MICROSTRUCTURE AND MECHANICAL PROPERTIES OF FLYASH PARTICLE REINFORCED ALUMINUM COMPOSITE

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1 International Journal of Mechanical Engineering and Technology (IJMET) Volume 9, Issue 8, August 2018, pp , Article ID: IJMET_09_08_096 Available online at ISSN Print: and ISSN Online: IAEME Publication Scopus Indexed MICROSTRUCTURE AND MECHANICAL PROPERTIES OF FLYASH PARTICLE REINFORCED ALUMINUM COMPOSITE V.V.Kondaiah, Ravi Kumar Panthangi and K. Srinivasa Rao Center of Exllence in Materials and Manufacturing, Department of Mechanical Engineering, CMR College of Engineering & Technology, Kandlakoya, Hyderabad, Telangana ABSTRACT In this work a metal matrix composite with the pure aluminum is a base metal and fly ash as filler material. Aluminum and fly ash composite have been made with stir casting process with different composition of fly ash from up to 9% insteps of 3%. The effect of the presence of fly ash on microstructure evolution and the mechanical properties like hardness, impact and wear tests are carried out for each composition of fly ash. Hardness of the composite increases with increasing of fly ash composite by 46%, whereas impact strength decreases with increasing of fly ash composite 60% and wear resistance increases with increasing of fly ash by 59%. Keywords: Metal Matrix Composite, Fly ash, Mechanical Properties, stir casting Cite this Article: V. V. Kondaiah, Ravi Kumar Panthangi and K. Srinivasa Rao, Microstructure and Mechanical Properties of Flyash Particle Reinforced Aluminum Composite, International Journal of Mechanical Engineering and Technology, 9(8), 2018, pp INTRODUCTION Metal matrix composites (MMCs), are light in weight and superior in mechanical properties, are very attractive for application in different industries like aerospace. Rajan et al, [1] studies dispesion of fly ash particle in aluminum alloy with three different routes of stir casting processes. Yar et al, [2] produced aluminum alloy and MgO nano-particle with stir casting process at different temperatures and mechanical properties are studied. Mandal et al, [3] produced synthetic aluminum foam with stir casting process and charactarised microstructure, hardness and deformation behavier. Kalaisevan et al, [4] focused on the fabrication of aluminum (6061-T6) matrix composites) reinforced with different weight percentage of B 4 C particulates by stir casting method and studied the mechanical properties like hardness and tensile properties. Sajid et al, [5] studied, the improvement of weldability of aluminum composite with particle reinforcement with three step mixing method. Sajid et al, [6] produced aluminum metal matrix composite as nano and micro particles with different weight percentages with melt techniques and studied the mechanical properties like hardness, tensile editor@iaeme.com

2 Microstructure and Mechanical Properties of Flyash Particle Reinforced Aluminum Composite strength and compressive strength. Su et al, [7] studies the application of ultrasonic vibration in production of metal matrix composite t during the solidification and studied microstructure refinement and mechanical properties. Thamtan et al, [8] prepared Master Metal Matrix Composite (MMMC) by addition of milled poweders, in semi-solid state and above the melting point and grain refinement was studied. Akbari et al, [9] studied the effects of milling process and milling time on mechanical properties of metal matrix composites, concluded that the composites, reinforced with Al 2 O 3 -metallic mixed powders, showed higher mechanical performance compared with that of the pure Al 2 O 3 nanoparticle reinforced composite. Jokhio et al, [10] studied the effect of elemental metal such as Cu-Zn-Mg in aluminum matrix composite produced by stir casting and improvements of mechanical properties were identified. In the literature metal matrix composites have been made, Aluminum as matrix and particle like Al 2 O 3 are used as reinforcement. In the present study, aluminium-fly ash composites were produced with different proportions of fly-ash by weight using stir casting process to investigate the mechanical properties like hardness, impact strength, Tensile strength etc., 2. EXPERIMENTATION The required amount of ash has been collected from Vijayawada Thermal Power plant. It has been washed with pure water to remove carbon content and dried at c. It has been sieved to fine particles. The final size of the particle is 53 microns. The figure 1.1 shows the fly ash before and after processing. The aluminum of 99.8 pure has been collected and used as base metal. The fly ash with different compositions i.e 3%, 6% and 9% by weight has been mixed with aluminum and composites are made with stir casting process. The prepared composites are shown in Fig 2.2. Figure 1.1 (a) Fly ash before processing (b) Fly ash after processing editor@iaeme.com

3 V. V. Kondaiah, Ravi Kumar Panthangi and K. Srinivasa Rao 3. RESULTS AND DISCUSSIONS Figure 2.2 Aluminum and fly ash composites The distribution of reinforcements was done by Optical microscopy after casting. The specimens cut at the middle of the cast ingots. The specimens were polished with different grades of emery papers and then diamond paste polishing. After polishing, the specimens were chemically etched with Keller s etchant (a mixture of distilled water (190 ml), hydrochloric acid (3ml), nitric acid (5ml) and hydrofluoric acid 2 ml). The etchant was placed on the surface of the specimen for 20 s and was cleaned with ethanol. The microstructure of the dried specimens was then observed using an optical microscope (Leica, Germany). Figure 3.1 Optical microscope images of the samples obtained a) pure Al, b) Al-3%Flyash, c) Al- 6%FlyasA, d) Al-9%FlyashA The Fig 3.1 shows that the dispersion of flyashpatricles and dispersion is uniform. The fly ash particles distributed at the boundaries of the dendrites structure.the hardness of sample have find with Micro Vickers Hardness Tester. It is found that the hardness value increases with increase of fly-ash in the composite by 46%. The variation is shown in Fig 3.2 (a) editor@iaeme.com

4 Microstructure and Mechanical Properties of Flyash Particle Reinforced Aluminum Composite Variation of VHN with fly ash % of fly ash 0 Figure 3.2 (a) Variation of VHN Figure 3.2 (b) Variation of Impact strength The strength of aluminum and fly ash composite decreases with increase of composition of fly ash. The variation of Impact strength is shown in Fig 3.2(b). 4. CONCLUSIONS Pure aluminum fly ash composites were produced by stir casting route successfully. There was a uniform distribution of fly-ash particles in the matrix phase. The optical microscopy reveals that distributions of fly-ash particles are uniform. The hardness of the composites increased with increasing the amount of fly ash than the base alloy by 46%. The impact strength decreases with increasing of fly ash composite by 60%. Wear resistance increases with increasing of fly ash composite by 59%. REFERENCES [1] Rajan, T. P. D., Pillai, R. M., Pai, B. C., Satyanarayana, K. G., &Rohatgi, P. K. (2007). Fabrication and characterisation of Al 7Si 0.35 Mg/fly ash metal matrix composites processed by different stir casting routes. Composites Science and Technology, 67(15-16), [2] Yar, A. A., Montazerian, M., Abdizadeh, H., &Baharvandi, H. R. (2009). Microstructure and mechanical properties of aluminum alloy matrix composite reinforced with nanoparticle MgO. Journal of Alloys and Compounds, 484(1-2), [3] Mondal, D. P., Das, S., Ramakrishnan, N., & Bhasker, K. U. (2009). Cenosphere filled aluminum syntactic foam made through stir-casting technique. Composites Part A: Applied Science and Manufacturing, 40(3), [4] Kalaiselvan, K., Murugan, N., & Parameswaran, S. (2011). Production and characterization of AA6061 B4C stir cast composite. Materials & Design, 32(7), [5] Sajjadi, S. A., Ezatpour, H. R., &Beygi, H. (2011). Microstructure and mechanical properties of Al Al2O3 micro and nano composites fabricated by stir casting. Materials Science and Engineering: A, 528(29-30), [6] Sajjadi, S. A., Ezatpour, H. R., &Parizi, M. T. (2012). Comparison of microstructure and mechanical properties of A356 aluminum alloy/al2o3 composites fabricated by stir and compo-casting processes. Materials & Design, 34, editor@iaeme.com

5 V. V. Kondaiah, Ravi Kumar Panthangi and K. Srinivasa Rao [7] Su, H., Gao, W., Feng, Z., & Lu, Z. (2012). Processing, microstructure and tensile properties of nano-sized Al2O3 particle reinforced aluminum matrix composites. Materials & Design ( ), 36, [8] Tahamtan, S., Halvaee, A., Emamy, M., &Zabihi, M. S. (2013). Fabrication of Al/A206 Al2O3 nano/micro composite by combining ball milling and stir casting technology. Materials & Design, 49, [9] Akbari, M. K., Baharvandi, H. R., &Mirzaee, O. (2013). Fabrication of nano-sized Al2O3 reinforced casting aluminum composite focusing on preparation process of reinforcement powders and evaluation of its properties. Composites Part B: Engineering, 55, [10] Jokhio, M. H., Panhwer, M. I., &Unar, M. A. (2016). Manufacturing of aluminum composite material using stir casting process. arxiv preprint arxiv: [11] Shaik Mohammd Shahbuddin and V.Ranga Rao, Experimental Study On Behaviour of Flyash Based Geopolymer Concrete. International Journal of Civil Engineering and Technology, 8(1), 2017, pp [12] M Prathap Kumar, Vaddi Srinivas, M Zoheb Nawaz, Experimental Investigation on High Strength Concrete Using GGBS, Flyash & SP-430 Super Plasticizer. International Journal of Civil Engineering and Technology, 8(9), 2017, pp editor@iaeme.com