MECHANICAL BEHAVIOUR OF ALUMINIUM AND STAINLESS STEEL METAL MATRIX COMPOSITE

NAME OF THE SCHOLAR NAME : L .Shanmuga Raj ROLL NO : 10CCR016 CLASS : M.E (CAD/CAM) Department of Mechanical Engineering, School of Building and Mechanical Sciences, Kongu Engineering College, Erode - 638052 NAME OF THE SUPERVISOR NAME : Mr. P .Muthu Kumar Designation : Asst . Professor Department of Mechanical Engineering, School of Building and Mechanical Sciences, Kongu Engineering College, Erode - 638052

INTRODUCTION
The aluminium metal matrix composite has various advantages when combined with stainless steel fibre reinforced. This project discuss about the experimental and analysis result of the metal matrix composite. The mechanical behaviour like stress strain behaviour, yield strength, has been increased on adding this reinforcement. Hence the aluminium and stainless is been used in many applications like high strength, good corrosive resistance, stiffness and low thermal expansion.

The welding is also a process of joining two parts into one. But when investigated microscopically the accuracy will be less when compared to diffusion bonding. As in aerospace and in nuclear applications such precise and accurate bonding results have been obtained. It is well known that Almatrix composites are used in various applications like landing gear for

aircraft, space shuttle, various satellite components for and various

armoured vehicles.

TYPES OF COMPOSITES
Fibre reinforced plastics Sandwich structures Fibre metal laminates Metal Matrix Composites (MMC's) Glass matrix composites Ceramic Matrix Composites Ceramic Composites Carbon Composites

METAL MATRIX COMPOSITES

A combination of two or more materials (reinforcing elements, fillers and composite matrix binder) differing in form or composition on a macroscale. The constituents retain their identities: that is, they do not dissolve or merge completely into one another although they act in concert. Normally, the components can be physically identified and exhibit an interface between one another.

Three Types of Metal Matrix Composite

Partial reinforced MMC Short fibre reinforced MMC Continuous fibre reinforced MMC

Advantages of Aluminium/Stainless Steel Metal Matrix Composite

Greater strength Improved stiffness Reduced density(weight) Improved high temperature properties Controlled thermal expansion Thermal/heat management Improved corrosive resistance Improved abrasion and wear resistance Control of mass (Especially in Reciprocating Applications) Improved damping capabilities.

PROCESSES FOR MANUFACTURING OF MMCS

Solid State Processing Powder blending and consolidation Diffusion bonding Physical vapour deposition Liquid State Processing Stir casting Inltration process Spray deposition In-situ processing

Diffusion Bonding
The method was invented by the Soviet scientist N.F. Kazakov in 1953. Diffusion Bonding (DFB) is a solid state Bonding process by which two metals can be bonded together. Diffusion bonding is a method of joining metallic or non-metallic materials. The two materials are pressed together at an elevated temperature usually between 50 and 70% of the melting point. As in aerospace and in nuclear applications such precise and accurate bonding results have been obtained. This bonding technique is based on the atomic diffusion of elements at the joining interface. Recently, diffusion bonding has become a viable process in the fabrication of structural hardware or fluid and gas flow devices for aerospace and electronic industries including thermal management devices for missiles, liquid rocket engines, and millimetre wave hybrid horns for land and space surveillance.

ADVANTAGE OF DIFFUSION BONDING

It is that, unlike welding, it is not a 'fusion' process the parent materials to be joined do not need to be melted. This makes diffusion bonding an ideal solution for joining materials such as: Metals Ceramics Other Advantages Include o Near-parent properties o Minimal shape change to parts o No post-finishing

PARAMETERS FOR DIFFUSION BONDING

Diffusion bonding do require certain parameters which determine its execution. These are primarily categorized into: Time Applied pressure Bonding temperature Heat application method

Processing parameter for diffusion bonding

METHODOLGY
LITERATURE REVIEW SELECTION OF MATERIAL EXPERIMENTAL INVESTIGATION ANALYSIS OF COMPOSITES COMPARESION OF RESULT CONCLUSION

Literature Review
S.No
1.

Title

Authors

Description
Mixed-mode (mode I+II) fatigue-crack growth thresholds for large and short through thickness cracks and micro structurally-small surface cracks have been examined in a finegrained Bimodal microstructure of a Ti6Al4V turbine engine alloy. The effects of bi-linear model on stressstrain, stress-life, and strain-life curves are discussed. Life predictions of aluminum alloys based on linear and bilinear models are also compared and discussed.

Mixed-mode, high-cycle fatigue-crack R.K. Nalla, J.P. growth thresholds in Ti Campbell 6Al4V: Role of small cracks

2.

Application of bi-linear loglog SN model to strain-controlled fatigue data of aluminum alloys and its effect on life predictions

A. Fatemia,, A. Plaseieda, A.K. Khosrovanehb, D. Tanner

S.No
3.

Title

Authors

Description
Very long life fatigue and near-threshold fatigue crack growth behavior of 7075 and 6061 Al-alloys in T6 condition were investigated using accelerated fatigue testing at 19.5 kHz on a piezoelectric machine. A boundary-element code has been used to calculate the stress-intensity factors for a wide range of cracklength-to-width ratios and various height-to-width ratios for M(T) specimens under remote uniform stress, remote uniform displacement, or pin-loaded holes.

Fatigue and fracture behavior of Q.Y. Wang a, N. structural Al-alloys up to very long life Kawagoishi b, Q. Chen regimes

4.

Verification of stress-intensity factors J.C. Newman Jr. , M. for various middle-crack tension test Jordan Haines specimens

S.No Title
5.

Authors

Description
In this paper, two different fracture criteria are applied to determine the crack trajectory or angle of crack propagation in test specimens containing inclined cracks emanating from open holes. Also, different crack growth rate models are assumed for each criterion. The maximum principal stress criterion is used with a crack growthrate equation based on an effective stress intensity factor.

Mixed mode fatigue crack growth D.Y. Jeong in test coupons made from 2024T3 aluminum

6.

Fatigue crack growth in thin L.P. Borregoa, aluminum alloy sheets under J.M. Costab, loading sequences with periodic J.M. Ferreirab overloads

This study analyses the fatigue crack growth behaviour in thin aluminum alloy sheets under several loading sequences containing periodic overloads. The observed fatigue crack growth behaviour is compared to constant amplitude loading and discussed in terms of type of loading sequence, intermediate baseline cycles and stress ratio.

PROBLEM DEFINITION
Aluminum is not very hard - it's easy to scratch. Welding of Aluminum requires specialized equipment and training compared to standard welding of steel. Its a soft material and wears easily. It is very temperature sensitive and expands and contracts with temperature change. Each part has to be formed on or in a mold and layered and baked while in vacuum. So it takes more time to make.

OBJECTIVE
The aluminium composites are widely used in various applications. Aluminium (AI1060) is major utilization in engineering filed so, AI1060 is concentrated in the project. The stainless steel wire is added as a composite to increase the strength. Since the stiffness is more for aluminum but less for stainless steel and percentage of elongation is less for aluminum but more for stainless steel. By the method of diffusion bonding the composite is prepared

MATERIAL PREPRATION
Two aluminium (Al1060) plates of 200mm length, 3mm thickness, and 35mm width is taken as matrix and stainless steel (AISI304) wire of dia 0.7mm are taken as fibre. These two aluminium plates where grooved. Between the grooved path 0.6cm gap is provided. Then metal matrix composite where to be kept in a mould. The mould is pressed for about 10bar pressure. The mould is heated directly. The temperature is maintained between 580-590c. Time interval of 45minutes is allowed to maintain the temperature to obtain good bonding result.

SPECIFICATION OF THE MATERIAL

DIMENSIONS OF ALUMINIUM PLATE Material grade =1060 Al alloy Thickness = 3mm Width (W1&W3) =40mm W2 =35mm Length L1&L3 =50mm L2 =100mm

Stainless steel fibre

DIMENSION OF STAINLESS WIRE Material grade = AISI 305 stainless steel as fibres Diameter =0.7mm

Aluminium plate

PROPERTY OF Al1060
Chemical Property Aluminum Copper Iron Magnesium Manganese Silicon Titanium Vanadium Zinc 99.6 min 0.05 max 0.35 max 0.03 max 0.03 max 0.25 max 0.03 max 0.05 max 0.05 max Modulus of Elasticity (E) (GPa) 69 Poisson ratio () 0.31 Density () (Kg/m3) 2.705 Physical Property

Melting Point (Deg C)

650

PROPERTY OF AISI304
Chemical Composition Carbon Chromium Manganese Nickel 0.12 max 17 - 19 2 max 10 - 13 Melting Point (Deg C) 1450 Poisson ratio () 0.29 Physical Property Density () (Kg/m3) 8

Phosphorus
Silicon Sulphur

0.045 max
1 max 0.03 max Modulus of Elasticity (E) (GPa) 193

 After the production the MMC is allowed to cool to the room temperature. After production the thickness of the metal matrix composite will be of 3mm thickness. However before production the thickness of the plate will be 6mm thickness.

BEFORE DIFUSSION BONDING

AFTER DIFUSSION BONDING

TENSILE TEST
In the tensile testing continuous

loading is given.
The specimen has been prepared as per the specification of tensile

testing machine.
The gauge length of 100mm has been provided as the specimen has

to deform in between the gauge

length

TENSILE TEST RESULT

Property Load at yield Elongation at yield Yield stress Load at peak Elongation at peak Tensile strength Percentage reduction area Percentage of elongation Value 4.60kN 0.600mm 41.441N/mm2 9.40kN 4.900mm 84.685N/mm2 11.71% 5.00%

TENSILE TEST READINGS

TENSILE TEST COMPARISON

Material Al1060 AISI302 Metal matrix composite 84.685

Tensile strength, MPa

69

515

After Deformation

ANSYS RESULT FOR DISPLACEMENT

ANSYS RESULT FOR VON MISES STRESS

ANSYS RESULT FOR VON MISES TOTAL MECHANICAL STRAIN

CONCLUSION
In this study the mechanical behaviour of aluminium and stainless steel laminated metal matrix composite where investigated. The metal matrix

composite was produced by diffusion bonding process. From this study it is

concluded that pressure, time, temperature plays an important role in diffusion bonding.

It is observed that 580-590 C is the best suited temperature for diffusion

bonding. These temperature has to be maintained for about 45minutes to obtain good bonding result.

The tensile strength of aluminum (Al1060) is 69 (Mpa) when compared to

MMC the tensile strength is 84.685 (Mpa). It is concluded that the tensile strength of Al1060 is less compared to Metal Matrix Composite.

SCOPE OF FEATURE WORK

The size of stainless steel wire diameter has to be differed. The fibre reinforcement has to be increased. Form different alloy combination the various grades of aluminium plate are selected. The crack has to be initiated with the help of fracture mechanics fatigue test has to be conducted.

REFERENCES
1. 2. Mixed-mode, high-cycle fatigue-crack growth thresholds in Ti6Al4V: Role of small cracks. R.K. Nalla, J.P. Campbell, R.O. Ritchie International Journal of Fatigue 24 (2002) 10471062. Influence of strain rate on the deformation and fracture response of a 6061-T6 Al50 vol. % Al2O3 continuous-reinforced composite. C.M. Cady, G.T. Gray III - Materials Science and Engineering A298 (2001) 5662. Fatigue crack growth in thin aluminium alloy sheets under loading sequences with periodic overloads. L.P. Borrego, J.M. Costa, J.M. Ferreira - Thin-Walled Structures 43 (2005) 772788. Effect of applied stresses on fatigue damage mode of an alumina fiber reinforced pure aluminium composite. Wenlong zhang, mingyuan gu, jiayi chen, zhengan wu, fan zhang - journal of materials science letters 21, 2002, 767 769. Damage accumulation during cyclic loading of a continuous alumina fibre reinforced aluminium composite. B. Moser, L. Weber, A. Mortensen - Scripta Materialia 53 (2005) 11111115. Effect of Notch and Test Conditions on the Fatigue of a Glass-FibreReinforced Polypropylene Composite. J. A. M. Ferreira: J. D. M. Costa & M. 0. W. Richardson - Composites Science and Technology 57 (1997) 1243-1248.

3.

4.

5. 6.

7.

Fracture behaviour of glass fiber reinforced polymer composite. A. Avci, H. Arikan, A. Akdemir - Cement and Concrete Research 34 (2004) 429 434. 8. Interfaces in cast metal-matrix composites. P. K. Rohatgi, S. Ray, R. Asthana and C. S. Narendranath - Materials Science and Engineering, A 162 (1993) 163 174. 9. Mixed mode fatigue crack growth in test coupons made from 2024-T3 aluminium. D.Y. Jeong - Theoretical and Applied Fracture Mechanics 42 (2004) 3542. 10. Application of bi-linear loglog SN model to strain-controlled fatigue data of aluminium alloys and its effect on life predictions. A. Fatemi, A. Plaseied, A.K. Khosrovaneh, D. Tanner - International Journal of Fatigue 27 (2005) 10401050. 11. Fatigue and fracture behaviour of structural Al-alloys up to very long life regimes. Q.Y. Wang, N. Kawagoishi, Q. Chen - International Journal of Fatigue 28 (2006) 15721576 12. Verification of stress-intensity factors for various middle-crack tension test specimens. J.C. Newman Jr, M. Jordan Haines - Engineering Fracture Mechanics 72 (2005) 11131118

LIST OF PUBLICATIONS

INTERNATIONAL CONFERENCE SHANMUGA RAJ .L, and MUTHU KUMAR .P Mechanical behaviour of aluminium and stainless steel metal matrix composite International conference on Science, Engineering and Technology (SET) 2012 , VIT University, vellore. pp, 1018-1022.