Effect of Al2O3 On Mechanical Behaviour of The Stir-Cast Aluminium Alloy Metal Matrix Composites

IPASJ International Journal of Mechanical Engineering (IIJME)
A Publisher for Research Motivation........
Volume 3, Issue 5, May 2015
Web Site: http://www.ipasj.org/IIJME/IIJME.htm

Email: editoriijme@ipasj.org
ISSN 2321-6441
Effect of Al2O3 on Mechanical Behaviour of the

Stir-Cast Aluminium Alloy Metal Matrix
Composites
1
Srestha Das ,R.Behera2 , B Nayak3
M.Tech.Scholar, Centurion University of Technology and Management, Bhubaneswar, Odisha 752050
Professor, Mechanical Engineering Department, Seemanta Engg. College, Mayurbhanj, Odisha,757086;
Associate Professor,Centurion University of Technology and Management, Bhubaneswar, Odisha 752050
ABSTRACT
Aluminium and its alloy based cast metal matrix composites have gained lot of popularity in all the emerging fields of
engineering and technology because of their superior mechanical properties compared to monolithic materials. The desired
properties of the metal matrix composites have influenced by the weight percentage of reinforcements in the cast metal matrix
composites, which imposed to study the mechanical behaviour of the cast metal matrix at different weight fraction of
reinforcement particles. The present paper aims to investigate the mechanical behaviour of aluminium alloy (LM6)- Al2O3p
composites at different weight fraction of reinforcement particles, which were produced by using stir cast technique.
Experiments were carried out over range of particle weight percentage of 2.5 -7.5 wt% in steps of 2.5wt%. The experimental
results show that the mechanical properties of cast MMCs are different at different weight percentage of Al2O3p. The
morphology of cast MMCs indicates that the distribution of Al2O3p is not uniform throughout the casting.
Key words: LM6, Al2O3, Metal matrix composites (MMCs), hardness, strength.
1. INTRODUCTION
There have been much pioneering efforts over the last 40 years in the development of MMCs as new engineering
materials; those have improved properties, and lightweight characteristics and competitive costs compared to
traditional materials. Recently, metal-matrix composites (MMCs) are emerged as potential alternatives to conventional
alloys in high-strength and stiffness applications [1]. But, the cost is the key factor for their wider application in
automotive and aerospace industries, although potential benefits in weight saving, increased component life, and
improved recyclability should be taken into account [2]. Today, even in those terms, MMCs are still significantly more
expensive than their competitors. Only simpler fabrication methods, higher production volumes, and use of cheaper
reinforcements [1] can reduce the cost of MMCs. There are several methods are used to manufacture aluminium alloy
based metal matrix composites such as powder metallurgy (PM), where metal and ceramic powders are blended and
hot-pressed [3], and liquid-state processes such as melt infiltration [4-8], compo casting, blending of ceramic powder
and molten aluminium, and casting, melt stirring [9-15], pressurized infiltration and squeeze casting [16-30]. Out of
which melt-stir casting technique is one of the cost effective and quite popular methods due to its unique advantages. In
this technique, the reinforcement particles are introduced directly into the liquid melt and stirred the melt at a suitable
stirring speed thoroughly to ensure their proper mixing in the matrix alloy.
The objective of the present investigation is to study the effect of varying weight percentage of Al2O3 on the mechanical
behaviour and the metallographic properties of the aluminium-silicon alloy (LM6) matrix composites. The results are
compared with the solidification behaviour of aluminium alloy i.e.LM6.
2. METHODOLOGY
The aluminiumsilicon alloy i.e.LM6, which is a well known alloy of aluminium, is used as the base/matrix metal in
the experiments for the fabrication of the composites that has been reinforced with 2 wt%, 4 wt% and 6 wt. % of Al2O3
of average 400 mesh size. The chemical composition of the matrix material (LM6) and the thermo physical properties
of aluminium alloy, Al2O3 & sand have given in the table-1 & table-2. The composites are fabricated by the liquid
metal stir casting technique. The aluminium alloy is melted in clay graphite crucible using an electric resistance
furnace and 3wt.% Mg has been added with the liquid metal, in order to achieve a strong bonding by decreasing the
surface energy (wetting angle) between the matrix alloy and the reinforcement particles. The addition of pure
magnesium has also enhanced the fluidity of the molten metal. The melt has mechanically stirred by using an impeller
after addition of the pre-heated Al2O3 particle (about 850-9000C). The processing of the composite has carried out at a
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ISSN 2321-6441
temperature of 7500C with a stirring speed of 400-500 rpm. The melt has poured at a temperature of 745 0C into a
silica sand mould. The geometry of mould cavity has shown in Fig.1. The figure of composite casting has shown below
in Fig.2. Experiments carried out for a wide range of particle weight percentage varying from 2 to 6% in steps of 2%.
The micro structural characteristics of the alloys and composites of the castings have also evaluated.
Elements
Si
Percentage (%)
10-13.0
TABLE-1 Chemical Composition (LM6)

Cu Mg Fe Mn
Ni
Zn Pb
0.1
0.1
0.6
0.5
0.1
0.1
Sb
Ti
0.1 0.05 0.2
Al
Remaining
TABLE-2 Thermo physical properties of the matrix, reinforcement particle and sand
Properties
LM6
SiC particulates
Sand
Density(gm/cm3)
2.66
3.2
1.6
Average particle size ( mesh)
------400
----Thermal conductivity(W/m-K)
155
100
0.52
Specific heat (J/Kg-K)
960
1300
1170
Figure:1.0.The geometry of mould cavity (All dimensions are in mm)
Figure:2.0. Composite casting.
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ISSN 2321-6441
3. RESULT AND DISCUSSION

3.1. Microstructural Analysis
Samples of as cast MMCs for metallographic examination are prepared by grinding through 320, 400, 600, 800, 1200
and 1500 grit papers followed by polishing with 6 m diamond paste. Then the samples are etched with the etchant i.e.
Kellers reagent (2.5 ml Nitric acid, 1.5 ml HCl , 1.0 ml HF,95.0 ml Water) . The etched samples are dried by using
electric drier and then the microstructure observed by scanning electron microscope (SEM) (JEOL, JSM 6360). The
microstructure of the as cast LM6 MMCs are shown in Fig. 3.1-3.4 at different percentage of reinforcement particles
(i.e. Al2O3). The micrograph of MMC castings shows that the distributions of SiC particles are not uniform throughout
the casting and segregation of particles are more in the middle section of the castings. This tendency may be attributed
to the fact that the rate of cooling is not uniform throughout the casting due to slower rate of cooling in the sand mould.
Fig 3.1. SEM Image of Al alloy (LM6)
Fig 3.3. SEM Image of Al alloy

(LM6)+4% Al2O3.
Fig 3.2. SEM Image of Al alloy (LM6)+2% Al2O3
Fig 3.4. SEM Image of Al alloy

(LM6)+6% Al2O3.
3.2. Hardness of the as-cast MMCs

Hardness is often a function of the particle size, porosity, and binder material. Hardness is very important to the success
of machining operations. Hardness is one of the important mechanical properties in case of composite material as the
hardness of the matrix metal is very low, which limits its wide application. The hardness of the matrix metal enhances,
due to reinforcement of ceramic particles with it. The hardness of the samples was measured using Vickers micro
hardness measuring machine by applying a load of 10gm and this load was applied for 20 seconds. The experimental
results reveals that the hardness of the as cast MMCs are increases on increasing the weight percentage of Al2O3
particulates in matrix metal i.e. LM6, shown fig 4.0.
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Figure: 4.0. Effect of wt% of Al2O3 on the hardness of as cast MMCs

3.3. Tensile Behaviour of as-cast MMCs
The important properties which come into play when a component is subjected to tensile loads are strength, Elasticity
& Ductility. From the as-cast MMCs, the standard tensile specimen were prepared by machining. The specification of
standard tensile sample and tensile test specimens are shown in Fig. 5.0(a) and (b).
The experimental result shows that the tensile strength of the as cast MMCs produced are somewhat higher than that of
the non-reinforced LM6 alloy. Fig.6.0 shows that the ultimate tensile strength of composites increases on increasing the
weight fraction of Al2O3 in the matrix metal i.e.LM6. The percentage of elongation gradually decreases on increasing
the weight percentage of Al2O3 in the matrix metal; shown in Fig.7.0. It is observed that the addition of silicon carbide
particles improves the tensile strength of the composites.
Figure: 5.0 (a). Specification of standard tensile sample.
Figure:5. 0(b).Tensile specimens for testing.
Figure:6.0. Effect of wt% of Al2O3 on the tensile

Figure:7.0 Effect of wt% of Al2O3 on the percentage
strength of as cast MMCs.
of reduction of as cast MMCs.
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4. CONCLUSIONS
The experimental study on the microstructural behaviour and mechanical behaviour of the LM6 reinforced with Al2O3
composites at different weight fraction of Al2O3 concluded, the following points: The microstructural analysis of MMC castings at different weight fraction of Al2O3p shows that the distributions of
Al2O3 particles are not uniform throughout the casting and segregation of particles are more at the middle of the
castings.
The mechanical behaviour of the as cast Al alloy/Al2O3 metal matrix composites such as hardness and tensile
strength of the casting are enhanced on increasing the weight percentage of Al 2O3 in the matrix metal.
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Effect of Al2O3 On Mechanical Behaviour of The Stir-Cast Aluminium Alloy Metal Matrix Composites

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IPASJ International Journal of Mechanical Engineering (IIJME)

A Publisher for Research Motivation........

Volume 3, Issue 5, May 2015

Web Site: http://www.ipasj.org/IIJME/IIJME.htm