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CHAPTER 3

FABRICATION OF Al-356 METAL MATRIX COMPOSITE

3.1 INTRODUCTION

Aluminium MMC based composites reinforced with hard ceramic

particles have generated considerable interest owing to their ease of
processing isotropic properties compared to the fibre-reinforced composites.
Further, these composites display high strength and stiffness, greater creep
resistance and enhanced wear resistance apart from providing good electrical
and thermal conductivity.

3.1.1 Fabrication of Metal Matrix Composites (MMCs)

Presently, the manufacturers follow various techniques/ schemes

for manufacturing different grades of AMCs. Based on the type of
reinforcement the AMCs can be classified into the following types:

1. Particle reinforced

2. Whisker or short – fibre reinforced

3. Continuous or long fibre reinforced

4. Mono filament reinforced

With conventional casting techniques for metals it is difficult to

control the microstructure and the metal-ceramic interface, both of which are
imperative for achieving better mechanical properties, during processing.
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Though several research attempts were made into the production of metal
matrix composites, a potential and satisfactory production method was not
evolved. The properties of the composites were either better by a negligible
margin or even worse than that of the un-reinforced metal or the processing
charges was unreasonably high. Eventually, after about two decades of
constructive development of traditional metal processing methods, it was
evident that if MMCs were to be produced in an economical way, new and
innovative production methods, dedicated for metal matrix composite
materials, were desired. The MMCs produced by these new methods have
been referred to as second generation MMCs

3.2 VARIOUS PROCESSES FOR FABRICATION OF MMCs

Manufacturing of AMCs are typically classified into two key

categories viz., solid - state processing and liquid state processing. Solid -
state processing comprises powder grinding followed by consolidation,
diffusion bonding and vapor deposition techniques. Stir casting, infiltration,
spray casting and reactive in-situ processing methods are classified under
liquid state processing.

3.2.1 Solid State Processing

In this process Metal Matrix Composites are fabricated as a result

of bonding matrix metal and dispersed phase due to mutual diffusion
occurring between them in solid states at elevated temperature and under
pressure. Low temperature of solid state fabrication process (as compared to
Liquid state fabrication of Metal Matrix Composites) depresses undesirable
reactions on the boundary between the matrix and dispersed (reinforcing)
phases. Metal matrix composites may be deformed also after sintering
operation by rolling, forging, and pressing, Drawing or Extrusion. The
deformation operation may be either cold (below the recrystallization
 39

temperature) or hot (above the recrystallization temperature). Deformation of

sintered composite materials with dispersed phase in the form of short fibers
results in a preferred orientation of the fibers and anisotropy of the material
properties (enhanced strength along the fibers orientation).

There are two principal groups of solid state fabrication of Metal

Matrix Composites:

1. Diffusion bonding and

2. Sintering or powder metallurgy

1. Diffusion Bonding

Diffusion Bonding is a solid state fabrication method, in which a

matrix in the form of foils and a dispersed phase in form of long
fibers are stacked in a particular order and then pressed at an
elevated temperature. The finished laminate composite material
has a multilayer structure.

Figure 3.1 Variants of diffusion bonding

The variants of diffusion bonding are classified into roll bonding

and wire/fiber winding
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1. Roll Bonding is a process of combined Rolling (hot or cold)

strips of two different metals (e.g. steel and aluminum alloy)
resulting in formation of a laminated composite material
with a metallurgical bonding between the two layers.

2. Wire/fiber Winding is a process of combined winding

continuous ceramic fibers and metallic wires followed by
pressing at elevated temperatures. Mono filament-reinforced
AMCs are majorly fabricated by the diffusion bonding (foil-
fibre-foil) or by the evaporation of relatively thick layers of
aluminium on the surface of the fibre. 6061 Al-boron fibre
composites have been fabricated by diffusion bonding
through the foil-fibre-foil process. However, the process is
more commonly used to produce Ti based fibre reinforced
composites (Surappa 2003).

3. Sintering or Powder Metallurgy Processing

Sintering fabrication of Metal Matrix Composites is a

process, in which a powder of a matrix metal is mixed with a
powder of dispersed phase in the form of particles or short
fibers for subsequent compacting and sintering in solid state
(sometimes in the presence of liquid). Sintering is the
method involving consolidation of powder grains by heating
the “green” compact part to a high temperature below the
melting point, when the material of the separate particles
diffuse to the neighbouring powder particles shown in
Figure 3.2
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Figure 3.2 Schematic presentation of the sintering process

In contrast to the liquid state fabrication of Metal Matrix

Composites, sintering method allows obtaining materials containing up to
50% of dispersed phase. When sintering is combined with a deformation
operation, the fabrication methods are called:

1. Hot Pressing Fabrication of Metal Matrix Composites

2. Hot Isostatic Pressing Fabrication of Metal Matrix Composites

3. Hot Powder Extrusion Fabrication of Metal Matrix Composites

4. Hot Pressing Fabrication of Metal Matrix Composites

Powder Metallurgy involves the blending of rapidly solidified

powders with particulates, platelets or whiskers, through a series of steps. The
sequence of steps include sieving of rapidly solidified particles, blending of
the particles with the reinforcement phases, compressing the reinforcement
and the matrix mixture to about 75 percent density, degassing and final
consolidation by extrusion, forging, rolling or any other hot working method.
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Advantages of Powder Metallurgy

1. Porous products like self lubricating bearings, filters, oil

pump etc., are manufactured by this process.

2. Refractory made out of tungsten, titanium, and molybdenum

used in electric bulb, radio valves, anode, control grids, X-
ray tube in the form of filament cathode etc.,

3. Products of metallic and non-metallic combinations are

produced.

4. Light – weight parts of moderate strength can be produced

economically through this process.

3.2.2 Liquid State Processing

Liquid state fabrication of Metal Matrix Composites involves the

incorporation of dispersed phase into a molten matrix metal, followed by its
solidification. In order to provide the high level of mechanical properties of
the composite, good interfacial bonding (wetting) between the dispersed
phase and the liquid matrix should be achieved. Wetting improvement may be
achieved by coating the dispersed phase particles (fibers). Proper coating not
only reduces interfacial energy, while also preventing the chemical interaction
between the dispersed phase and the matrix.

The methods of liquid state fabrication of Metal Matrix Composites

are as follows:

1. Melt Stirring or Stir Casting

2. Gas Pressure Infiltration

3. Squeeze Casting Infiltration or Pressure Die Infiltration

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3.2.2.1 Melt stirring or stir casting

Stir Casting is the simple and economical method of liquid state

fabrication. In this method,the dispersed phase (ceramic particles, short fibers)
is mixed with a molten matrix metal by means of mechanical stirring. This is
followed by liquid composites by conventional casting methods and may also
be processed by conventional metal forming technologies.

Stir Casting is characterized by the following features, Viz.,

Content of dispersed phase which is limited (usually not more than 30 vol. %)
and distribution of dispersed phase throughout the matrix which may not be
exactly 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 particles often tend to form agglomerates, which demand

intense stirring. Before dissolving, caution is required before the dispersion of
the reinforcement components, due to the reactivity of the components used in
coordination with the temperature of the melt and the duration of stirring,
since reactions with the melt can lead to the dissolution of the reinforcement
components. Attributed to their lower surface to volume ratio of spherical
particles, reactivity is generally less critical with the stirred particle
reinforcement than with the fibers. The melt can be cast directly or processed
with alternative procedures such as squeeze casting or thixocasting shown in
Figure 3.3.
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Figure 3.3 Schematic Operational Sequences during Melt Stirring

Figure 3.4 Gas Pressure Infiltration Techniques

3.2.2.2 Gas pressure infiltration process

In gas pressure infiltration, the melt infiltrates the preform with a

gas applied from the external sources. A gas that is inert with respect to the
matrix is applied. The melting of the matrix and the infiltration take place in a
suitable pressure vessel. The molten bath is pressed to the preform by the
 45

applied gas pressure using a standpipe and followed by infiltrating the bath as
shown in Figure 3.4.

The beneficial aspects of this procedure are that there is no

development of pores when completely dense parts are present.

3.2.2.3 Squeeze casting or pressure casting

Squeeze casting or pressure casting are the usually employed

manufacturing variants for MMCs. After a slow mould filling the melt
solidifies under very high pressure, leading to a fine-grained structure. In
comparison with the die-casted parts the squeeze-casted parts do not contain
gas inclusions enabling thermal treatment of the fabricated
specimens/components shown in Figure 3.5.

Figure 3.5 (a) Direct Squeeze Casting and (b) Indirect Squeeze Casting

Vortex mixing is another technique developed by Rohatgi (2010),

which are yet to be adopted by various industrial firms and hence not
discussed in detail.
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3.2.3 In-situ Processing (Reactive Processing)

London and Scandinavian Metallurgical Company developed an in-

situ technique, which is benefited by the reaction between the mixed salts to
produce a dispersion of the fine TiB2particles in an aluminium matrix. The
same technique has been employed in this research work also for the
manufacturing of Al-TiB2 composite.

3.3 CASTING OF ALUMINIUM METAL MATRIX

COMPOSITES

Aluminium casting processes are classified as Ingot casting or

Mould casting. During the first process, primary or secondary aluminium is
cast into rolling ingot (slab), extrusion ingot (billet) and wire bar ingot which
are subsequently transformed in semi- and finished products.

The second process is used in the foundries for producing cast

products. This is the oldest and simplest (in theory but not in practice) means
of manufacturing shaped components.

This section describes exclusively Mould casting which can be

divided into two main groups:1.Sand casting and 2.Die casting

3.3.1 Sand Casting

In sand casting, re-usable, permanent patterns are used to make the

sand moulds. The preparation and the bonding of this sand mould are the
critical stepsthat govern the rate-controlling steps of this process. Steps of this
process. Two main routes are used for bonding the sand moulds:

• The "green sand" consists of mixtures of sand, clay and

moisture.
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• The "dry sand" consists of sand and synthetic binders cured

thermally or chemically.

3.3.2 Die Casting

In die casting, the mould is permanent, and not destroyed since it is

made up of metals such as cast iron or steel. The die casting processes, are
presented in Figure 3.6. High pressure die casting is highly preferred for all
light alloys casting production.(Approximately 50%). Low pressure die
casting accounts for the nearly 20% ofproduction. Gravity die casting
attributes for the rest, with the small contribution from the vacuum die casting
and squeeze casting process, which are gradually gaining significance.

Figure 3.6 Classifications of die casting processes

3.4 SAMPLE PREPARATION BY SAND CASTING METHOD

In the present investigation sand casting is used which involves

pouring the molten metal into a sand mould. Many metal casters prefer using
sand casting over many of the other forms of processes because it's cheap and
the sand used is readily available. In sand casting, a mould is created inside
the frame of the mould (flask) as shown in the Figure3.7 and Figure 3.8 which
are filled with sand. The top and the bottom of the mould (cope and drag) are
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tightly packed so that the molten metal does not creep outside the parting line.
Green sand is a type of casting sand that is widely used to retain the shape of
the mould and it is far better than normal sand. Green sand usually contains
bentonite clay, sand, and water. One of the benefits of using bentonite in
green sand is that it makes the sand more permeable which allows more gas to
escape. Care should be taken that too much water can ruin the mould and
possibly destroy it while too little water will create a poor casting.

Figure 3.7 Mould for the sand casting method

After the sand is packed, the pattern or original is removed

carefully. Then a series of channels or gates, to carry the molten metal to the
cavity, is incorporated. Molten metal is poured through the pouring cup which
flows through the vertical channel called sprue. The runner guides the molten
metal in to the core. The vents provided allow the air and the gasses that is
formed during the molten state. After the required time the mould is allowed
to cool. The metal casting is then shaken out after which the required forms of
the samples are prepared.
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Figure 3.8 Sand casting method adopted for the present investigations.

3.4.1 Experimental Sample Compositions used in the Present

Investigation

Aluminium, fly ash and magnesium with different compositions of

90:9:1, 85:14:1 and 80:19:1 was mixed by the stir casting process and was
named as Sample-1, Sample-2 and Sample-3 respectively. Standard fly ash
particles were used for the present study which was procured from a thermal
power plant from Mettur Dam; Salem, India was used in the present
investigation. Sand casting process was adopted to fabricate the samples in to
required size which was then used for mechanical and Tribological analysis.
In all the samples, the magnesium content was added small in quantity and
was maintained at 1 % to increase the wettability of fly ash with the metal
matrix. The fly ash content is increased, thus by decreasing the aluminium
content to ascertain the variation in Tribological properties.
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3.5 MATERIALS AND METHODS

3.5.1 Sample preparation for Al-SiC-FA MMC (SiC @ 5 %)

Aluminium, SiC, fly ash and magnesium were mixed by stir casting
process with different compositions of 90:5:4:1, 85:5:9:1, 80:5:14:1, and
75:5:19:1. These were melted by stir casting process and then by sand casting
the required preforms were prepared by traditional sand casting method. In
the whole process, the SiC content was maintained at 5 %, with only the fly
ash content is varied to investigate the mechanical and Tribological
properties.

The percentage compositions of the samples are provided in

Table 3.1.

Table 3.1 Percentage compositions of the samples Al-SiC MMC (SiC

@ 5 %)

Sample No. Aluminium SiC Fly ash Magnesium

1 90 5 4 1
2 85 5 9 1
3 80 5 14 1
4 75 5 19 1

In all the samples, the magnesium content was added small in

quantity and was maintained at 1 % to increase the wettability of flyash with
the metal matrix. The flyash content is increased, thus by decreasing the
aluminium content to ascertain the variation in tribological properties.
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3.5.2 Sample preparation for Al-SiC-FA MMC (SiC @ 10 %)

The composition of the aluminium was varied as 75, 80 and 85 %.

The SiC content was maintained at 10 %. The fly ash content was varied as
14, 9 and 4 %. The magnesium content was mixed at 1 %. Homogeneous
melting was done for the above mentioned compositions and then the samples
were fabricated by sand casting method. The obtained samples were then
mounted on the spindle of wear and friction set-up to measure the tribological
behavior. The standard samples (pins – cylindrical shape) have been prepared
(Ø12mm × 40 mm) out of castings with different wt. % of aluminium is
shown in Figure.3.9.

Aluminium-SiC-fly ash-magnesium metal matrix composites with

different ratio were melted and sand casting process was applied to fabricate
the required samples. The percentage compositions of the samples are
provided in Table 3.2.

Table 3.2 Percentage compositions of the samples Al-SiC MMC (SiC

@ 10 %)

Sample .No. Aluminium SiC Fly ash Magnesium

1 75 10 14 1
2 80 10 9 1
3 85 10 4 1
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Figure 3.9 Al-SiC-Fly ash metal matrix samples used for standard
Wear Test

3.5.3 Sample preparation for Al-SiC-FA MMC (FA @ 14 %)

Three different composites were prepared as follows: (Al-80 % :

SiC – 5 %), (Al-75 % : SiC – 10 %), (Al-70 % : SiC – 15 %) and in addition
(Al-85 %) with SiC – 0 % for reference purposes. The required aluminium,
SiC, flyash and magnesium 1% was melted and the samples were moulded to
required shapes by using sand casting technique. In the whole process, the fly
ash content was maintained at 14 %, and the SiC content is varied to
investigate the Tribological properties. Table 3.3 presents the percentage
compositions.

Table 3.3 Chemical compositions of the samples

Sample No. Aluminium SiC Flyash Magnesium

1 85 0 14 1
2 80 5 14 1
3 75 10 14 1
4 70 15 14 1
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3.6 SUMMARY

Solid state and liquid state processing for fabrication of Al-356

Metal Matrix Composite were discussed in detail. Liquid state processing
comprises stir casting, infiltration, spray casting and reactive processing
methods were explained. The present study utilizes sand casting method for
the preparation of samples. Totally eleven specimen with varying composition
of SiC, Flyash, Magnesium reinforced with Aluminium were fabricated.