8050 Composite Vs Brinell Hardness Test 29
4.2 AA8050 Composite Vs Ultimate Tensile 30
Strength
4.3 AA8050 Composite Vs Percentage 30
Elongation

8
 LIST OF TABLES
CHAPTER. TABLE. TITLE PAGE.
NO NO NO

4 4.1 Brinell Hardness Test 28

4.2 Tensile Test 29

9
 CHAPTER 1

INTRODUCTION
1.1 COMPOSITE MATERIALS

Conventional monolithic materials have limitations with respect to

achievable combinations of strength, stiffness, and density. In order to overcome
these shortcomings and to meet the ever-increasing engineering demands of
modern technology, metal matrix composites are gaining importance. In recent
years, discontinuously reinforced aluminum based metal matrix composites have
attracted worldwide attention as a result of their potential to replace their
monolithic counterparts primarily in automobile and energy sector.

The basic idea is that continuous fiber reinforced composite has better
strength but the processing methods is highly expensive which hinders their
adoption. The continuous fiber reinforced composites do not allow secondary
forming such as rolling, forging and extrusion. As results of these limitations new
efforts on the research of discontinuous reinforcements have been used.

At early stages of development of metal matrix composite emphasis was

given on the preparation of fiber reinforced composite only. But due to the high
cost associated with the process of production, anisotropic properties of the
resultant composite and difficulties associated with the fabrication process,
production of this type of composites has been limited.A composite material is a
material made up of two or more materials that are combined in a way that allows
the materials to stay distinct and identifiable. The purpose of composites is to
allow the new material to have strengths from both materials.

1
 Composites are different from alloys because alloys are combined in such a
way that it is impossible to tell one particle, element, or substance from the other.
Some common composite materials include concrete, fiberglass, mud bricks, and
natural composites such as rock and wood.

Composites that forms heterogeneous structures which meet the

requirements of specific design and function, incorporated with desired properties
which limit the scope for classification. However, this lapse is made up for, by the
fact new types of composites are being innovated all the time, each with their own
specific purpose like the filled, flake, particulate and laminar composites.

Fibers or particles embedded in matrix of another material would be the best

example of modern-day composite materials, which are mostly structural.
Laminates are composite materials here different layers of materials give them the
specific character of a composite material laving 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.

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.

2
 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 implications 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 inter phase, there has to be two inter phases
between each side of the inter phase and its ad joint constituent. Some composites
provide inter phases when surfaces dissimilar constituents interact with each other.
Choice of fabrication method depends on matrix properties and the effect of matrix
on properties it reinforcements .One of the prime considerations in the selection
and fabrication of composites s that the constituents should be chemically inert non-
reactive.

2. DEFINITION OF COMPOSITE

Jartiz “Composites re multifunctional material systems that provide

Characteristics not obtainable from any discrete material.

They are cohesive structures made by physically combining two or more

compatible materials, different in composition and characteristics and sometimes
in form”.

3. CLASSIFICATION OF COMPOSITES

Composite materials can be classified into many categories depending on

reinforcing material type, matrix type etc. They are namely:

3
1.3.1 Types of Matrix Material

(a) Metal Matrix Composite

It consists of a metallic matrix (Al, Mg, Cu, Fe). There are several reasons
for the re-emergence of interest in metal matrix, the most important one being their
engineering properties. They are of light weight, and exhibit good stiffness and low
specific weight as compared to other metals and metal alloys. It is generally
considered that these materials offer savings in weights, at the same time maintain
their properties. Although it has many advantages, cost remains a major point of
interest for many applications.

(b) Polymer Matrix Composite

Polymer matrix composites are considered to be a more prominent class of

composites when compared to ceramic or metal matrix composites once in
commercial applications. It comprises of a matrix from thermosetting (unsaturated
polyester, epoxy) or thermoplastic (nylon, polystyrene) and embedded glass
carbon, steel or Kevlar fibers (dispersed phase).

The industries supporting reinforced polymer markets include

transportation, marine accessories, electronic products etc.

(c) Ceramic Matrix Composite

It comprises of a material consisting of a ceramic combined with a ceramic

dispersed phase. The availability of new technologies, processing methods and the
demand for high performance products, have together promoted the growth of
advanced ceramic products, but the brittleness of ceramics still remains a major
disadvantage.

4
1.3.2 Type of Reinforcing Materials Composite

a) Particulate Composites

Particulate Composites consist of a matrix reinforced by a dispersed phase

in form of particles.

Composites with random orientation of particles.

Composites with preferred orientation of particles. Dispersed phase of

these materials consists of two-dimensional flat platelets (flakes), laid parallel
to each other.

b) Fibrous Composites

Short-fiber reinforced composites; Short-fiber reinforced composites

consist of a matrix reinforced by a dispersed phase in form of discontinuous
fibers (length
< 100×diameter).

Composites with random orientation of

fibers. Composites with preferred orientation

of fibers.

Long-fiber reinforced composites. Long-fiber reinforced composites

consist of a matrix reinforced by a dispersed phase in form of continuous
fibers.

Unidirectional orientation of fibers.

Bidirectional orientation of fibers (woven).

c) Laminate Composites

When a fiber reinforced composite consists of several layers with

different fiber orientations, it is called multilayer (angle-ply) composite.
5
1.4 METAL MATIX COMPOSITE

A metal matrix composite (MMC) is composite material with at least two

constituent parts, one being a metal. The other material may be a different metal or
another material, such as a ceramic or organic compound. When at least three
materials are present, it is called a hybrid composite.

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 module. 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

7
the melting temperature of matrix materials. Engineered MMCs consisting
of continuous or discontinuous fibers, whiskers, or particles in a metal achieve
combinations of very high specific strength and specific modulus. Furthermore,
systematic design and synthesis procedures allow unique combinations of
engineering properties in composites like high elevated temperature strength,
fatigue strength, damping property, electrical and thermal conductivities, friction
coefficient, wear resistance and expansion coefficient.

Structurally, MMCs consist of continuous or discontinuous fibers, whiskers,

or particles in an alloy matrix which reinforce the matrix or provide it with
requisite properties not achievable in monolithic alloys. In a broader sense, cast
composites, where the volume and shape of phase is governed by phase diagrams,
for example, cast iron and aluminium-silicon alloys, have been produced by
foundries for a long time. The modern composites differ in the sense that any
selected volume, shape and size of reinforcement can be artificially introduced in the
matrix. The modern composites are non-equilibrium combinations of metals and
ceramics, where there are fewer thermodynamic restrictions on the relative
volume percentages, shapes and size of ceramic phases.By carefully controlling the
relative amounts and distribution of the ingredients constituting a composite as
well as the processing conditions.

These could include increased strength, decreased weight, higher service

temperature, improved wear resistance, higher elastic modulus, controlled
coefficients of thermal expansion and improved fatigue properties. The quest for
improved performance has resulted in a number of developments in the area
of MMC fabrication technology.

These include both the preparation of the reinforcing phases and the
development of fabrication techniques. Reinforcing phase for MMCs fall into three

8
important categories: (i) continuous and discontinuous filament, (ii) whiskers,
and
(iii) particulate. The important improvements in mechanical properties are
obtained from filaments in the direction of their alignment, with whiskers and
particulates
offering lesser strength with greater isotropy.

1.4.1 Fabrication Techniques for metal matrix composites

A number of composite fabrication techniques have been developed that

can be placed into four broad categories. These are (i) Liquid metallurgy (ii)
Powder metallurgical techniques (iii) Diffusion bonding of filaments and foils and
(iv)Vapor phase infiltration.

a) Liquid metallurgy

The liquid metallurgy techniques include unidirectional also solidifications

to produce directionally aligned MMCs, suspension of reinforcement in melts
followed by solidification, compo casting, squeeze casting, spray casting,
and pressure infiltration.

The liquid metallurgy techniques are the least expensive of all, and the multi-
step diffusion bonding techniques may be the most expensive. From a technological
standpoint of property performance relationship, the interface between the matrix
and the reinforcing phase (fiber or particle) is of primary importance.
Processing of MMCs sometimes allows tailoring of the interface between the
matrix and the fiber in order to meet specific property-performance requirements.

b) Powder Metallurgical Techniques

Powder blending followed by consolidation (PM technique), diffusion

bonding and vapor deposition techniques come under solid state processing
Powder metallurgy techniques offer the following three advantages over liquid
9
metallurgy techniques for fabricating MMCs. (a) Lower temperatures can be used
during preparation of a PM-based composite compared with preparation of a liquid
metallurgy-based composite. The result is lesser interaction between the matrix and
the reinforcement when using the PM technique. By minimizing undesirable inter-
facial reactions, improved mechanical properties are obtained. (b) In some cases,
PM techniques will permit the preparation of composites that cannot be prepared by
the liquid metallurgy. For instance, fibers or particles of silicon carbide will
dissolve in melts of several metals like titanium, and such composites will be
difficult to prepare using liquid metallurgy techniques, (c) However, PM
techniques remain expensive compared to liquid metallurgy techniques for the
composites like Al-SiC particle composites. In addition, only small and simple
shape can be produced by PM techniques.

c) Diffusion bonding:

Mono filament-reinforced AMCs are mainly produced by the diffusion

bonding (foil-fiber-foil) route or by the evaporation of relatively thick layers
of aluminum on the surface of the fiber. 6061 Al-boron fiber composites have been
produced by diffusion bonding via the foil-fiber-foil process.

However, the process is more commonly used to produce Ti based fiber

reinforced composites. The process is cumbersome and obtaining high fiber
volume fraction and homogeneous fiber distribution is difficult. The process is not
suitable to produce complex shapes and components.

d) Physical Vapor Depositions

The process involves continuous passage of fiber through a region of high

partial pressure of the metal to be deposited, where condensation takes place so as to
produce a relatively thick coating on the fiber. The vapor is produced by
directing a high power electron beam onto the end of a solid bar feed stock.

10
Typical deposition rates are 5 -10 μm per minute. Composite fabrication is usually
completed by assembling the coated fibers into a bundle or array and consolidating
in a hot press operation. This technique can produced composites with uniform
distribution of fiber and volume fraction as high as 80%.

2. Solidification processing of MMC’s

Solidification processing represents one of the simplest methods of

producing MMCs. Cast irons and aluminum-silicon alloys are in a sense phase
diagram dictated MMCs. Unidirectional solidification of eutectics can produce
fiber reinforced composites in a single step. However, these are all phase diagram
restricted modern cast MMCs, not restricted by phase diagrams, are made by
introducing fibers or particles in molten or partially solidified metals followed by
casting of these slurries in molds. Alternately perform of fibers or particles is made
and it is infiltrated by molten alloys, which then freeze in the inter fiber spaces to
form the composite. In both these processes, adequate wetting between molten
alloys and dispersions is essential.

3. MMC Properties Compared to Other Structural Materials

Compares the most important material properties of MMCs with those of
other structural materials discussed in this assessment.
a) Strength and Stiffness
The stiffness’s and strengths of particulate-reinforced aluminum MMCs
are
significantly better than those of the aluminum matrix. For exam pie, at a
volume fraction of 40 percent silicon carbide particulate reinforcement, the
strength is about 65 percent greater than that of the 6065 aluminum matrix, and the
stiffness is doubled.6 Particulate-reinforced MMCs, which are isotropic materials,
have lower strength than the axial strength (parallel to the direction of continuous
fiber reinforcement) of advanced polymer matrix composites (PMCs), they have
much 11
better strength than the transverse strength (perpendicular to the direction of
continuous fiber reinforcement) of PMCs.
The stiffness of particulate MMCs can be considered to be about the same as
that of PMCs. Unlike particulate-reinforced MMCs and monolithic metals in
general, fiber-reinforced MMCs can be highly an isotropic, having different
strengths and stiffness’s in different directions. The highest values of strength and
stiffness are achieved along the direction of fiber reinforcement. In this direction,
strength and stiffness are much higher than in the unreinforced metal, In fact, the
stiffness in the axial direction can be as high as six times that of the matrix
material in a graphite fiber/aluminum matrix composite. However, in the transverse
directions, strength values show no improvement over the matrix metal. Transverse
strengths and stiffness’s of continuous fiber-reinforced MMCs compared to PMCs
are very good, thereby giving MMCs an important advantage over the leading
PMCs in structures subject to high transverse stresses.
High values of specific strength and specific stiffness (strength and stiffness
divided by density) are desirable for high-strength, low-weight applications such as
aircraft structures. Typically, particulate MMCs have somewhat better specific
strength and specific stiffness than the matrix metal, and fiber-reinforced MMCs
have much better specific strength and specific stiffness than the matrix metal.
b) High-Temperature Properties
MMCs offer improved elevated-temperature strength and modulus over
both
PMCs and metals. Reinforcements make it possible to extend the useful
temperature range of low density metals such as aluminum, which have limited
high temperature capability. MMCs typically have higher strength and stiffness
than PMCs at 200 to 300° C (342 to 5720 F), although development of resins with
higher temperature capabilities may be eroding this advantage. No other structural
material, however, can compete with ceramics at very high temperature.
11
 Fiber-reinforced MMCs experience matrix/reinforcement interface reactions
at high temperatures. In addition, the transverse high-temperature strength of fiber-
reinforced MMCs is only as good as that of the matrix metal, since mechanical
properties in the transverse direction are dominated by the matrix and the
fiber/matrix interface. For example, at 320 C (608° F), the axial tensile strength of
boron fiber-reinforced aluminum is about 1.1 Gigapascals (GPa) compared to only
0.07 GPa for monolithic 6061 aluminum, whereas the transverse strength is
0.08 GPa, about the same as that for the monolithic 6061.2
c) Wear Resistance
Wear resistance of MMCs is excellent compared to that of monolithic metals
and PMCs, owing to the presence of the hard ceramic reinforcements. For instance,
in one test, the abrasive wear of 2024 aluminum under a 1 kilogram load was
shown to be 6 times greater than the wear of the same alloy containing 20
percent
volume fraction of silicon carbide whiskers. An alumina-silica fiber-
reinforced aluminum piston used in Toyota automobiles demonstrated an 85 percent
improvement in wear resistance over the cast iron piston with nickel insert used
previously.
d) Fracture and Toughness
There is a wide variation in fracture toughness among MMCs, although it
is
generally lower than that of the monolithic metal. Fracture toughness can
vary between 65 and 100 percent of the fracture toughness of the monolithic
metal alloy. Lower toughness is a trade-off for higher strength and stiffness.
Particulate-reinforced MMCs have a lower ultimate tensile strain than the
unreinforced metals. which may be important in some applications. This
brittleness can complicate the design process and make joining more difficult as
12
well. Comparison to PMCs is difficult, because the toughness of PMCs is
very temperature-dependent.
e) Thermal Properties
The introduction of silicon carbide particulate into aluminum results in
materials having lower coefficients of thermal expansion, a desirable property for
some types of applications. By choosing an appropriate composition,
the
coefficient of thermal expansion can be near zero in some MMCs. MMCs
also tend
to be good heat conductors. Using high thermal conductivity graphite fibers,
aluminum-matrix or copper-matrix MMCs can have very high thermal
conductivity, compared with other types of composites.
f) Environmental Behavior
In terms of environmental stability, MMCs have two advantages over PMCs.
First, they suffer less water damage than PMCs which can absorb moisture,
thereby reducing their high-temperature performance. Second, some MMCs, such as
reinforced titanium, can stand high-temperature corrosive environments, unlike
PMCs. Nevertheless, some MMCs are subject to environmental degradation
not found in PMCs. For instance, graphite fibers undergo a galvanic reaction with
aluminum. This can be a problem when the graphite/aluminum interface is
exposed to air or moisture. In addition, PMCs are resistant to attack by many
chemicals (e.g., acids) that corrode aluminum, steel, and magnesium.

13
 CHAPTER 2

LITERATURE REVIEW

2.1 INTRODUCTION

Review of the related literature allows the researcher to acquaint himself

with current knowledge in the field or in which he is going to conduct his research,
serves the following specific purposes. The review of related literature enables the
researcher to define the limit in this field. It helps the researcher to delimit
and define his problem.

The knowledge of related literature brings the researcher up to date work on

which others have done and thus to state the objectives clearly and concisely. By
reviewing the literatures the researchers can avoid unfruitful and less problem
areas. He can select the areas in which positive findings are very likely to add to the
knowledge in a meaningful way.

The review of related literature gives understanding of research

methodology to the researcher which refers the way of study, which is to be
conducted. It helps the researcher to know about the tools and instruments, which
provided to be useful and promising in the preview studies. The content of related
literature also provides insight into the statistical methods through which validity of
results is to be established.

The final and important specific reason for reviewing the related literature is
to know about the recommendation of previous researchers which light in their
studies for further research.

14
2.2 LITERATURE STUDIES

B. Vijaya Ramnath1, C. Elanchezhian1, RM. Annamalai1, S.Aravind1,

T. Sri Ananda Atreya, V. Vignesh , and C. Subramanian

Aluminium matrix composites (AMCs) are potential materials for

various applications due to their good physical and mechanical properties.
The addition of reinforcements into the metallic matrix improves the
stiffness, specific strength, wear, creep and fatigue properties compared
to the conventional engineering materials. This paper presents the overview of
the effect of addition on different reinforcements in aluminium alloy
highlighting their merits and demerits. Major issues like agglomerating
phenomenon, fiber-matrix bonding and the problems related to distribution of
particles are discussed in this paper. Effect of different reinforcement on
AMCs on the mechanical properties like tensile strength, strain,
hardness, wear and fatigue is also discussed in detail. Major applications of
different AMCs are also highlighted in this work.
G.G. Sozhamannan, S. Balasivanandha Prabu, V. S. K.
Venkatagalapathy

Conventional stir casting process has been employed for producing

discontinuous particle reinforced metal matrix composites for decades. The
major problem of this process is to obtain sufficient wetting of particle by
liquid metal and to get a homogenous dispersion of the ceramic particles.

15
 In the present study, aluminium metal matrix composites were
fabricated by different processing temperatures with different holding time to
understand the influence of process parameters on the distribution of
particle in the matrix and the resultant mechanical properties. The
distribution is exam-index by microstructure analysis, hardness distribution
and density distribution.
K.Shahin Soltani, R.Azari Khosroshahi, V.Zhengyi Jiang
Stir casting is an economical process for the fabrication of aluminum
matrix composites. There are many parameters in this process, which affect
the final microstructure and mechanical properties of the composites. In this
study, micron-sized SiC particles were used as reinforcement to fabricate Al-
3 wt% SiC composites at two casting temperatures (680 and 850
°C) and stirring periods (2 and 6 min). Factors of reaction at matrix/
ceramic
interface, porosity, ceramic incorporation, and agglomeration of the
particles were evaluated by scanning electron microscope (SEM) and high-
resolution
transition electron microscope (HRTEM) studies.
From microstructural
characterizations, it is concluded that the shorter stirring period is
required for ceramic incorporation to achieve metal/ceramic bonding at the
interface.
The higher stirring temperature (850 °C)also leads to improved ceramic
incorporation. In some cases, shrinkage porosity and intensive formation of
Al4C3 at the metal/ceramic interface are also observed. Finally, the
mechanical properties of the composites were evaluated, and their relation
with the corresponding microstructure and processing parameters of the
composites was discussed.
16
M. Pulkit Garg, D. Pallav Gupta, P. Devendra Kumar, M. Parkash
In this study, effect of sintering temperature on structural and
has been investigated. Initially, graphene reinforcement was prepared by
oxidizing graphite powder to graphite oxide (GO) using Hummer’s method
followed by chemical reduction of graphite oxide using benzyl alcohol
(BnOH). Graphene reinforced aluminum matrix composites were prepared
by powder metallurgy process.
X-ray diffraction pattern, density, microstructure, hardness and
compressive strength of prepared samples have been investigated.
XRD studies showed the presence of pure aluminum and graphene
phase only. However, SEM studies showed dendrite microstructure
indicating to the formation of Al4C3 phase due to reaction between
aluminum and graphene particles.
Density and hardness of the samples depend on the sintering
temperature while compressive strength depends on the concentration of
graphene reinforcement. Addition of graphene as reinforcement in aluminum
matrix increases the strength of aluminum. Strength of the composite
increases with increase in the percentage of graphene.

Chaman Lall , Paul Williamson, Metal Powder Products Company

Wear resistance is often important in structural applications that use
light weight PM aluminum alloys. Several aluminum PM alloys were
evaluated for wear resistance using the ASTM G65 test method.
This
consists of dry sand that is dropped into the interface between
the test
sample and a rotating rubber wheel. Test results indicate that the ACT1
2014 alloy, which is the most popular PM aluminum alloy for structural parts,
has slightly better wear resistance than the cast A380 alloy.

17
 Significantly better wear resistance was achieved with an Al-14%Si
alloy and a ceramic reinforced composite. Surprisingly, a high strength Al- Zn
alloy showed poor wear resistance, while pure Al demonstrated excellent
wear resistance when a liquid was present. The wear resistance of the softer
PM aluminum alloys was attributed to the creation of hard and soft spots at
the wear interface. In the presence of a liquid at the interface,
“hydroplaning” over the fluid trapped in the worn pockets is expected to
occur.

18
 CHAPTER 3
EXPERIMENT DETAILS
1. Stir Casting Process
2. Hardness Test
Brinell hardness test
3. Tensile Test
4. EDM
1. STIR CASTING PROCESS

Stir Casting is a liquid state method of composite materials fabrication, in

which a dispersed phase (ceramic particles, short fibers) is mixed with a molten
matrix metal by means of mechanical stirring.

The liquid composite material is then cast by conventional casting methods

and may also be processed by conventional Metal forming technologies.

Stir Casting is characterized by the following features:

Content of dispersed phase is limited (usually not more than 30vo. %).

Distribution of dispersed phase throughout the matrix is not

perfectly homogeneous:

1. There are local clouds (clusters) of the dispersed particles (fibers);

2. There may be gravity segregation of the dispersed phase due to

a difference in the densities of the dispersed and matrix phase.

The technology is relatively simple and low cost.

Distribution of dispersed phase may be improved if the matrix is in semi-

solid condition. The method using stirring metal composite materials in semi-solid

19
state is called Rheocasting. High viscosity of the semi-solid matrix material
enables better mixing of the dispersed phase.

Figure 3.1 Casting Rod

20
 Figure 3.2 Casting Plate

3.2 HARDNESS TEST

Hardness is the property of a material that enables it to resist plastic
deformation, usually by penetration. However, the term hardness may also refer to
resistance to bending, scratching, abrasion or cutting.

Hardness is not an intrinsic material property dictated by precise definitions in

terms of fundamental units of mass, length and time. A hardness property value is
the result of a defined measurement procedure. Hardness of materials has
probably long been assessed by resistance to scratching or cutting. An
example would be material B scratches material C, but not material A.
Alternatively, material A scratches material B slightly and scratches material C
heavily. Relative hardness of minerals can be assessed by reference to the Moh's
Scale that ranks the ability of materials to resist scratching by another material.
Similar methods of relative hardness assessment are still commonly used today.
21
 An example is the file test where a file tempered to a desired hardness
is rubbed on the test material surface. If the file slides without biting or marking
the surface, the test material would be considered harder than the file. If the file
bites or marks the surface, the test material would be considered softer than the
file. The above relative hardness tests are limited in practical use and do not
provide accurate numeric data or scales particularly for modern day metals and
materials. The usual method to achieve a hardness value is to measure the depth or
area of an indentation left by an indenter of a specific shape, with a specific force
applied for a specific time. There are three principal
standard test methods for expressing the relationship
between hardness and the size of the impression, these being Brinell, Vickers,
and Rockwell. For practical and calibration reasons, each of these methods is
divided into a range of scales, defined by a combination of applied load
and indenter geometry.
3.2.1 Brinell Hardness Test

The Brinell hardness test is the most commonly adopted test for hardness of
iron and steel. In this test a hardened steel ball of 10 mm diameter is impressed
on a flat polished surface of the sample under a load, usually 500 or
3,000 kg. A load of 750 kg with a 5 mm ball is also used. The load is
maintained for 10 to 15 seconds and the diameter of the impression made on the test
piece is subsequently measured by means of a microscope the order of accuracy
being + 0.01 mm.

22
The Brinell hardness number is obtained from the
equation.

BHN = Load on ball/Area of indentation

=P D2
- d2 )]
/[( d/2)(D-

Where, BHN - Brinell hardness number

P - Load applied in kg

D - Diameter of ball in mm

d - Diameter of ball impression in mm

Figure – 3.3 Brinell Hardness Testing Machine

23
3.3 UNIVERSAL TESTING MACHINE

To determine the tensile properties like Ultimate tensile strength yield

strength, percentage of elongation and strain rate sensitivity. It has the following
ways of tests have been tested. They are:

Tensile Test

The most common testing machine used in tensile testing is the universal
testing machine. This type of machine has two crossheads. One is adjusted for the
length of the specimen and the other is driven to apply tension to the test specimen.
There are two types:

Hydraulic powered

Electromagnetically powered machines.

The machine must have the proper capabilities for the test specimen being
tested. There are three main parameters: force capacity, speed, and precision and
accuracy. Force capacity refers to the fact that the machine must be able to
generate enough force to fracture the specimen.

Alignment of the test specimen in the testing machine is critical, because if

the specimen is misaligned, either at an angle or offset to one side, the machine
will exert a bending force on the specimen.

24
 Figure 3.4 Tensile Testing Machine (UTM)

The strain measurements are most commonly measured with an extensometer,

but strain gauges are also frequently used is being measured.

Figure 3.5 Tensile Specimen before Testing

Newer test machines have digital time, force, and elongation measurement
systems consisting of electronic sensors connected to a data collection device and

25
software. Analog machines continue to meet and exceed ASTM, NIST, and ASM
testing to be used today.

Figure 3.6 Tensile Specimen after Testing

26
3.4 WEAR TEST
EDM is one of the most widely used non-conventional machining processes
which uses electrical spark to erode unwanted material and creates desired shape.
EDM process does not involve mechanical energy, the material removal rate is not
influenced by the material properties like hardness, strength, toughness, etc.
Materials with poor machinabilty such as cemented tungsten carbide and
composites can also be processed without much difficulty by the EDM process.

27
 CHAPTER 4
RESULT AND DISCUSSION
4.1 BRINELL HARDNESS TEST

Table 4.1 Brinell Hardness

Test
Brinell hardness number

Sl.No Material
BHN

HB

1. 67
AA8050

2. 74
AA8050 + 5wt. %
ZrO2
AA8050 + 10wt.
%
3. 83
ZrO2

28
 Brinell Hardness Test
90
80
70
Brinell Hardness (BHN)
60
50
40
30
20
10
0 1 2 3
Series1 67 74 83

Figure 4.1 AA8050 Composite Vs Brinell Hardness Test

From the above hardness graph values of the AA8050 + 10% of ZrO2 is
better hardness than the AA8050 + 5% of ZrO2.

AA8050 + 10% of ZrO2 have hardness is 83

BHN. AA8050 + 5% of ZrO2 have hardness is
74BHN. AA8050 have hardness is 68 BHN.
4.2 TENSILE TEST
Table 4.2 Tensile Test
Ultimate
Sl.No Material Tensile % Elongation
Strengt
h
1 AA8050 MPa 7.35
263

2 AA8050 + 5wt. % ZrO2 296 6.25

3 AA8050 +10wt. % ZrO2 310 5.6

29
 Ultimate Tensile Strength
320
310
UTS (MPa) 300
290
280
270
260
250
240
230
1 2 3
Series1 263 296 310

Figure 4.2 AA8050 Composite Vs Ultimate Tensile Strength

Percentage Elongation
8
7
% Elongation

6
5
4
3
2
1
0
1 2 3
Se 7.35 6.2 5.6
rie 5
s1
Figure 4.3 AA8050 Composite Vs Percentage Elongation

30
 From the above Tensile Test graph values of the AA8050 + 10% of ZrO2 is
better Ultimate tensile strength than the AA8050 + 5% of ZrO2.

AA8050 + 10% of ZrO2 have hardness is 310

MPa. AA8050 + 5% of ZrO2 have hardness is 296
MPa. AA8050 have hardness is 263 MPa.

31
 CHAPTER 5
CONCLUSION

AA8050 and (5&10) wt% of ZrO2 reinforcement particles were mixed

successfully by stir casting method.
The mechanical properties were increased with the reinforcements of
10wt% of ZrO2 confirmed by hardness test such as Brinell Hardness
test and Tensile test.

32
 CHAPTER 6
REFERENCE
1.M.C.Y. Niu, Composite Airframe Structures, 2nd ed., Hong Kong Conmilit
Press Limited, 2000 High-Performance Composites Sourcebook 2009, Gardner
Publications.
2.R .E. Horton and J.E. McCarty, Damage Tolerance of Composites, Engineered
Materials Handbook, Vol 1, Composites, ASM International, 1987.
3.S.K. Mazumdar, Composites Manufacturing:Materials, Product, and Process
Engineering,CRC Press, 2002.
4.L. J. Ebert, P. K. Wright: Mechanical Aspects of the Interface, in Interfaces in
Metal Matrix Composites, A. G. Metcalfe (Ed.), Academic Press, New York
(1974).
5.R. F. Tressler, Interfaces in Oxide Reinforced Metals, in Interfaces in Metal
Matrix Composites, A. G. Metcalfe (Ed.), Academic Press, New York (1974).
6. K. U. Kainer, Herstellung und Eigenschaften von faserverstärkten
Magnesium
verbund werkst offen, in: DGM Information s gesellschaft, K. U. Kainer (Ed.),
Oberursel (1994).
7.Graf, K. U. Kainer, Einfluß der Wärmebehandlungen bei
Al2O3- kurzfaserverstärktem Magnesium, Prakt. Metall(1993).

33