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CONTENTS
Abstract
Introduction
Literature Survey
Al6082 Properties
Procedure
Ilmenite Powder
Tests and their procedure
References
Results
ABSTRACT
In this aluminum alloy Al6082 was reinforced with the ilmenite
powder (FeTiO3) by stir casting method. In this experiments were
conducted by varying weight fraction of ilmenite powder (0% , 5% ,
10% , 15% ).
The mechanical properties of material can be studied by using
tensile, fatigue and wear tests. Microstructure of the Al6082 composite
can be studied to investigate the grains in alloy and good dispersion of
reinforcements in the matrix for the composite.
INTRODUCTION
Aluminum based metal matrix composite has emerged as an important class
of high performance material for use in Aerospace, Automobile because of its
improved strength.
In liquid state methods, the ceramic particulates are incorporated
into a molten metallic matrix and casting of the resulting MMC is done. Stir
Casting is a liquid state method of composite materials fabrication, in which a
ceramic particle is mixed with a molten matrix.
Aluminum 6082 is a metal alloy with high hardness, thermal conductivity but it has
poor corrosion resistance. So in this we reinforce FeTiO3 with this alloy to increase
in mechanical properties, such as Tensile, Fatigue, Microstructure, Wear resistance.
Ilmenite is an oxide mineral with bulk density of 4.55gm/cc. It is a nonfluorescent and submetallic, black colored mineral. It crystallizes in trigonal
system.
LITERATURE SURVEY
Al6082 PROPERTIES
Typical material properties for 6082 aluminum alloy include:[2]
Density: 2.71 g/cm3, or 169lb/ft3 .
Young's modulus: 71 Gpa , or 10 Msi .
Ultimate tensile strength: 140 to 330 MPa, or 20 to 48 ksi.
Yield strength: 90 to 280 MPa, or 13 to 41 ksi.
Thermal Expansion: 23.1 m/m-K.
Solidus: 575C or 1070F.
PROCEDURE
CASTING PROCESS:
First we take BASE METAL, taking 600g of Al2014 and must be
melted in the Stir Casting machine(capacity 1050c).
Now the melted form is poured in the die we had taken.
Second we take 5% of ilmenite powder and 570g of Al6082 metal.
The Ilmenite powder is heated in the Muffle Furnace for about
600c.
The heated powder is wrapped into aluminum coil sheet piece.
Mean while the Al6082 metal must be heated in the Stir Casting
machine.
After the completion of stirring in the Stir Cast Machine, the melted
form is poured in the die for the model.
This is repeated for 10% and 15% also.
Electrical Heater
TABULAR FORM:
AL6082
Wt of Wt of
AL
ilmenite
(g)
powder(g)
Stir
castingm/c
temp.(0c)
Time of
heating
rods(hr)
Muffle
furnace
temp.
(0c)
Time of heating
powder(hr)
BASE
METAL
600g
900
1 hr
5%
570g
30g
900
1hr
600
hr
10%
540g
60g
900
1 hr
600
hr
15%
510g
90g
900
1 hr
600
hr
ILMENITE POWDER(FeTiO3)
TESTS
TENSILE TEST
Tensile strength is the capacity of a material or structure to withstand
loads tending to elongate, as opposed to compressive strength, which
withstands loads tending to reduce size. In other words, tensile
strength resists tension (being pulled apart), whereas compressive
strength resists compression. Ultimate tensile strength is measured by
the maximum stress that a material can withstand while being
stretched or pulled before breaking.
Specimen
FATIGUE TEST
Fatigue is the weakening of a material caused by repeatedly applied
loads Fatigue strength used to describe a property of materials: the
amplitude of cyclic stress that can be applied to the material without
causing fatigue failure. The ASTM defines fatigue strength, SNf, as
the value of stress at which failure occurs after Nf cycles, and fatigue
limit, Sf, as the limiting value of stress at which failure occurs as Nf
becomes very large. Fatigue occurs when a material is subjected to
repeated loading and unloading. If the loads are above a certain
threshold, microscopic cracks will begin to form at the stress
concentrators such as the surface, persistent slip bands (PSBs), and
grain interfaces. Eventually a crack will reach a critical size, the crack
will propagate suddenly, and the structure will fracture.
WEAR TEST
Wear is related to interactions between surfaces and specifically the
removal and deformation of material on a surface as a result of
mechanical action of the opposite surface. Wear is erosion or sideways
displacement of material from its "derivative" and original position on a
solid surface performed by the action of another surface. Wear can also
be defined as a process where interaction between two surfaces or
bounding faces of solids within the working environment results in
dimensional loss of one solid, with or without any actual decoupling and
loss of material.
MICROSTRUCTURE
Microstructure is defined as the structure of a prepared surface of
material as revealed by a microscope above 25 magnification. The
microstructure of a material (such as metals, polymers, ceramics or
composites) can strongly influence physical properties such as
strength, toughness, ductility, hardness, corrosion resistance, high/low
temperature behavior or wear resistance.
RESULTS:
TENSILE TEST
FOR AL6082 PURE
FOR AL6082 5%
Specimen
Label
Maximum Load
(KN)
Load at break
(KN)
UTS (MPa)
Tensile stress at
yield
offcet(0.2%)
1Modules (MPa)
Load at 2%
strain (KN)
0%
9.36
7.32
186.21
107.79
16634.37042
7.09
5%
2.62
1.64
52.10
52.07
14364.80255
10%
3.82
2.48
75.90
69.18
12779.10919
15%
2.90
2.01
57.76
53.05
9796.09528
6082
WEAR TEST
FOR AL6082 PURE
FOR AL6082 5%
MICROSTRUCTURE RESULTS
0% 5X
5% 5X
10% 5X
15% 5X
0% 10X
5% 10X
10% 10X
15% 10X
0% 20X
5% 20X
10% 20X
15% 20X
0% 50X
5% 50X
10% 50X
15% 50X
6082
ILMENITE%
TRAIL 1
TRAIL 2
TRAIL 3
AVERAGE
101.7
102.9
109
105.53
189.5
225.3
275.1
229.96
10
237.6
232.8
251
240.46
15
217.3
271.1
238.3
242.23
HARDNESS GRAPH
250
200
150
Average value
100
50
X370
X500
X250
X330
6082 10%
X230
X700
X400
X270
X300
X230
Quantitative Result
Quantitative results
0.6
W e ig h t %
0.5
0.4
0.3
0.2
0.1
0.0
-0.1
O
Mg
Al
Ti
Cr
Mn
Fe
Zn
Al6082 10%
Quantitative result
Quantitative results
0.6
W e ig h t %
0.5
0.4
0.3
0.2
0.1
0.0
-0.1
O
Mg
Al
Cr
Mn
Fe
Zn
Equivalent Stress
Normal Stress
Conclusion
By comparing
References
Dora siva Prasad,
D.J. Smith , G. Zheng, P.R. Hurrell , C.M. Gill, B.M.E. Pellereau , K. Ayres D. Goudar
c, E. Kingston, Measured and predicted residual stresses in thick section electron beam
welded steels, International Journal of Pressure Vessels and Piping 120-121 (2014) 6679
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