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ABSTRACT

Metal matrix composites (MMCs) combine a stiff but brittle phase, typically a ceramic, with a more ductile metal matrix. The correct fractional combination of materials can result in a material with improved stiffness, creep resistance, yield stress and wear resistance relative to the monolithic matrix. The use of MMCs in recent years has become more widespread due to growing understanding of the dependence of composite properties on a number of factors (e.g., interface properties, metallurgy of the matrix and stress partitioning between the constituent phases) and appreciation of the problems that can occur in their usage. The most commonly used discontinuously reinforced metal matrix composites consist of Aluminium alloy reinforced with SiCp, Al2O3 or graphite particles. Aluminiumsilicon alloys are one of the most commonly used foundry alloys because they offer many advantages such as good thermal conductivity, excellent castability, high strength-to-weight ratio, wear and corrosion resistance, pressure tightness and good weldability. They are therefore well suited to automotive cylinder heads, engine blocks, aircraft components, pipe fittings and military applications. The mechanical properties of Aluminiumsilicon alloys are related to the grain size, and the shape, size and distribution of the discontinuous phase. LM25 is an Aluminium-Silicon alloy which is commercially available and used for above said applications, but FSW of LM25-SiC was not reported in many literature. LM25 based metal matrix composites find applications in aerospace and

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automotive industries where the temperature plays a vital role. The material may be subjected to different temperatures like elevated and cryogenic temperature. The mechanical, wear and corrosion properties of metal matrix composites treated at different temperatures after welding were not reported in many literatures. The main objective of the present research work is to manufacture the metal matrix composites, weld using GTAW and FSW, subject it to post weld heat treatment and compare the hardness, corrosion and wear behaviors of GTA welded and FS welded LM25-SiC MMCs. Stir casting method was used to manufacture the LM25-SiC MMCs. MMCs containing 5%, 10% and 15% SiC were manufactured by stir casting process. The fabricated MMCs were welded by GTAW and FSW processes. The welded composites were treated at elevated temperature and cryogenic temperature. Pitting corrosion and wear tests were carried out for GTA and FS welded MMCs. Box Benkehn design and analysis of variance (ANOVA) were employed to develop regression models for analyzing the influence of process parameters on microhardness, corrosion and wear behavior of MMCs. Second order quadratic mathematical models were developed to correlate the process variables with microhardness, pitting potential and wear rate. The results revealed that the microhardness of MMCs increased with the increase in % SiC. The microhardness of cryo treated composites was higher than that of as welded composites. The composite treated at elevated temperature had slightly higher microhardness than that of as welded composite specimens. The microhardness of GTA welded MMCs initially

increased with the increase in welding current and then decreased with the further increase in welding current. The microhardness of FS welded MMCs increased with the increase in tool rotational speed. FS welded MMCs had higher microhardness than that of GTA welded MMCs. The tensile strength of GTA and FS welded MMCs was high containing 15% SiC. It was found that the tensile strength of FS welded MMCs was higher than that of GTA welded MMCs. The experiments on pitting corrosion test revealed that the pitting potential was high in MMCs containing 15% SiC compared to MMCs containing 5% and 10% SiC, joined by GTAW and FSW. Pitting potential of GTA and FS welded MMCs treated at elevated temperature was higher than that of GTA and FS welded MMCs treated at cryogenic temperature and as welded MMCs. The pitting potential of GTA welded composites and parent material was less than that of FS welded composites. The study on wear behavior of welded MMCs revealed that the wear rate of composites containing 5% SiC was high and that of composites containing 15% SiC was less. The wear rate of composites treated at cryogenic temperature was less and it increased with increase in temperature. The wear rate of FS welded composites was less than that of GTA welded composites and parent material. The present study concludes that the FSW is more advantageous for welding MMCs compared to GTAW process. These investigations may help

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the designers and manufacturers to use these welded LM25-SiC MMCs for aerospace and automobile applications. Properties of hybrid composites can also be studied and they may be characterized using XRD and EDAX. Keywords: Metal Matrix Composites, Gas Tungsten Arc Welding, Friction Stir Welding, Stir Casting, Post Weld Heat Treatment, Cryogenic Temperature, Elevated Temperature, Design of Experiments, Box Benkehn Design, Welding Current, Tool Rotational Speed, Pitting Potential, Corrosion Potential, Microhardness, Wear.