Aluminium Metal Matrix Nano Composites Reinforced With

Palm ash
Submitted in partial fulfillment of requirements for the award of the degree
of
BACHELOR OF TECHNOLOGY
In
DEPARTMENT OF MECHANICAL ENGINEERING
BY
G.N. SUBRAHMANYAM 15MQ1A0311
N.SAI RAM 16MQ5A0310
S.N.V.SAI VITAL 15MQ1A0343
T. DURGA RAO 15MQ1A0345
Under the guidance of
Sri P.SATYANARAYANA, M.Tech
Assistant Professor

DEPARTMENT OF
MECHANICAL ENGINEERING

SRI VASAVI INSTITUTE OF ENGINEERING AND TECHNOLOGY

(Approved by AICTE, New Delhi and Affiliated to JNTU, Kakinada)

Nandamuru, Pedana (M), 521369, Krishna Dt., Andhra Pradesh

2015-2019
SRI VASAVI INSTITUTE OF ENGINEERING AND TECHNOLOGY
(Approved by AICTE, New Delhi and Affiliated to JNTU, Kakinada)

Nandamuru, Pedana (M), 521369, Krishna Dt., Andhra Pradesh

CERTIFICATE
This is to certify that this fabrication project entitled “Aluminium Metal Matrix
Nano Composites Reinforced with Palm Ash” Submitted by

G.N. SUBRAHMANYAM 15MQ1A0311

N.SAI RAM 16MQ5A0310
S.N.V.SAI VITAL 15MQ1A0343
T. DURGA RAO 15MQ1A0345
in partial fulfillment of requirement for the award of degree of B. Tech in Mechanical
Engineering from Jawaharlal Nehru Technological University Kakinada is a record of
bonofide work carried out by them Sri Vasavi Institute of Engineering & Technology. The result
embodied in this project report have not been submitted to any other University or Institute for
the award of degree or diploma

PROJECT GUIDE HEAD OF THE DEPARTMENT

P.SATYANARAYANAM.Tech Dr. D.RAJA RAMESHM.Tech, Ph-D

EXTERNAL EXAMINER
DECLARATION

We hereby declare that this documentation is a record of original research work

done by us and carried out by us under the guidance and supervision of

Sri.P.SATYANARAYANAM.Tech Assistant Professor, MECHANICAL

ENGINEERING Department, SRI VASAVI INSTITUTE OF ENGINEERING
AND TECHNOLOGY, Nandamuru and it has not previously formed the basics
for the award of any degree, diploma or other similar title in this or any other
University

PLACE: NANDAMURU
DATE: G.N. SUBRAHMANYAM
(15MQ1A0311)

N.SAI RAM
(16MQ5A0310)

S.N.V.SAI VITAL
(15MQ1A0343)

T. DURGA RAO
(15MQ1A0345)
ACKNOWLEDGEMENT

We take great pleasure to express our deep sense of gratitude to our project

guide P. SATYANARAYANAM.Tech, Assistant Professor, for his valuable guidance during

the course of our project work. We would like to thank Dr. D. RAJA RAMESHM.Tech, Ph-D, and
Head of the department of mechanical engineering for his encouragement. We would like to
express our heart-felt thanks to Dr. A.B.SRINIVASA RAOM.Tech, MISTE, Ph-D, Principal, Sri
Vasavi Institute of Engineering & Technology, Nandamuru for providing all facilities for our
project. Our special thanks to all Faculty members and Non-Teaching Staff of the Department of
Mechanical Engineering for their support through our project work.

G.N. SUBRAHMANYAM 15MQ1A0311

N.SAI RAM 16MQ5A0310
S.N.V.SAI VITAL 15MQ1A0343
T. DURGA RAO 15MQ1A0345
. ABSTRACT

In the recent years metal matrix composites (MMCs) attracted the researchers more as they
become one of the most important structural materials depending on the requirement.
Specifically, the particulate reinforced Aluminum metal matrix composites have received
significant attention due to the improved mechanical and tribological properties such as strength,
stiffness, impact resistance, wear resistance etc. The ceramic particles such as silicon carbide and
aluminium oxide are the most widely used for reinforcement of aluminium matrix. In the recent
times, the growing concern of manufacturing industries is to use cost effective reinforced
Aluminium metal matrix composites for meeting their production rates with least cost
considerations without sacrificing the specific properties.

In this context, several attempts made by the researchers to use various materials such as
graphite, red mud, bagass ash, palm ash, fly ash etc for reinforcement of Aluminium metal
matrix. In our work an attempt has been made to employ PNA as a reinforcement material for
Aluminium metal matrix composites as it is readily available less denser eco-friendly material at
low cost and it could be the alternative to palm ash in respect of better physical and mechanical
properties.

In the present work stir casting method is employed for preparing the specimens of
Aluminium matrix composite with palm ash reinforcement. An experimental study has been
carried on mechanical characterization of aluminium metal matrix composites using palm ash
and as reinforcement materials separately. The findings of the experimental investigation reveal
that there is a significant improvement in mechanical properties such as hardness, wear, density,
and microstructure and impact strength when used as reinforcement material to that of palm ash.

.
CONTENTS

CHAPTER DESCRIPTION PG.NO

1 INTRODUCTION 1 - 9
1.1 Composite 1

1.1.1 MATRIX PHASE 1

1.1.2 REINFORCING PHASE 2

1.2. CLASSIFICATIONS OF COMPOSITES 3

1.2.1 On the basis of Matrix: 3

1.2.2 On the basis of Material Structure: 3

1.3. RULE OF MIXTURES 4

5 - 9
1.4. Metal Matrix Composites (MMCs)

2
LITRATURE REVIEW 10 - 14
2.1 Based on Aluminium Metal Matrix Composites 11 - 13
2.2. Based On PNA with Aluminium 13 - 14

3 MATERIALS & METHODS 15 - 23

3.1. MATERIALS 16
3.1.1. Matrix material 16
3.1.2. Reinforcement material 17
3.2 METHODS 18
3.2.1. Stir casting method 18
3.2.2. Powder metallurgy Method 19

3.2.3. Ball Milling 20

3.2.4. Spark Plasma Sintering 21
3.2.5. Ultrasonic Assisted Casting 22

4
EXPERIMENTAL PROCEDURE 24 - 28
4.1 PROCEDURE 25
4.2 WORKS DONE 27
4.3. SPECIFICATIONS 28

5 MECHANICAL PROPERTIES 29 - 34
5.1 HARDNESS TEST
30
5.2 DENSITY TEST
31
5.3 WEAR TEST
32
5.4 IMPACT TEST
33
5.5 MICROSTRUCTURAL TEST
34

6 RESULT & DISCUSSION 35 - 41

6.1 HARDNESS TEST 36 - 37
6.2 WEAR TEST 37 - 38
6.3 DENSITY TEST 39
6.4 MICROSTRUCTURAL TEST 40
6.5 IMPACT TEST 41

7 CONCLUSION 42 - 43

REFERENCES 44 - 47
LIST OF FIGURES

FIG.NO DESCRIPTION PG.NO

3.1 ALUMINIUM COMPOSITION MATERIAL 16
3.2 REINFORCEMENT MATERIAL PALM NUT 17
3.3 STIR CASTING DIAGRAM 18
3.4 BALL MILLING 20
3.5 SPARK PLASMA SINTERING 21

3.6 ULTRASONIC ASSISTED CASTING 22

4.1 STIR CASTING MACHINE 26
5.1 HARDNESS TEST MACHINE 30
5.2 DENSITY MEASUREMENT MACHINE 31
5.3 WEAR TEST MACHINE 32
5.4 IMPACT TEST MACHINE 33
5.5 MICROSTRUCTUAL TEST MACHINE 34
6.1 HARDNESS VS % OF REINFORCEMENT 37

6.2 WEAR VS % OF REINFORCEMENT 38

6.3 FRICTION FORCE VS % OF REINFORCEMENT 38
6.5 ALUMINIUM STRAUCTURE 40

6.6 1 % PALM ASH STRAUCTURE 40

6.7 2 % PALM ASH STRAUCTURE 40

6.8 IMPACT STRENGTH VS % OF REINFORCEMENT 41

TABLES
TABLE.N DESCRIPTION PG.NO
O
3.1 Chemical composition of the matrix alloy 23

3.2 Palm ash composition 24

4.3 Specifications of stir casting 31

6.1 Hardness test tabular form 40

6.2 Impact test tabular form 41

CHAPTER-1

INTRODUCTION
1

1. Introduction
1.1. COMPOSITE

Composite material is a material composed of two or more distinct phases (matrix

phase and reinforcing phase) and having bulk properties significantly different from those of any

of the constituents. Many of common materials (metals, alloys, doped ceramics and polymers

mixed with additives) also have a small amount of dispersed phases in their structures, however

they are not considered as composite materials since their properties are similar to those of their

base constituents (physical property of steel are similar to those of pure iron) . Favorable

properties of composites materials are high stiffness and high strength, low density, high

temperature stability, high electrical and thermal conductivity, adjustable coefficient of thermal

expansion, corrosion resistance, improved wear resistance etc.

1.1.1 MATRIX PHASE

 The primary phase, having a continuous character,
 Usually more ductile and less hard phase,
 Holds the reinforcing phase and shares a load with it.
1.1.2 REINFORCING PHASE
 Second phase (or phases) is imbedded in the matrix in a discontinuous form,
 Usually stronger than the matrix, therefore it is sometimes called reinforcing phase.
Composites as engineering materials normally refer to the material with the
Following characteristics:
 These are artificially made (thus, excluding natural material such as wood).
 These consist of at least two different species with a well defined interface.
 Their properties are influenced by the volume percentage of ingredients.
 These have at least one property not possessed by the individual constituents.
2

Performance of Composite depends on:

 Properties of matrix and reinforcement,
 Size and distribution of constituents,
 Shape of constituents,
 Nature of interface between constituents.
1.2. CLASSIFICATIONS OF COMPOSITES
Composite materials are classified

a. On the basis of matrix material,

b. On the basis of filler material.

1.2.1 On the basis of Matrix:

1. Metal Matrix Composites (MMC)

Metal Matrix Composites are composed of a metallic matrix (aluminium,

magnesium, iron, cobalt, copper) and a dispersed ceramic (oxides, carbides) or metallic (lead,
tungsten, molybdenum) phase.

2. Ceramic Matrix Composites (CMC)

Ceramic Matrix Composites are composed of a ceramic matrix and imbedded fibers of

other ceramic material (dispersed phase).

3. Polymer Matrix Composites (PMC)

Polymer Matrix Composites are composed of a matrix from thermo set (Unsaturated
polyester (UP), Epoxy) or thermoplastic (PVC, Nylon, Polystyrene) and embedded glass, carbon,
steel or Kevlar fibers (dispersed phase).

1.2.2 On the basis of Material Structure:

1. Particulate Composites
Particulate Composites consist of a matrix reinforced by a dispersed phase in form of particles.

Composites with random orientation of particles. Composites with preferred orientation of

particles. Dispersed phase of these materials consists of two-dimensional flat platelets (flakes),

laid parallel to each other.

2. Fibrous Composites

 Short-fiber reinforced composites; Short-fiber reinforced composites consist of a

matrix reinforced by a dispersed phase in form of discontinuous fibers (length <

100*diameter)

1. Composites with random orientation of fibers.

2. Composites with preferred orientation of fibers.

 Long-fiber reinforced composites; Long-fiber reinforced composites consist of a matrix

reinforced by a dispersed phase in form of continuous fibers.
1. Unidirectional orientation of fibers.
2. Bidirectional orientation of fibers (woven).
 Laminate Composites
When a fiber reinforced composite consists of several layers with different
fiber orientations, it is called multilayer (angle-ply) composite.
1.3. RULE OF MIXTURES
Rule of Mixtures is a method of approach to approximate estimation of composite
material properties, based on an assumption that a composite property is the volume weighed
average of the phases (matrix and dispersed phase) properties. According to Rule of Mixtures
properties of composite materials are estimated as follows:

Density

DC =d m∗V m −DF∗VF

Where

Dc, dm, DF – densities of the composite, matrix and dispersed phase respectively;
4
Vm, VF – volume fraction of the matrix and dispersed phase respectively.

Tensile Strength
 Tensile strength of long-fiber reinforced composite in longitudinal direction
σ C =σ m∗V m +σ f ∗V f
Where
σ C ,σ m, σ f – tensile strength of the composite, matrix and dispersed phase (fiber) respectively.

 Tensile strength of short-fiber composite in longitudinal direction

(fiber length is less than critical value LC)

LC =σ f ∗d / σ C
Where, d – Diameter of the fiber;
σ C –shear strength of the bond between the matrix and dispersed phase (fiber).

σ C =σ m∗V m +σ f ∗V f ∗¿(1- LC /2 L )

Where, L – Length of the fiber

 Tensile strength of short-fiber composite in longitudinal direction
(fiber length is greater than critical value LC)

σ C =σ m∗V m + L∗T C ∗V f /d
1.4 Metal Matrix Composites (MMCs)

Metal Matrix Composites are composed of a metallic matrix (Al,Mg,Fe,Cu etc) and a dispersed
ceramic (oxide, carbides) or metallic phase( Pb,Mo,W etc). Ceramic reinforcement may be
silicon carbide, boron, alumina, silicon nitride, boron carbide, boron nitride etc. whereas Metallic
Reinforcement may be tungsten, beryllium etc. MMCs are used for Space Shuttle, commercial
airliners, electronic substrates, bicycles, automobiles, golf clubs and a variety of other
applications. From a material point of view, when compared to polymer matrix composites, the
advantages of MMCs lie in their retention of strength and stiffness at elevated temperature, good
abrasion and creep resistance properties. Most MMCs are still in the development

Stage or the early stages of production and are not so widely established as polymer matrix
composites. The biggest disadvantages of MMCs are their high costs of fabrication, which has
placed limitations on their actual applications . There are also advantages in some of the physical
attributes of MMCs such as no significant moisture absorption properties, non-inflammability,
low electrical and thermal conductivities and resistance to most radiations. MMCs have existed
for the past 30 years and a wide range of MMCs have been studied.

Compared to monolithic metals, MMCs have:

 Higher strength-to-density ratios
 Higher stiffness-to-density ratios
 Better fatigue resistance
 Better elevated temperature properties
o Higher strength
o Lower creep rate
o Lower coefficients of thermal expansion
o Better wear resistance
The advantages of MMCs over polymer matrix composites are:
 Fire resistance
 Higher transverse stiffness and strength
 No moisture absorption
 Higher electrical and thermal conductivities
 Better radiation resistance
 No out gassing
 Fabric ability of whisker and particulate-reinforced MMCs with conventional
metalworking equipment.
Some of the disadvantages of MMCs compared to monolithic metals and polymer

matrix composites are:

 Higher cost of some material systems

 Relatively immature technology

6
 Complex fabrication methods for fiber-reinforced systems (except for casting)
 Limited service experience

Metal-matrix composites(MMCs) is promising in the application of aerospace, missile,

automotive owing to its performance of high strength-to-weight ratio, elastic modulus, enhanced
mechanical and thermal properties over conventional materials. Metal matrix composites
(MMCs) are made of a continuous metallic matrix and one or more discontinuous reinforcing
phases. The reinforcing phase may be in the form of fibers, whiskers or particles. The results
revealed that the particulate reinforcement was most beneficial for improving the wear resistance
of MMCs. In practice most composites consist of a bulk material ("matrix") and reinforcement of
some added primarily to increase the strength and stiffness matrix.

Metal matrix composites which are increasingly applied in aerospace, automotive because
of its properties such as high strength, high stiffness, low density, wear resistance, modulus of
elasticity and tensile strength. The metal matrix composites have various advantages over other
types of composites. Such as high strength, high modulus, high toughness and impact properties,
Low sensitivity to changes in temperature or thermal shock, high surface durability and low
sensitivity to surface flaws, high electrical conductivity. In order to improve and achieve both the
strength and toughness of ductile metallic phases, metal matrix composites (MMCs) are being
used currently. That is the reason the requirement for metal matrix composites (MMC’s) with
extraordinary properties (high strength, high stiffness and low weight) compared to monolithic
material is developing every day.

Stir casting is to manufacture a composite material by adding reinforcing particles to a

liquid metal, which has the advantages of easy control of matrix structure, simple and
inexpensive processing. The effects of particle size on the density of the composite materials
have shown that the sample contains low porosity with increasing weight fraction and decreased
size. However liquid melt process has two major disadvantages like low wettability and
dispersion of ceramic particles are not uniform because of the high density this problem will
overcome by increasing the mixing speed and pre heating of ceramic particles to improve the
wettability before mixing with matrix materials.

In this method the manufacturing parameters need to be considered like impeller speed,
impeller size and crucible size, molten metal temperature, stirring time and stirring speed. In our
research work, an effort has been made to study the mechanical and wear properties of LM4-SiC
composite by varying weight percentage by varying particle size in MMCs developed by vertex
method. MMCs exhibits hybridization of valuable properties like high stiffness, strength,
corrosion resistance, hardness, lightweight and high wear resistance when compared with the
parent metal or alloy. Aluminum based metal matrix composites (MMC) have been gaining
importance due to their higher strength and stiffness and light weight especially in the field of
aerospace, automobiles and energy engineering.

Ceramic-reinforced aluminium matrix composite materials are well known for their high
strength-to-weight ratio, superior tribological properties and corrosion resistance behavior, for
which they are replacing their monolithic alloys in the field of automobile, marine and aviation
engineering. Hybrid Aluminium Metal Matrix composites reinforced with particulate ceramics
plays a vital role in recent engineering materials having excellent properties of high Hardness,
less weight and wear resistance. The density, tensile strength and wear resistance improved with
increase in composite percentage of Al2O3 reinforced with Al7075 [3].The hybrid Al7075 metal
matrices developed by stir casting method by varying weight fraction of Al 2O3 and fixed weight
percentage of SiC The micro hardness and wear resistance improved by increasing weight
fraction of reinforcement.

The conventional aluminum alloys are progressively replaced by AMCs in many

applications due to high strength to weight ratio, low thermal expansion, good wear and
corrosion resistance, the processing method of AMCs plays a crucial role to attain good
mechanical properties. Because of their advanced properties like high strength, light weight, non-
corrosive, non-conductive, long life, design flexibility these are used in various applications like
automobile components, sports goods, etc. Al-based metal matrix composites (AMMCs) are
widely used in many industries like aerospace, transportation and several structural applications
because of their high strength, high Young’s modulus, and improved resistance to wear.
Aluminum (Al) and its alloys are most widely used in many industries like aerospace,
transportation and several structural applications because of their high specific strength.

8
Good formability and excellent corrosion resistance. In recent years, how to further
improve the strength of Al alloys becomes a main concern. Aluminium and its alloy exhibit high
electrical conductivity, good strength to weight ratio and corrosion resistance. On the other hand,
the low stiffness wear resistance, and yield strength restricts its utilization in various
applications. The growing demand for novel lightweight materials with higher strength and
toughness has led to the development of composite materials. However, the ductile metallic
phases are usually having more value of toughness; but these ductile metallic phases have
possessed the lower value of strength. Further, these AMCs have more attractive in high
strength-to-weight ratio, high stiffness-to weight ratio, high wear resistance, less cost, easily
available one, more in thermal conductivity, good in thermal stability, and so on.

Several researchers have focused on and studied the Al-based MMCs reinforced with
Al2O3, Sic, B4C, TiB2, ZrB2, and TiO2. Refining the metals' grains is a well-known method to
improve their strength. metal matrix composites’ functional properties, including high structural
efficiency, excellent wear resistance, and attractive thermal and electrical characteristics, have
enabled their application in ground transportation, including auto and rail; thermal management;
and the aerospace, recreational, and infrastructure industries. Aluminum is widely available in
the Earth's crust and accounts for about 8% by weight of the Earth’s stable surface.
Its properties, such as high strength-to-weight ratio, ductility, durability. Heat treatment of
1 wt. % of alumina in aluminum metal matrix composites resulted in significant improvement in
mechanical properties such as hardness and compressive strength. Attempts to improve the
performance characteristics of aluminum alloys with a high strength second phases are required
for high strength to weight ratio. TiB2 reinforcements not only increased hardness and elastic
modulus but also it acted as a good grain refiner for the matrix. The increase in wear resistance
by adding carbide reinforcement has been reported by many researchers. Additionally, attraction
of TiC with Al matrix is due to its superior wettability, high hardness, relative thermal stability
and low density. Al-TiC MMCs are now widely used for defense, aerospace and structural
applications Other than reinforcement reaction; there is a formation of second phase inside the
alloy matrix.

CHAPTER-2

LITERATURE REVIEW
10
2. Literature Review
2.1 Based on Aluminium Metal Matrix Composites

 Balasivanandha Prabu et al. [5]: Studied that better stir process and stir time the
content of silicon in aluminium alloy is high Al-silicon carbide MMC material with 10%
of silicon carbide by using a varying stirring speed and time. The scanning electron
microscope (SEM) and optical microscope was used for examine the microstructure of
composites. The various effects on microstructure and strength have been studied due to
stirring speed and time. By increase in stirring speed and time resulted in uniform
distribution of particles, the mechanical properties hardness of composites is also affected
by stirring speed and stirring time. The most uniform value of hardness was achieved at
580 rpm with 12 min. stirring.
 Dora Siva Prasad et al. [6]: Studied that hybrid metal matrix composites with up to 8 %
rice husk ash and silicon carbide particles could be manufactured by using double stir
casting process. The matrix showed uniform distribution of rice husk ash and SiC. With
the increase of reinforcement percentage hardness and porosity also increases but density
decrease with increase in rice husk ash and SiC content the yield strength and ultimate
tensile strength increases. The most significant property of aluminium silicon carbide
composites with aerospace industries is its strength to weight ratio, which is 3 times
greater than mild steel. [7]
 Hashim et al, [8]: Have identified four technical difficulties in stir casting: difficulty of
achieving a uniform distribution of the reinforcement materials; wet ability between the
two main substances; porosity in the cast metal matrix composites; and chemical
reactions between the reinforcement materials and the matrix alloy. These difficulties
need to be overcome in order achieve a MMC with a broad range of mechanical
properties. They have also identified the important processes variables that affect the
mechanical properties of MMC. The holding temperature, stirring speed, size of the
impeller and the position of the impeller in the melt are to be considered in the production
of cast metal matrix composites.

11

 Alaneme & Aluko (2012) [9]: Has Pay attention on double stir-casting technique to cast
the Al (6063) scrape and SiC and reinforcements of SiC in 3, 6.1, 9.2and12 % volume
into the furnace. And melt at temperature 750 °C. Then molten metal allowed cooling at
580 °C. They found this stage dehydrated borax mixture and silicon carbide was added
into the molten Metal and stirred for 15-20 minutes.
 Gopalkrishan & murugan (2012) [10]: Studied the fabrication of MMC by modified
stir casting method for improved specific strength, temperature wear resistance, hardness.
Al-TiC composites are having a good potential and composites was fabricated in argon
gas atmosphere by using modified stir casting process. The specific strength of the MMC
increased with addition larger % of TiC.
 Nhar et al [2004] [11]: Fabricate Al-SiC composites by using liquid stir casting and
semi-solid stir casting methods. The speed range of stirring is 200 to 500 rpm. The 30 µm
sized silicon carbide particles were used by 10 % volume the main purpose was to
fabricate uniformly distributed homogeneous composites. Faster rate of solidification.
 Rajan et al [2007][12] : Pay attention the effect of different stir casting methods on the
structure and properties of fly ash particles reinforced Al-Si-Mg composites. Molten
metal stir casting, compo-casting and modified compo-32 casting followed by squeeze
casting route were studied. Newly modified compo-casting provide uniformly distributed
minimum porosity composites.
 Nabil Fat Halla et al. [1988][13]: Compared the mechanical properties and
microstructure of modified and no modified stir cast aluminium composites A-S7go₃ and
A-S₄G the stir cast structure partially improved the mechanical properties in comparison
to those of traditionally cast alloys. By the addition of 0-0.2% strontium in the form of
Al-5 mass % Sr master alloy. During stir casting enhanced the eutectic silicon into very
fine spheroidal morphology, the phase particles also showed the same morphology as stir
cast composites. This structure show the highly improvement in mechanical properties. In
various fabrication techniques stir casting is one of the most low cost and highly efficient
techniques to produce a composite.

12

 Rama rao et al [14]: Manufactured aluminium boron carbide composites by liquid state
metallurgy method with different particulate weight ratio. The variation in weight is 2.5,
5, 7.5 %.X-ray diffraction method is used for phase identification of boron carbide SEM
(scanning electron microscope) is used for microstructure analysis. Toughness, hardness
and compression carried out for mechanical properties result shows with the increase
amount of composites decreases but hardness is increased. With the increase of weight
percentage of boron carbide in composites the compressive strength increases.
 Jayaseelan et al. 2010 [15]: Have compared extrusion characteristics of Al-SiC
fabricated by two methods compared materials fabricated by powder metallurgy. Stir cast
material give fine microstructure and high hardness as compared material fabricated by
powder metallurgy. And also have higher strength.
 Anil Kumar et al. [16] ; Have conducted the mechanical properties of fly ash reinforced
Al6061 composites and found that the tensile strength, compressive strength, and
hardness of the Al6061 composites decrease with the increase in particle size of
reinforced fly ash. Increase in the weight fractions of the fly ash particles increases the
ultimate ensile strength, compressive strength, and hardness and decreases the ductility of
the composite.
 Asif et al. [17]; Have investigated the development of aluminum based hybrid metal
matrix composites for heavy duty applications and Investigated the dry sliding wear
behaviour of aluminum alloy based composites, reinforced with silicon carbide particles
and solid lubricants such as graphite/antimony disulphide. The results revealed that wear
rate of hybrid composites are lower than the binary composite. The wear rate decreases
with the increasing load and increases with increasing speed.

2.2. Based On PNA with Aluminium

 Muruganandhan.P et al;- They investigated the effect of Palm ash reinforced with
Al6061.By varying the wt% of palm ash using the stir casting method the specimens was
developed. The found that increase of palm ash increase the mechanical properties upto
20% of palm ash in the metal matrix but the corrosion resistance decreases with increase
of palm ash addition

13
 M.Sankar;- They investigated the Silicon carbide and palm ash reinforced with the
Aluminium 6061 alloy. They developed the specimens using the stir casting method.
They found that as the reinforcement contents increased in the matrix material, the
composites hardness also increased. Tensile strength decreased with increased amount of
reinforcement. The wear rate of the composites reduced with increased weight
percentages of the reinforcements.
 Rohatgi et al[5]; Analyzed that A356-palm ash cenosphere composites can be
synthesized using gas pressure infiltration technique over a wide range of reinforcement
volume fraction from 20 to 65%. The densities of Al356-palm ash cenosphere
composites, made under various experimental conditions, are in the range of 1250-2180
kg/m3 corresponding to the volume fraction of cenosphere in the range 20-65%. The
density of composites increased for the same cenosphere volume fraction with increasing
size of particles, applied pressure and melt temperature. This appears to be related to a
decrease in voids present near particles by and enhancement of the melt flow in a bed of
cenosphere. The compressive strength Plateau stress and modulus of the composites
increased with the composite density.
 Anil Kumar et al [10]; Investigation that mechanical properties of palm ash reinforced
aluminium alloy (Al 6061) composites fabricated by stir casting. They are three sets of
composites with palm ash particle sizes of 75-100, 45-50 and 4- 25 µm were used. Each
set had three types of composite samples with the reinforcement weight fractions of 10 15
and 20%. The mechanical properties studied were the compressive strength, tensile
strength, ductility and hardness. Unreinforced Al6061 samples also tested the mechanical
properties. It was found that the compressive strength, tensile strength and hardness of the
aluminium alloy composites decreased with the increase in particle size of reinforced
palm Increase in the weight fractions of the palm ash particles the ultimate tensile
strength, compressive strength, hardness and decreases the ductility of the composite. The
SEM of the samples indicated uniform distribution of the palm ash particles in
the matrix without any voids.

14

CHAPTER-3
MATERIALS AND
METHODS

15

3. MATERIALS AND METHODS

3.1. MATERIALS
They are following two basic materials are used in metal matrix composite materials. In
this materials are mostly used in industries, researchers, aero planes, automobiles, and space
ships etc,.

3.1.1. Matrix material

For experimental investigation, AlSi10Mg aluminium alloy was used as a matrix material
whose chemical composition (in wt %) is listed in Table 1. AlSi10Mg is typical casting alloy
with good casting properties and is used for cast parts with thin walls and complex geometry.
The alloying elements silicon and magnesium leads to high strength and hardness. The
components made with AlSi10Mg alloy are ideal for applications which require a combination of
good thermal properties and low weight. It is easily castable and main advantage of this material
is preheating is not required before casting or testing as shown in figure (3.1.1) below
Fig.3.1 Aluminium composition material

16

Table-3.1. Chemical composition of the alloys

Cu Mg Si Fe Mn Ni Zn Pb Sn Ti Al
Chemical
composition

0.2

0.1 to 10.0 to 0.6 0.3 to 0.7 0.1 0.1 0.1 0.05 0.2
% Balance
M
ax 0.6 13.0 Max max max max max max
3.1.2. Reinforcement material
Palm ash is procured from local sources in India (Tamilnadu Coimbatore), and then it was
washed with water to remove the dust and dried at room temperature for 1 day. Washed palm ash
is then heated to 200°C for 1 hr duration to remove the moisture and organic matter. During this
operation, the colour of the ash is changed from yellowish to black because of charring of
organic matter. It is then heated to 600 °C for 12 h to remove the carbonaceous material. After
this operation, once again the colour is changed from black to grayish white (Figure). The
obtained palm ash (PA) is used as a reinforcement material for the preparation of composites.
The chemical composition of the palm ash after the above treatments is given in Table 2. Palm
nut is a procured from local areas and it is shown in fig.1.2 below

17

Constituent SiO2 Al2O3 Fe2O3 CaO MgO Na2O K2O LOI

% 94.04 0.249 0.136 0.622 0.442 0.023 2.49 3.52

Table3.2. Palm ash composition

Fig.3.2 Reinforcement material palm nut

3.2. METHODS
The following methods are mostly used metal matrix composite

18

3. 2.1. Stir Casting Method

Stir casting is a liquid state process of composite materials fabrication, in which the
reinforcement particles mixed with a molten metal matrix by means of mechanical stirring. Then
the liquid composite material is cast by conventional casting methods and conventional metal
forming techniques. In last five decades the aluminium alloy based metal matrix composites are
fabricated through stir casting method by reinforcing ceramic hard particles. Ali et al. [34]
produced nano composites of A356/ (0 to 4.5 vol. %) SiCp/ 1 wt % Mg through stir casting
route. The aluminium matrix alloy was melted to 750˚C and stirred at a speed 600rpm for 15 min
by graphite impeller. From the SEM it is observed that the reinforcement particles were
distributed uniformly in the A356 alloy matrix.

Fig. 3.3 Stir Casting Method

3.2.2. Powder metallurgy Method
Powder metallurgy is a material processing technique in which particulate materials are
consolidated to semi finished and finished products. It consists of four basic steps i.e. powders
manufacture, blending of powders, compacting of powders in a die and sintering. Powder
metallurgy route is suitable for parts that are required to be manufactured from a single or
multiple materials in powder form and minimizes the machining, scrap losses and suited to high
volume production of components. Lauri et al. [35] fabricated nano composites of Al/ (1vol. %
of size 30nm) SiCp through high energy planetary milling followed by powder metallurgy route
and sintering.

19

They were investigated the formation of nano composites by varying number of milling
parameters. The morphology of the nano composites reveals that the 10 mm ball size used for 20
hours milling distributed better than 20 mm ball size for same milling time at 360 rpm speed.
Gallardo et al. [36] produced nano composites of Al2024/ (0 to 5) wt % nano SiCp through the
ball milling and followed by powder metallurgy route. The milling process was done for 2h.
From SEM and TEM micrographs it is observed that the reinforcements of SiCp were distributed
uniformly in the Al2024 alloy matrix, and the interface in between SiCp and Al2024 alloy was
good without any formation of crack. The interaction of dislocation lines also observed in a
particular orientation.

3.2.3. Ball Milling

Ball milling is a process in which grinding balls crush and disintegrate the starting material
into small sizes. There is some control over the size reached by the speed of the rotation, amount
of the sample, size and number of grinding balls and grinding time.

Fig.3.4. Ball Milling

The homogeneity of the sample can be improved either by increasing the number of grinding
balls or by increasing the powder to ball ratio. Hot isostatic pressing is a process for the
densification of castings and the powder metallurgy products. The uniform distribution of ball
milled powder can be processed through hot isostatic pressing method. Feng et al. [37] fabricated
nano composites of Al5083/(6.5 vol. % of 25nm size) SiCp through cryomilling followed by HIP
consolidation and hot rolling processes.

20
They investigated the SEM micrographs and showed that the SiCp particles were distributed
homogeneously in the Al5083 matrix. The SEM and TEM micro graphs reveals that the
reinforcement of nano particles was of uniform distribution , good interface bonding in between
SiCp and Al5083 alloy matrix and the interparticle region in rolling direction. Knowles et al.
[38] synthesized nano composites of Al 6061/ (10, 15) wt % of 500 nm size SiCp through high
energy ball milling, hot isostatic pressing and extrusion process. The SEM micrographs revealed
the homogeneous distribution of particles in the Al6061 alloy matrix with minimal clustering of
the nano particles Kollo et al. [39] produced nano composites of Al/ (1, 5, 10, 20) vol. % of size
55nm SiCp through both planetary and attrition ball milling and followed by hot pressed at
350˚C. It is observed from results that the reinforcement particles were dispersed uniformly. But
the aluminium crystallite size was dependent on the milling technique. By eliminating the effect
of the crystallite size, planetary milling proved to be more effective than attrition milling as it is
effectively dispersing large amounts of nano particles in the aluminium matrix where as attrition
milling is more effective in decreasing the matrix crystallite size.

3.2.4. Spark Plasma Sintering

Spark plasma sintering is a high speed powder consolidation sintering process capable of
processing conductive and non conductive materials. The basic theory of spark plasma sintering
process is based on the electrical spark discharge phenomenon where low voltage pulse current
momentarily generates spark plasma in fine local areas between the particles at high energy. The
spark plasma sintering temperatures were lower than the conventional sintering temperatures and
material processing time is 5 to 25 min. The relatively low temperatures combined with fast
processing times ensure tight control over grain growth and microstructure. Sivaiah et al. [40]
produced nano composites of Al 5083/10 wt% SiCp through high energy ball milling followed
by spark plasma sintering process. They investigated the samples of nano composites with SEM
micrographs (Fig.) and XRD plots for the crystalline size of the ball milled Al 5083 matrix, it
was observed to be 25nm and it was coarsened up to 30nm after spark plasma sintering Sherif et
al. (1998) fabricated nano composites of Al/ (2, 5, 7, 10) vol. % of size 5nm SiCp through high
energy ball milling followed by plasma activated sintering method. They investigated SEM
micrographs and revealed that the reinforcement particles were distributed uniformly.

21
The XRD analysis showed that no formation of reactive products like Al4C3 and Si after 0ks and
86ks of the ball milling time.
Fig.3.5. Spark Plasma Sintering
3.2.5. Ultrasonic Assisted Casting
Ultrasonic assisted casting is a process of subjecting melts with ultrasonic waves during
or after adding a reinforcing material followed by casting. The basic principle behind this
method is the generation of high intensity ultrasonic waves which cause transient cavitations and
acoustic streaming in liquids. Acoustic streaming causes pressure gradient within the bulk of a
molten metal and produces stirring effect. During cavitations, cyclic high intensity ultrasonic
waves induce the formation, growth, pulsating and collapsing of tiny bubbles in the liquid phase.
At every cavitations cycle, bubbles implosively collapse in less than a microsecond, producing
micro hot spots that can reach temperatures of 5000 ˚C and 1000 atm pressure. During
cavitations of nano composite melt, air entrapped in voids of particle clusters serves as nuclei for
cavitations, which is strong enough to break the clusters by providing uniform dispersion. The
high pressure and temperature develop and remove gases, impurities and enhances the
wettability of nano reinforcement with matrix. This method is more successful in producing
composites with uniform dispersion of nano reinforcements at laboratories in small scale and
also for large scale production. Bulk production requires up scale the probe size with higher
source power to ensure its effect over large volume of melts.

22
Dehnavi et al. [42] synthesized metal matrix nano composites of A413/ (05, 1, 1.5, 2) wt. %
SiCp/ 0.5 wt. % Mg through ultrasonic assisted casting technique. The A413 alloy was melted in
a graphite crucible with the help of resistance furnace under protective argon atmosphere. The
SiCp nano particles were preheated at 1000 ˚C for 1 hour in a muffle furnace. The SiCp nano
particles were added to the melt and mechanically stirred by using graphite stirrer at a stirring
speed of 650 rpm for 30 min. The mechanically stirred slurry was treated ultrasonically for 10 to
20 min at a frequency of 20 kHz and 350W power and then poured into a preheated cylindrical
grey cast iron die. They studied the effect of mechanical stirring as well as continuous and
discontinuous ultrasonic treatments on the microstructure and, particle distribution. The
mechanical properties of discontinuous ultrasonic treatments were improved better than the
continuous ultrasonic treatments for 20 min period. Yong et al. [43] produced metal matrix nano
composites of A356/ (2 wt % of size 30nm) SiCp by ultrasonic assisted casting method.

Fig. 3.6 Ultrasonic Assisted Casting

The above few methods are mostly useful and in this project work stir casting is using them. The
process of casting easy and low cost.

23
CHAPTER-4

EXPERIMENTAL
PROCEDURE

24

4. EXPERIMENTAL PROCEDURE
4.1 PROCEDURE
In last five decades the aluminium alloy based metal matrix composites are fabricated
through stir casting method by reinforcing ceramic hard particles. The casting unit consists of a
graphite crucible of about 5 kg capacities, which is heated by electrical resistance type heating
coil. It is observed that the reinforcement particles were distributed uniformly in the A356 alloy
matrix. Initially 400 grams of pure aluminium is melted in a resistance heated muffle furnace.
The required amount of Al 6061 alloy was added into graphite crucible and melted in a furnace
to a temperature of 750 ºC and stirred at a speed 600 rpm for 15 min by graphite impeller.

Before adding the reinforcement to the slurry is preheated for 200 ºC in the oven to
remove the absorbed gases in reinforcement. The tensile strength of the prepared composite was
measured using a computerized unaxial tensile testing. Micro hardness test was measured on
composites using Zwick micro- Vickers hardness tester under a load of 50 grams for 10 seconds.
The various advantages of stir casting are simplicity, flexibility, applicability to large quantity,
near net shaping, lower cost of processing and easier control of matrix structure. In this work,
stir-casting method is used for preparing aluminium metal–matrix composite. This whirlpool
technique provides high strength and homogeneous set of aluminium composite materials.

After the molten metal is fully melted, degassing tablets is added to reduce the porosity.
Simultaneously, 1wt% of magnesium is added into the molten melt to enhance the wettability
between the rice husk particles and alloy melt. It is noticed that without the addition of
magnesium, the particles of rice husk ash are rejected. A coke feed melting furnace with graphite
crucible was used for melting. Al-7072 alloy was melted in a crucible by heating it in a melting
furnace around 800 oC for 2-3 hours.

25
FIG.4.1. STIR CASTING

26
More about stir casting
Bottom pouring Aluminium stir casting furnace with rotary centrifugal casting. ‘ASCO’ make
aluminium melting furnace bottom type for melting up to 10kg aluminium in cast iron crucible
maximum temperature of furnace 1000 oC duly insulated with ceramic fiber blanket and
insulating bricks fitted digital temperature controller cum indicator range 0 – 1000 0C fitted with
energy regulator magnetic contactor lamp & chord suitable for 220 volt A.C.

Silent features
 Easy to Operate
 Single person can handle the entire casting process
 Adjustable speed controls are provided for stirring and rotary centrifugal casting

 Safe and secure

 Exposure to heat & melt is very minimal

 Thermocouple broken indicator and over load protection

 Uniform mixing

4.2. WORKS DONE

1. Commercially pure Al was melted and casted.

2. Al-10% fly ash composite was fabricated by stir casting method.
3. Chemical composition analysis was done for fly ash used.
4. Particle size analysis was done for fly ash used.
5. Density and hardness measurement was carried out for both commercially pure Al sample
and Al-10% fly ash composite sample.
6. The wear characteristics of both commercially pure Al and Al-10% fly ash composite was
evaluated and compared.
7. SEM analysis was done for both the samples.8. EDS microanalysis was done for both the
samples.

27
4.3. SPECIFICATIONS
We use temperature in 7500C melt AL – PNA reinforcement condition and 600 rpm speed.

Maximum temperature 1000 0C

HEATING ELEMENT KANTHAL A1

Report Stainless steel

Bottom pouring Manual open & close

Stirrer Manual up/down

Variable speed from 100 – 1500 rpm with digital indicator

28
CHAPTER-5

MECHANICAL
PROPERTIES

29
5. MECHANICAL PROPERTIES
It is very important to understand mechanical properties of any material because they are used
in various areas. The mechanical properties of Al-MMCs depend upon the parent composite,
type of reinforcement, particle size and shape. Various ceramic hard particles, organic polymers,
fibers etc. are added as reinforcement to increase the mechanical properties of aluminium
composite have various effects on the mechanical properties that impart many modern-day
applications

5.1. Hardness Test

The hardness of a material indicates the resistance to permanent indentation. While testing
the hardness of a material an indenter is pressed into the surface of the material to be tested under
a specific load for a definite time interval. The diameter of the indentation left in the test material
is measured with a low powered. The experiment conducting and the observation values are
shown in results

FIG. 5.1. Hardness Test

30
5.2. Density Measurement
The Archimedes principle was employed to determine the density of the composites. The
AMC-PA samples were weighed in air and then in distilled water separately. According to
Archimedes principle the following expression was used to determine the density of the
composites. The experiment conducting and the observation values are shown in results

Fig.5.2. Density measurement

31
5.3. Wear Test
Wear is a process of removal of material from one or both of two solid surfaces when
their surfaces are in solid contact during sliding or rolling under a load. In order to make the best
choice of material for a specific application, it is necessary to know the wear resistance of the
material because wear is the main cause of material wastage. In the present work the AMC-PA
specimens were subjected to dry sliding wear test under dry conditions using a horizontal pin-on-
disc wear tester. The experiment conducting and the observation values are shown in results

FIG.5.3. Wear Test

32
5.4 IMPACT TEST
Impact strength is the ability of a material to absorb energy before actual fracture occurs.
The impact strength of the composites was tested using a standard impact testing machine using
Izod specimens. The Izod test is carried out by a pendulum-type testing machine, which employs
a cantilever test specimen 75 mm long with a 10×10 mm2 cross section, having a standard 45°
notch 2 mm deep. The experiment conducting and the observation values are shown in results

FIG.5.4 IMPACT TEST

33
5.5 Microscopic Examination

The samples of AMC-PA were prepared for examining their micro structures using
Scanning electron microscope (SEM). The microstructures of AMC-PA are depicted in the Fig.
respectively. It is observed from the micrographs that the AV powder particles distributed more
uniformly in aluminium matrix as compared to that of the distribution of FA particles. The
experiment conducting and the observation values are shown in results

FIG. 5.5 Microscopic Examination

34
CHAPTER-6

RESULT & DISCUSSION

intensity
35

6. RESULT
6.1 HARDNESS
The Brinell hardness number (BHN) is calculated by dividing the load applied by the surface
area of the indentation. The BHN values obtained for AMC-PA are 28.2 and 33.8 respectively.
The relation between weight percentage of RHA reinforcement and hardness of fabricated
MMCs was shown in figure. It was observed that the hardness of the composite linearly
increasing with the increase in weight fraction of the ash particles. This occurs due to increases
in surface area of the matrix and thus the grain sizes are reduced. The presence of such hard
surface area offers more resistance to plastic deformation which leads to increase hardness.
Similar findings were by Radhakrishna et.al, 2007 for SiC particle reinforcements.

OBSERVATIONS
 Diameter of the indenter = 2.5 mm
 Load = 187.5 kgf

DIAMETER OF THE
IMPRESSION (mm)
S.NO MATERIAL DIAMETER
OF THE TRAIL TRAI AV LOAD B.H.N
INTENDER -1 L-2 G P
(mm)
1 ALUMINIU 2.5 1.8 1.8 1.8 187.5 62.4
M
2 ASH 1 % 2.5 1.7 1.6 1.66 187.5 75.7

3 ASH 2% 2.5 1.6 1.5 1.33 187.5 90.91

6.1 HARDNESS TEST TABULAR FORM

2P
B.H.N = ∅ D( D−√ D 2−d 2 )

36
 BRINELL HARDNESS TEST FOR ALUMINIUM MATERIAL = 62.4
 BRINELL HARDNESS TEST FOR 1 % MATERIAL = 75.7
 BRINELL HARDNESS TEST FOR 2 %MATERIAL M = 90.91

B.H.N
100
90
80
70
Hardness

60
50 AL
40
30
20
10
0
AL 1% 2%

% Of Reinforcement

6.1 HARDNESS VS % OF REINFORCEMENT

6.2 WEAR TEST

The photoelectric balance with an accuracy of ±0.1 mg was used to find the mass of the
specimens before and after the experiments. The wear for the specimens AMC-FA and AMC-
AV are observed from the wear test are. The final result is decreases wear and friction force is
increase in reinforcement of palm sprout shell ash in aluminium composite

WEAR
 Aluminium = 80µ at 15N, 125µ at 25N and 170µ at 35N
 1 % PNA = 75µ at 15N, 120µ at 25N and 155µ at 35N
 2 % PNA = 65µ at 15N, 115µ at 25N and 145µ at 35N
FRICTION FORCE
 Aluminium = 4.5N at 15N, 6.8N at 25N and 7.50N at 35N
 1 % PNA = 5.0N at 15N, 7.3N at 25N and 8.0N at 35N
 2 % PNA = 5.5N at 15N, 7.8N at 25N and 8.60N at 35N
37

6.2 WEAR VS % OF REINFORCEMENT

FRICTION FORCE

6.3 FRICTION FORCE VS % OF REINFORCEMENT

38
6.3 DENSITY
The values of densities obtained for AMC-PA are respectively in the below

 aluminium = 2.6 g/cc

 1% = 2.7 g/cc
 2% = 2.73 g/cc
The values of the densities are slightly increases in reinforcement of palm ash and pure
aluminium materials

DENSITY
2.75

2.7

2.65
Density

AL
2.6

2.55

2.5
AL-6061 ash1% ash2%

% of reinforcement

6.4 DENSITY VS % OF REINFORCEMENT

6.4. MICROSTRUCTURAL TEST

A good bonding between matrix material and the particles of ash powder has been
observed from the micro graphs. The micrographs depict the microstructure of as cast Al and
PNA reinforced Aluminium alloy. A uniform distribution of palm nut ash particles without
voids and discontinuities can be observed from these micrographs along with good bonding
between matrix material and palm nut ash particles; however no gap is observed between the
particle and matrix

39

6.5. ALUMINIUM STRAUCTURE

6.6. 1 % PALM ASH STRAUCTURE

6.7. 2 % PALM ASH STRAUCTURE

40
6.5 IMPACT STRENGTH
The impact strength obtained for the specimens AMC-PA are shown in the table

TABULAR FORM
AREA ENERGY SPECIFIC
OFTHE ENERGY ABSORBED IMPACT
S.NO MATERIAL SPECIMEN ABSORBED AT BREAK POWER
AT THE THE (J/mm2)
NOTCH SPECIMEN
1 AL 10*80=80 2 2 0.0255

2 1% 80 3 3 0.0375

3 2% 80 6 6 0.0 755

IMPACT
0.08
0.07
Impact strength, j/mm2

0.06
0.05
0.04 AL
0.03
0.02
0.01
0
AL-6061 ash1% ash2%
% of reinforcement

6.8 IMPACT STRENGTH VS % OF REINFORCEMENT

41

CHAPTER-7

CONCLUSION
42

CONCLUSION

The conclusions drawn from the present investigation are as follows:

 Palm nut Ash, the agricultural waste generated from milling paddy can be successfully used
as a reinforcing material to produce Aluminium Metal-Matrix Composite. It can be
successfully used in place of conventional aluminium intensive material.
 The use PNA ash for the production of composites can turn agricultural waste into
industrial wealth. This can also solve the problem of storage and disposal of PNA.
 There was good dispensability of PNA particles in aluminium matrix which improves the
hardness of the matrix material and also the tensile behavior of the composite. The effect is
increase in interfacial area between the matrix material and the PNA particles leading to
increase in strength appreciably.
 The Tensile Strength, Compression Strength and Hardness increases with the increase in the
weight fraction and ductility gets decrease with increase in the weight fraction of reinforced
palm nut ash
 It was concluded that the enhancement in the mechanical properties can be well attributed to
the high dislocation density. However, for composites with more than 12% weight fraction
of PALM nut ash particles, the tensile strength was seen to be decreasing.
43

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