EXPERIMENTAL PROBE OF HARDNESS, TENSILE STURDINESS AND IMPACT EVALUATION RESULT OF AL 2 O 3 & SIC FOR DIVERSE REINFORCEMENT WEIGHTAGE

Transcription

1 International Journal of Mechanical Engineering and Technology (IJMET) Volume 8, Issue 8, August 217, pp , Article ID: IJMET_8_8_52 Available online at ISSN Print: and ISSN Online: IAEME Publication Scopus Indexed EXPERIMENTAL PROBE OF HARDNESS, TENSILE STURDINESS AND IMPACT EVALUATION RESULT OF AL 2 O 3 & SIC FOR DIVERSE REINFORCEMENT WEIGHTAGE Mr. Karthick.M, Mr. Belgin Paul.D.L, Mr.Satheshkumar.A Assistant Professor Department of Mechanical Engineering, Vel Tech University, Chennai,Tamilnadu ABSTRACT: This manuscript investigates about the physical properties like Hardness, tensile strength and evaluation of Charpy v-notch test for Al 2 O 3 & SiC composite material for diverse reinforcement weightage and its experimental analysis which facilitates decisive information to pollster like the dispersion range of reinforcement, brittleness of the composite material, hardness of the composite material after the addition of SiC gradually as mentioned. Keywords: Hardness, charpy v notch, Al 2 O 3 & SiC, composite materials, tensile strength etc Cite this Article: Mr. Karthick.M, Mr. Belgin Paul.D.L and Mr.Satheshkumar.A, Experimental Probe of Hardness, Tensile sturdiness and impact evaluation result of Al2O3 & SiC for diverse reinforcement weightage, International Journal of Mechanical Engineering and Technology 8(8), 217,pp INTRODUCTION The primary objective involved in designing metal matrix composite materials is to combine the desirable traits of ceramics and metal s. the intercalation of high modulus refractory particles to a ductile metal, high strength produce a material whose mechanical properties are in mid between the matrix alloy and the ceramic reinforcement, aluminium is the most abundant metal in Earth s crust and the third most abundant element after oxygen and silicon. It makes up about 8% by weight of the Earths solid surface. Due to easy availability, High strength to weight ratio, easy machinability, durable, ductile and malleability Aluminium is the most widely used nonferrous metal in 25 was 37.9 million tones. advantages of Aluminium are light weight, strong, long lasting, Highly corrosion Resistant, excellent heat and Electricity conductor, good reflective properties, very ductile, completely impermeable, odorless and totally recyclable editor@iaeme.com

2 Mr. Karthick.M, Mr. Belgin Paul.D.L and Mr.Satheshkumar.A (A) Brief info about Aluminium alloys Selecting the right alloy for a given application entails considerations of its tensile strength, density, ductility, formability, workability, weldability, and corrosion resistance. Aluminium alloys are alloys in which aluminium (Al) is the predominant metal [1]. The typical alloying elements are copper, magnesium, manganese, silicon, and zinc. There are two principal classifications, namely casting alloys and wrought alloys, both of which are further subdivided into the categories heat-treatable and non-heat-treatable. About 85% of aluminium is used for wrought products, for example rolled plate, foils and extrusions. Cast aluminium alloys yield cost effective products due to its low melting point, although they generally have lower tensile strengths than wrought alloys [2]. The most important cast aluminium alloy system is Al-Si, where the high levels of silicon (4.% to 13%) contribute to give good casting characteristics. Aluminium alloys are widely used in engineering structures and components where light weight or corrosion resistance is required. Wrought aluminium alloys are used in the shaping processes: rolling, forging, extrusion, pressing, stamping. Cast Aluminium alloys are comes after sand casting, permanent mould casting, die casting [3], investment casting, centrifugal casting, squeeze casting and continuous casting. Aluminium alloys are classified as shown in Figure 1. [4] Aluminium Alloys Wrought Alloys Cast Alloys Figure 1 Classification of Aluminium Alloy (B) Cast Aluminium Alloys Aluminium and its alloys are used in a variety of cast and wrought form and conditions of heat treatment. Forgings, sections, extrusions, sheets, plate, strip, foils and wire are some of the examples of wrought form while castings are available as sand, pressure and gravity diecastings e.g. Al-Si and Al-Mg alloys. [4] The designation of Cast Aluminium alloy is shown in Table 1. Alloy Designation Details 1XX.X 2XX.X 3XX.X 4XX.X 5XX.X 6XX.X 99% pure Aluminium Cu containing alloy Si, Cu/Mg containing alloy Si containing alloy Mg containing alloy Zn containing alloy Table 1 Designation of cast Aluminium Alloy (C) Wrought Aluminium Alloys To meet various requirements, aluminium is alloyed with copper, manganese, magnesium, zinc and silicon as major alloying elements. The designation of wrought aluminium alloy is shown in Table 2. [4] editor@iaeme.com

3 Experimental Probe of Hardness, Tensile sturdiness and impact evaluation result of Al2O3 & SiC for diverse reinforcement weightage Alloy designation 1XXX 2XXX 3XXX 4XXX 5XXX 6XXX 7XXX 8XXX Details 99% pure Aluminium Cu containing alloy Mn containing alloy Si containing alloy Mg containing alloy Mg and Si containing alloy Zn containing alloy Other alloys Table.2: Designation of Wrought Aluminium alloys [4] 2. DESCRIPTION OF ALUMINIUM ALLOYS The Aluminium Association of America has classified the wrought aluminium alloys according to a four-digit system. The classification is adopted by the International Alloy Development System (IADS). Table 3 gives the basis of designation of wrought and cast aluminium alloys in the four-digit system. The first digit identifies the alloy type the second digit shows the specific alloy modification. The last two digits indicate the specific aluminium. Aluminium Alloy in present work is shown in Table 4. Letter F O T4 T6 Condition of alloy As-fabricated Annealed Solution treated Solution treated and aged Table 3: Temper Designation System [5] Chemical Composition Weight Percentage Copper.1 Magnesium.1 max. Silicon 11 Iron.6 Manganese Nickel Zinc Tin Titanium Aluminium.5 max.1 max.1 max.5 max.2 max Remainder Table 4: Alloys conforms to British Standards 149 LM6 Cast Aluminium [5] editor@iaeme.com

4 Mr. Karthick.M, Mr. Belgin Paul.D.L and Mr.Satheshkumar.A (A) ALUMINIUM ALLOY s Promising Applications: The application of aluminium alloy is shown in Table 5 Aluminium alloy Alloy Characteristics Commen use 15/12 Non heat-treatable. Good formability, weld ability and corrosion resistance Food and Chemical Industry 214 Heat-treatable. High strength. Non wieldable Poor corrosion resistance Airframes 5251/552 Non-heat-treatable. Medium strength work Vehicle paneling, structures exposed hardening alloy. Good weld ability, formability to marine atmospheres, mine cages. and corrosion resistance / Heat-treatable. Medium strength alloy. Good weld ability and corrosion resistance. Used for intricate profiles. Heat-treatable. Properties very similar to 682. Preferable as air quenchable, therefore has less distortion problems. Not notch sensitive. Heat-treatable. Age hardens naturally, therefore will recover properties in heat-affected zone After welding. Susceptible to stress corrosion. Table 5 Application of Aluminium alloys [6] Architectural extrusions (internal and external) window frames, irrigation pipes. Stressed structural members, bridges, cranes, roof trusses, beer barrels Armored vehicles, military bridges, motor cycle and bicycle frames B. Glimpse about composite materials: Composites are materials in which two phases are combined, usually with strong interfaces between them. They usually consist of a continuous phase called the matrix and discontinuous phase in the form of fibers, whiskers or particles called the reinforcement. Considerable interest in composites has been generated in the past because many of their properties can be described by a combination of the individual properties of the constituent phases and the volume fraction in the mixture. Composite materials are gaining wide spread acceptance due to their characteristics of behavior with their high strength to weight ratio. The interest in metal matrix composites (MMCs) is due to the relation of structure to properties such as specific stiffness or specific strength. Like all composites, aluminium matrix composites are not a single material but a family of materials whose stiffness, density and thermal and electrical properties can be tailored. 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. The matrix holds the reinforcement to form the desired shape while the reinforcement improves the overall mechanical properties of the matrix. When designed properly, the new combined material exhibits better strength than would each individual material. [7] C. MATRIX (PRIMARY PHASE) The selection of suitable matrix alloys is mainly determined by the intended application of the composite material. 1. For the development of light metal composite materials that are mostly easy to process, conventional light metal alloys are applied as matrix materials. Mainly Aluminium Alloy is used for Light weight Composites. 2. The matrix is the monolithic material into which the reinforcement is embedded, and is completely continuous. This means that there is a path through the matrix to any point in the material, unlike two materials sandwiched together editor@iaeme.com

5 Experimental Probe of Hardness, Tensile sturdiness and impact evaluation result of Al2O3 & SiC for diverse reinforcement weightage 3. In structural applications, the matrix is usually a lighter metal such as Aluminium, magnesium, or titanium, and provides a compliant support for the reinforcement. In high temperature applications, cobalt and cobalt-nickel alloy matrices are common. [8] D. REINFORCEMENT (SECONDARY PHASE) The reinforcement material is embedded into the matrix. The reinforcement does not always serve a purely structural task (reinforcing the compound), but is also used to change physical properties such as wear resistance, friction coefficient, or thermal conductivity. The reinforcement can be either continuous, or discontinuous. Discontinuous MMCs can be isotropic, and can be worked with standard metalworking techniques, such as extrusion, forging or rolling. In addition, they may be machined using conventional techniques, but commonly would need the use of poly crystalline diamond tooling (PCD). Continuous reinforcement uses monofilament wires or fibers such as carbon fiber or silicon carbide [9]. Because the fibers are embedded into the matrix in a certain direction, the result is an anisotropic structure in which the alignment of the material affects its strength. One of the first MMCs used boron filament as reinforcement. Discontinuous reinforcement uses "whiskers", short fibers [1], or particles. The most common reinforcing materials in this category are alumina and silicon carbide [11-16]. Examples of some current application of composites include the tires, diesel piston, brakeshoes and pads. Examples of different reinforcement of aluminium alloy are shown in Table 6. The Al 2 O 3 and SiC are used as reinforcement in present experimental work. Comparison between reinforced & unreinforced aluminium alloy is done in Table 7. Non Metallic Alumina Boron Silicon Carbide Metallic Beryllium Niobium Stainless Steel Advantages Table 6 Reinforcement of Aluminium Alloy [8] Compared to Un- Reinforced Aluminium Alloys Disadvantages Higher Specific Strength Lower toughness and ductility More Expensive and complicated Higher Specific Stiffness Production Method Improved High Temperature Creep Resistance Improved Wear Resistance Compared To Polymer Matrix Composites Higher Transverse Strength Higher Toughness Higher Damage Tolerance Improved Environmental Resistance Higher Electrical and Thermal Conductivity Higher Temperature Capability Less developed Technology Smaller Database Technology Higher Cost editor@iaeme.com

6 Mr. Karthick.M, Mr. Belgin Paul.D.L and Mr.Satheshkumar.A Higher Toughness and Ductility Ease of Fabrication Lower Cost Compared Ceramic Matrix Composites Inferior High Temperature Capability Table 7 Comparison between Reinforced & Un- Reinforced Aluminium Alloy [8] E. PROCESSING OF MMCS Accordingly to the temperature of the metallic matrix during processing the fabrication of MMCs can be classified into three categories: (a) Liquid phase processes, (b) Solid state processes, and (c) Two phase (solid-liquid) processes Liquid Metal Techniques Liquid state fabrication of Metal Matrix Composites involves incorporation of dispersed phase into a molten matrix metal, followed by its Solidification. In order to provide high level of mechanical properties of the composite, good interfacial bonding (wetting) between the dispersed phase and the liquid matrix should be obtained. Wetting improvement may be achieved by coating the dispersed phase p articles (fibers). Proper coating not only reduces interfacial energy, but also prevents chemical interaction between the dispersed phase and the matrix. The simplest and the most cost effective method of liquid state fabrication is Stir Casting [9]. The methods of liquid state fabrication of Metal Matrix Composites are: Stir casting Infiltration Gas Pressure Infiltration Squeeze Casting Infiltration Pressure Die Infiltration Deposition Processes F. Reinforcement of Silicon carbide Silicon Carbide is the only chemical compound of carbon and silicon. It was originally produced by a high temperature electro-chemical reaction of sand and carbon. Silicon carbide is an excellent abrasive and has been produced and made into grinding wheels and other abrasive products for over one hundred years. Today the material has been developed into a high quality technical grade ceramic with very good mechanical properties [1]. Properties of Silicon Carbide Low density High strength Low thermal expansion High thermal conductivity High hardness editor@iaeme.com

7 Experimental Probe of Hardness, Tensile sturdiness and impact evaluation result of Al2O3 & SiC for diverse reinforcement weightage High elastic modulus Excellent thermal shock resistance Superior chemical inertness Detailed properties of SiC are shown in Table 8. Properties Values properties Melting Point ( C) Linear coefficient of expansion Limited of application Fracture toughness (MPa-m) Moh s Hardness 9 Crystal structure Density (g/cm ) 3.2 Linear coefficient of expansion Table 8 Properties of Silicon carbide 3. EXPERIMENTAL SETUP Experimental setup utilized for stir casting are described as following table 9. S.No Equipment used 1 Muffle furnace 2 Graphite stirrer 3 Stainless steel rod (SS316) of diameter 12mm, length 6 mm. 4 Radial drilling machine 5 Graphite crucible mould 6 Universal testing machine 7 Hardness testing machine 8 Impact toughness machine 9 Power hacksaw 1 Scanning Electron microscope Table 9 Equipment s used for stir casting experiments 4. RESULTS AND DISCUSSION The Charpy impact test, also known as the Charpy v-notch test, is a standardized high strainrate test which determines the amount of energy absorbed by a material during fracture. This absorbed energy is a measure of a given material's toughness editor@iaeme.com

8 Mr. Karthick.M, Mr. Belgin Paul.D.L and Mr.Satheshkumar.A Table 1 Results of Impact Test Serial No Composites Trial Total Force Nm Average Force Nm 1 Aluminium Alloy (LM6) LM % SiC LM6 + 5 % SiC LM % SiC LM6 + 1 % SiC LM % Al 2 O LM6 + 5 % Al 2 O LM % Al 2 O LM6 + 1 % Al 2 O LM6 + ( ) % SiC+Al 2 O LM6 + (5+5) % SiC+Al 2 O LM6 + ( ) % SiC+Al 2 O 3 LM6 + (1+1) % SiC+Al 2 O Comparison of Impact strength with weightage variation of SiC Impact of Load Nm Al Alloy (LM6) LM LM6 + 5 % % SiC SiC LM % SiC LM6 + 1 % SiC Figure 2 Comparison of Impact Strength with weightage variation of SiC editor@iaeme.com

9 Experimental Probe of Hardness, Tensile sturdiness and impact evaluation result of Al2O3 & SiC for diverse reinforcement weightage Impact of Load Nm Comparison of Impact strength with weightage variation of Al2o3 LM % Al2O3 LM6 + 5 % Al2O3 LM % Al2O3 LM6 + 1 % Al2O3 Figure 3 Comparison of Impact Strength with weightage variation of Al 2 o 3. Above bar chart depics that with the increase in SiC & Al 2 O 3 constituent Impact strength is increases w.r.t base metal. This is due to proper dispersion of SiC & Al 2 O 3 into the matrix or strong interfacial bonding in between the Al alloy LM6 and SiC& Alumina interfaces HARDNESS TEST A Rockwell hardness testing machine used for the hardness measurement. The surface being tested generally requires a metallographic finish and it was done with the help of 1, 22, 4, 6 and 1 grit size emery paper. Load used on Rockwell s hardness tester was 2 grams at dwell time 2 seconds for each sample. The result of Rockwell s hardness test for simple alloy without reinforcement (Sample No.1) and the wt.% variation of different reinforcements such as SiC/ Al 2 O 3 and Al alloy LM6 (Sample No. 2-13) are shown in Table number 11. Table 11 Results of hardness Test Hardness Sample No Sample Name Mean Rockwell Hardness hardness LM 6 + Trial 1 Trial 2 Trial 3 Trial 4 1 Pure % SiC % SiC % SiC % SiC % Al 2 O % Al 2 O % Al 2 O % Al 2 O % T % T % T % T editor@iaeme.com

10 Mr. Karthick.M, Mr. Belgin Paul.D.L and Mr.Satheshkumar.A Comparison the hardness with wt. % variation of SiC Hardness Pure 2.5% SiC 5% SiC 7.5% SiC 1% SiC weightage of Reinforcement Figure 4 Comparison the hardness with wt. % variation of SiC Comparison the Hardness with wt. % variation of Al2O3 Hardness Pure 2.5 % Al2O3 5 % Al2O3 7.5 % Al2O3 1 % Al2O3 Figure 5 Comparison the Hardness with wt. % variation of Al 2 O 3 Comparison the Hardness with wt. % variation of combined Al 2 O 3 & SiC Hardness % T 5+ 5 % T % T 1+ 1 % T Series1 Series2 Series3 Figure 6 Comparison of the Hardness with weightage variation of combined Al 2 O 3 & SiC editor@iaeme.com

11 Experimental Probe of Hardness, Tensile sturdiness and impact evaluation result of Al2O3 & SiC for diverse reinforcement weightage 4.2. TENSILE STRENGTH TEST Tensile tests were used to assess the mechanical behavior of the composites and matrix alloy. The composite and matrix alloy rods were machined to tensile specimens with a diameter of 6mm and gauge length of 3 mm. Ultimate tensile strength (UTS), often shortened to tensile strength (TS) or ultimate strength, is the maximum stress that a material can withstand while being stretched or pulled before necking, which is when the specimen's cross-section starts to significantly contract. Figure 7 Tensile Strength Specimens of different composition Alloy (LM6) Yield Strength N/mm2 UTS N/mm2 Elongation (%) Pure 2.5% SiC 5% SiC 7.5% SiC 1% SiC 2.5 % Al2O3 5 % Al2O3 7.5 % Al2O3 1 % Al2O3 2. 5% SiC %Al2O3 5% SiC + 5 %Al2O3 7. 5% SiC %Al2O3 1 % SiC + 1 %Al2O Yeild Strength N/mm2 Comparsion of Yield strength with weightage variation of Reinforcement Figure 8 Comparison of Yield strength with weightage variation of reinforcement 47 editor@iaeme.com

12 Mr. Karthick.M, Mr. Belgin Paul.D.L and Mr.Satheshkumar.A UTS N/mm Comparison of UTS N/mm2 with weightage of reinforcement Figure 9 Comparison of UTS N/mm2 with weightage of reinforcement Elongation Comparison of Elongation with weightage of Reinforcement Figure 1 Comparison of Elongation with weightage of reinforcement 5. CONCLUSION: From the above experiments and obtained data s result of this investigation deduced as Upshots of investigation witnesses that stir formed Al alloy LM 6 with SiC/Al 2 O 3 reinforced composites is clearly superior to base Al alloy LM 6 in the comparison of tensile strength, Impact strength as well as Hardness. It is eloquent that elongation tends to decrease with increasing particles wt. percentage, which confirms that silicon carbide and alumina addition increases brittleness. Aluminium matrix composites have been successfully fabricated by stir casting technique with fairly uniform distribution of SiC & Al 2 O 3 particles. After addition of SiC, Al 2 O 3 particles in the matrix hardness of the composite material increases editor@iaeme.com

13 Experimental Probe of Hardness, Tensile sturdiness and impact evaluation result of Al2O3 & SiC for diverse reinforcement weightage REFERENCES [1] It seems from this study that UTS and Yield strength trend starts increases with increase in weight percentage of SiC and Al 2 O 3 in the matrix which is clear from the obtained result. [2] Hashim J et al., Metal matrix composites: production by the stir casting method, Journal of Materials Processing Technology (1999) 1-7. [3] on date 1/4/211 [4] on date 6/5/211. [5] Seymour G. Epstein, Aluminium and Its Alloys, the Aluminium Association, Inc. 21 [6] on date 7/4/211 [7] J. R. Davis, Aluminium and aluminium alloys, ASM International, 1993 [8] Sanjeev kumar, Effect of thermal ageing on Al-SiC Metal Matrix, ME Thesis Thapar University Patiala, 21. [9] Sudipt Kumar et al, production and characterization of Aluminium-Fly Composites using Stir Casting Method, Department of Metallurgical & Materials Engineering National Institute of Technology Rourkela, 28. [1] matri x_composites.htp on date 15/4/211 [11] DIVECHA, A P et al, Silicon carbide reinforced aluminium - A formable composite [12] Journal of Metals. Vol. 33, pp Sept [13] C. M. Friend, The effect of matrix properties on reinforcement in short alumina fibrealuminium metal matrix composites Journal of Materials Science,Volume 22, Number 8, 35-31,Journal of Materials Science Volume 22, Number 8, 35-31, DOI: 1.17/BF18655 [14] N. Chawla et al, Tensile and fatigue fracture of Discontinuously Reinforced Aluminium [15] D, Advances in Fracture Research, (21), pp [16] D Tabor, The hardness of metals Oxford University Press, 1951 [17] Toshiro Kobayashi, Springer, 24 - Technology & Engineering pages [18] 11/5/211. [19] Joseph Goldstein, Scanning electron microscopy and x-ray microanalysis, Plenum Publishers, 21. [2] Dr. Sumathy Muniamuthu, Dr. Naga Lingeswara Raju, S. Sathishkumar and K. Sunil Kumar, Investigation on Mechanical Properties of Al 775-Al2O3 Metal Matrix Composite. International Journal of Mechanical Engineering and Technology, 7(6), 216, pp [21] T.Teressa, A.ChanduSagar, B.SaiNithin, K.SharanTeja, G.Suresh Reddy, P.Akhil Experimental Investigation on Heat Transfer Enhancement on Plate Heat Exchanger Using Al 2 O 3 International Journal of Mechanical Engineering and Technology (IJMET) Volume 8, Issue 5, May 217, pp editor@iaeme.com