Damage modeling and critical damage evaluation of AA2014 cast alloy embedded with fly ash composite under upsetting

2019 ◽  
Vol 233 (15) ◽  
pp. 5227-5236 ◽  
Author(s):  
Ch HariKrishna ◽  
MJ Davidson
Keyword(s):  
Fly Ash ◽  
Ductile Fracture ◽  
Cast Alloy ◽  
Matrix Material ◽  
Casting Process ◽  
Stir Casting ◽  
Damage Evaluation ◽  
Primary Metal ◽  
Cast Alloys ◽  
Critical Damage

Abstract: Upsetting is one of the primary metal forming techniques and needs to be applied to reduce the cross section of the billets for further processing. Ductile fracture in metal upsetting process is an issue and depends on the material used and processing conditions. The current work focus is on the critical damage evaluation of AA2014 cast alloy embedded with fly ash composite. AA2014 alloy was heated to a pouring temperature of 750 ℃ and fly ash of 3% and 6% were added separately with AA2014 matrix material to prepare three sets of cast alloys namely pure AA2014, AA2014 + 3% fly ash, and AA2014 + 6% fly ash. After manufacturing three sets of rods from stir casting process, three sets of billets were machined to a height and diameter of 24 mm. Three sets of billets were compressed between rigid dies to different levels of strain until the initiation of fracture. Ductile fracture criterions were modeled to evaluate the critical damage value and fracture loci were constructed for different compositions.

scholarly journals Optimization of Machining Parameters in Drilling of Aluminum Matrix Composites (LM6/Fly Ash) utilizing Taguchi Technique

2019 ◽  
Vol 9 (2) ◽  
pp. 1229-1232 ◽  
Keyword(s):  
Fly Ash ◽  
Thrust Force ◽  
Matrix Material ◽  
Aluminum Matrix ◽  
Casting Process ◽  
Stir Casting ◽  
Aluminum Matrix Composites ◽  
Feed Speed ◽  
Machining Parameters ◽  
The Impact

The present study revolves around the possibility of setting machining parameters in the drilling of composites of aluminum matrix (LM6/Fly ash) using the signal to noise ratio analysis. The aim of this work is to consider, the impact of input parameters, feed, speed, drill and percentage of composite material reinforcement on thrust force during AMCs drilling. AMCs were manufactured by the stir casting process with LM6 aluminium alloy as matrix material and fly ash as reinforcement material. Investigations were directed on a CNC vertical machining center for estimating thrust force. The Taguchi strategy for trial configuration is a generally admitted system employed for delivering great items requiring less effort. In the same way, L27 orthogonal array is employed for the analyses. The response table, graphs and variance analyzes are used to demonstrate the potential environment and the effects of machining parameters. It is evident that there is a tremendous improvement in the drilling procedure by using this methodology.

scholarly journals Synthesis of Al-Fly Ash Composites by Modified Two Step Stir Casting Method

2012 ◽  
Vol 488-489 ◽  
pp. 775-781 ◽  
Author(s):  
P. Shanmughasundaram ◽  
R. Subramanian ◽  
G. Prabhu
Keyword(s):  
Mechanical Properties ◽  
Fly Ash ◽  
Matrix Material ◽  
Casting Process ◽  
Stir Casting ◽  
Casting Method ◽  
Industrial Preparation ◽  
The Matrix ◽  
Method Analysis ◽  
Properties Of Composites

In the stir casting process, homogeneous dispersion of reinforcing particles within the matrix material is one such major problem, which influences on the properties of composites. In this research, an attempt has been made to study the influence of fly ash wt.% (10 ,15 and 20), ratio of the impeller outer dia to crucible inner dia (0.7,0.5 and 0.3) and processing method (liquid state stirring, two step stirring and modified two step stirring) on the mechanical properties and the distribution of fly ash particles in the Al matrix.Optimum parameters were identified for attaining the maximum mechanical properties such as hardness and tensile strength of composites by the application of Taguchi method, Analysis of Variance (ANOVA) and the results were validated by confirmation test.The present work could provide a guide for the industrial preparation of composites.

scholarly journals Recent studies on particulate reinforced AZ91 magnesium composites fabricated by Stir casting – A review

2020 ◽  
Vol 4 (2) ◽  
pp. 115-126
Author(s):  
Anil K. Matta ◽  
Naga S. S. Koka ◽  
Sameer K. Devarakonda
Keyword(s):  
High Performance ◽  
Matrix Material ◽  
Weight Ratio ◽  
High Strength ◽  
Casting Process ◽  
Stir Casting ◽  
Critical Conditions ◽  
Matrix Composites ◽  
The Matrix ◽  
Magnesium Composites

Magnesium Metal Matrix Composites (Mg MMC) have been the focus of consideration by many researchers for the past few years. Many applications of Mg MMCs were evolved in less span of time in the automotive and aerospace sector to capture the benefit of high strength to weight ratio along with improved corrosion resistance. However, the performance of these materials in critical conditions is significantly influenced by several factors including the fabrication methods used for processing the composites. Most of the papers addressed all the manufacturing strategies of Mg MMC but no paper was recognized as a dedicated source for magnesium composites prepared through stir casting process. Since stir casting is the least expensive and most common process in the preparation of composites, this paper reviews particulate based Mg MMCs fabricated with stir casting technology. AZ91 series alloys are considered as the matrix material while the effect of different particle reinforcements, sizes , weight fractions on mechanical and tribological responses are elaborated in support with micro structural examinations. Technical difficulties and latest innovations happened during the last decade in making Mg MMCs as high performance material are also presented.

scholarly journals Experimental Evaluation of Mechanical, Wear and Corrosion properties of AA5083/Graphite Metal Matrix Composite Prepared using Compocasting Process

2019 ◽  
Vol 9 (1) ◽  
pp. 2352-2357
Keyword(s):  
Tensile Strength ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Metal Matrix ◽  
Matrix Material ◽  
Research Work ◽  
Casting Process ◽  
Stir Casting ◽  
Corrosion Properties ◽  
Mechanical And Tribological Properties

In most of the engineering applications such as aviation, defence, marine and automotive requires components with light weight and along with favorable mechanical properties; this demand perhaps satisfied by metal matrix composites (MMCs) of aluminium by virtue of its distinguished achievement. Also MMCs suffer from insufficient process stability, in-adequate economic efficiency and reliability. In the present research work an experiment was developed to synthesize metal matrix composite adopting Aluminium Alloy (AA) 5083 as matrix material reinforced with graphite particulates (6 wt %, 8 wt % & 10 wt %) using two stage in-situ stir casting process. Experiments were implemented to analyze mechanical and tribological properties like ultimate tensile strength, microhardness, wear characteristics and corrosion properties. From the above investigations, it is revealed that microhardness increases with decrease in tensile strength with upsurge in more wt % of reinforcement. Due to the very high self-lubricating property of graphite significant reduction in wear can be observed with deepen in wt % of graphite. Also corrosion rate decreases with more amount of graphite particulate when compared with base matrix material.

scholarly journals Effect of fly ash particle reinfo rcement on microstructure, porosity and hardness in Al-(Si-Mg) cast composites

2017 ◽  
Vol 23 (1&2) ◽  
pp. 113 ◽  
Author(s):  
M.B. Harun ◽  
S.R. Shamsudin ◽  
H. Yazid ◽  
Z. Selamat ◽  
M.S. Sattar ◽  
...  
Keyword(s):  
Fly Ash ◽  
Casting Process ◽  
Matrix Alloy ◽  
Stir Casting ◽  
Image Analyzer ◽  
Microscopy Image ◽  
Optical Microscopy Image ◽  
Cast Composites ◽  
The Matrix ◽  
Scanning Electron

The microstructure of cast Al-4Si-Mg reinforcedwith fly ash particles at various particlecontents has been studied. The composites were fabricated by stir casting process andcharacterized by optical microscopy, image analyzer, scanning electron microscopy and hardness measurements. The results showed that particle contents affected to the presence oforosities and hardness of the composites. It was observed that increasing the fly ash contentincrease the porosity in the composites, with the matrix alloy reinforced with 15 wt.% of fly ash particles having the highest porosity and lowest hardness.

Analysis of anisotropy in the upsetting process of AA2014 cast alloy embedded with fly ash

2020 ◽  
Vol 234 (14) ◽  
pp. 2833-2841
Author(s):  
Ch Hari Krishna ◽  
Ravikumar Dumpala ◽  
MJ Davidson ◽  
P Srinivasaraju ◽  
G Srinivasarao
Keyword(s):  
Fly Ash ◽  
Fracture Strain ◽  
Cast Alloy ◽  
Matrix Material ◽  
Matrix Composites ◽  
White Grease ◽  
Lubrication Condition ◽  
Cylindrical Samples ◽  
Lubrication Conditions ◽  
Anisotropy Coefficients

Developing new metal matrix composites for a wide variety of applications and analyzing the formability aspects are challenging in the area of manufacturing. In the current study, solid cylindrical samples with AA2014 as matrix material and fly ash as reinforcement were used for the investigation. AA2014 was heated to a pouring temperature of 750 ℃ and the preheated fly ash was added to the molten AA2014 in different compositions. The whole mixture was stirred to prepare composite rods of AA2014, AA2014 + 3% fly ash and AA2014 + 6% fly ash. Each set of cylindrical samples were compressed between a set of dies till fracture by employing grease, white grease and no lubrication conditions. The varying friction conditions and composition influence the anisotropy of the billets at fracture. Empirical equations were modeled to investigate the effect of anisotropy on the stress trixiality and fracture strain at the onset of fracture. The developed equation is useful in estimating critical damage constants for any material and for any lubrication condition. A correlation between damage anisotropy factor, damage constant and fracture strain was established to understand the formability limits for different anisotropy coefficients.

Synthesis and Characterization of Al 7075 Alloy Reinforced with Silicon Carbide and Fly Ash

2019 ◽  
Vol 11 (3) ◽  
Author(s):  
G. Sathishkumar ◽  
S.J. Irudayaraja ◽  
S. Sivaganesan ◽  
M. Thuyavan
Keyword(s):  
Mechanical Properties ◽  
Fly Ash ◽  
Casting Process ◽  
Stir Casting ◽  
Industrial Applications ◽  
Matrix Composites ◽  
Specific Strength ◽  
Al 7075 ◽  
7075 Alloy

Metal matrix composites are of great interest in industrial applications for its light weight with high specific strength, stiffness and heat resistance. The processing of MMCs by stir casting process is an effective way of manufacturing. In this paper the comparison of mechanical properties of Aluminium 7075 as a base metal and varying composition of fly ash by 3 and 6 wt.% SiC and 7% fly ash as reinforcement is carried out. Scanning electron microscope was used to confirm the presence of SiC and fly ash. The composites with 6% SiC was found to have maximum hardness whereas composites of 6% and 5 % fly ash were found to have minimum hardness. The mechanical properties such as wear resistance were studied. From the results, it has been finalized that the addition of 6% SiC was identified to show the least wear rate.

scholarly journals Analysis of Surface Roughness and Burr Height in Drilling of Aluminium Matrix Composites using Taguchi Technique

2020 ◽  
Vol 12 (2) ◽  
pp. 173-182
Author(s):  
C. SARALA RUBI ◽  
J. UDAYA PRAKASH
Keyword(s):  
Surface Roughness ◽  
Fly Ash ◽  
Casting Process ◽  
Stir Casting ◽  
Al Alloy ◽  
Matrix Composites ◽  
Taguchi Technique ◽  
Burr Height ◽  
Response Table ◽  
Reinforcing Material

The present research involves the opportunity of utilising the signal to noise (S/N) ratio analysis to set machining factors in the drilling of aluminium alloy LM6-Fly ash composites (AMCs). The purpose of this research is to understand, during drilling of AMCs, the consequences of variables, feed rate, spindle speed, drill material and amount of reinforcing material on surface roughness and burr height. AMCs are formed with LM6 (Al alloy) as continuous component via the stir casting process and fly ash as reinforced content. The Taguchi design strategy is a widely accepted method which is used to produce quality products that require minimum commitment. Likewise, the L27 orthogonal array is used for conducting experiments. The response table, response graphs and analysis of variance (ANOVA) illustrate the prospective atmosphere and the impacts of input process variables. Taguchi technique considerably enhances the drilling operation.

Corrosion Investigation and Microstructure of High Calcium Fly Ash Reinforced Al6061

2019 ◽  
Vol 824 ◽  
pp. 260-266
Author(s):  
Onthida Kosasang ◽  
Autsadawooth Kummoo ◽  
Ratchapol Konghakot ◽  
Sukangkana Talangkun
Keyword(s):  
Fly Ash ◽  
Corrosion Behavior ◽  
Casting Process ◽  
Stir Casting ◽  
Polarization Measurement ◽  
Matrix Composites ◽  
Alloy Matrix ◽  
High Calcium ◽  
High Calcium Fly Ash ◽  
Corrosion Investigation

In this study, the effect of high Ca fly ash on the corrosion behavior and microstructure of Al6061 alloy matrix composite was investigated. The Al6061 matrix composites containing 5, 7, and 10 wt% of fly ash particles were prepared by the stir casting process. The corrosion behavior was investigated using potentiodynamic polarization measurement using 5 wt% NaCl. The results revealed that the Icorr increased from 2.44 µA/cm2 to 8.60 µA/cm2 as the fly ash concentration increased from 5 wt% to 10 wt%. This increase of Icorr indicates an increase of the corrosion rate. The corrosion mainly occurs at the interface between fly ash particles and Al 6061 matrix.

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