Fabrication of Al Alloy Composite Reinforced with Silicon Carbide and Graphite through Stir Casting Process and Wear Analysis

Aluminium composite materials are exponentially growing up and rapidly gaining importance because of their properties like low density, high strength, high stiffness, environmental resistance, low co-efficient of thermal expansion etc. In this context aluminum-boron carbide composites, with 2.5, 5 and 7.5 wt% of boron carbide (B4C) particulate reinforced, were prepared by stir casting process and the effect of the percentage of reinforcement of B4C on dry sliding wear and friction coefficient were investigated. The wear tests were carried out on a pin-on-disc type apparatus at a linear speed of 1m/s, sliding distance of 500 m and a constant load of 30 N. The coefficient of friction was recorded on line. Wear rates were calculated from mass loss measurements. Scanning electron microscope was used to examine the tribo-surface of worn Al- B4C composites. The results showed that the wear rate of 7.5 wt% B4C composites is 0.375 mg/min which is significantly lower than pure Al alloy (3.125 mg/min). The friction coefficient decreases from 0.477(for pure Al alloy) to 0.261(for 7.5 wt% B4C composites).

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Synthesis and characterization of 7075 Al alloy–SiC composites

International Journal of Structural Integrity ◽

10.1108/ijsi-01-2020-0010 ◽

2020 ◽

Vol ahead-of-print (ahead-of-print) ◽

Cited By ~ 1

Author(s):

Rajesh Kumar Bhushan

Keyword(s):

Mechanical Properties ◽

Electron Probe ◽

Microscopic Analysis ◽

Casting Process ◽

Stir Casting ◽

Al Alloy ◽

X Ray Diffraction ◽

Content Type ◽

X Ray ◽

7075 Al Alloy

PurposeMechanical properties are highly sensitive to the microstructure, and these are indirectly related to solidification parameters and processing conditions. AA7075 possesses lightweight and excellent properties as structural material which can be optimized with SiCp addition and a good fabrication technique.Design/methodology/approach7000 series aluminium alloys exhibit the highest mechanical properties. They are used for high-strength structural applications such as aircraft parts and sporting goods. The desirable properties of these alloys are: low density, high stiffness, specific strength, good wear resistance and creep resistance. The focus of this work is to investigate the microstructure of composites formed by the dispersion of silicon carbide particles (SiC) into AA7075 by stir casting processes. 7075 Al alloy is reinforced with 10 and 15 wt.% SiCp of size 10–20 µm by stir casting process. The composites have been characterized by X-ray diffraction and scanning electron microscopy, differential thermal analysis and electron probe microscopic analysis.FindingsSiCp distribution and interaction with AA7075 matrix have been studied. AA7075/10 wt.%/SiCp (10–20 µm) and AA7075/15 wt.%/SiCp (10–20 µm) composites microstructure showed excellent SiCp distribution into AA7075 matrix. In addition, no evidence of secondary chemical reactions has been observed in X-ray diffraction and electron probe microscopic analysis.Originality/valueLittle experimental work has been reported so far about effect of addition of 10 and 15 wt.% SiCp of size (10–20 µm) on the microstructure of 7075 Al alloy fabricated by stir casting process. The present investigation has been carried out to study the microstructure and carry out XRD, DTA and EPMA analysis of 7075 Al alloy, 10 and 15 wt.% SiCp of size (10–20 µm) composite and detect the interfacial reactions with the objective to minimize the formation of Al4C3.

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Mechanical and Wear Properties of SiC/Graphite Reinforced Al359 Alloy-based Metal Matrix Composite

Defence Science Journal ◽

10.14429/dsj.65.8676 ◽

2015 ◽

Vol 65 (4) ◽

pp. 330 ◽

Cited By ~ 26

Author(s):

Shubhranshu Bansal ◽

J. S. Saini

Keyword(s):

Silicon Carbide ◽

Wear Test ◽

Casting Process ◽

Stir Casting ◽

Wear Properties ◽

Sem Images ◽

Graphite Composite ◽

Reinforced Composite ◽

Worn Surface ◽

Distance Conditions

Al359 alloy was reinforced with Silicon Carbide and Silicon Carbide/Graphite particles using stir casting process. Thereafter their mechanical and wear properties were investigated. It was found that the hardness of the Al359-Silicon Carbide composite is better than Al359-Silicon Carbide-Graphite composite. The Silicon Carbide/Graphite reinforced composite exhibits a superior ultimate tensile strength against Silicon Carbide reinforced composite. The wear test was conducted at different loading, sliding velocities and sliding distances conditions. Results showed that the wear resistance of Al359 alloy increased with the reinforcement of Silicon Carbide/Graphite material for higher loading, sliding velocities and sliding distance conditions. SEM images of the worn surface of the pin were examined to study their wear mechanism.Defence Science Journal, Vol. 65, No. 4, July 2015, pp. 330-338, DOI: http://dx.doi.org/10.14429/dsj.65.8676

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Synthesis, Characterization and Testing of Al Alloy Based Hybrid Composite Materials

International Journal of Innovative Technology and Exploring Engineering - Special Issue ◽

10.35940/ijitee.b1033.1292s219 ◽

2019 ◽

Vol 9 (2S2) ◽

pp. 139-142

Keyword(s):

Composite Materials ◽

Casting Process ◽

Stir Casting ◽

Homogeneous Distribution ◽

Al Alloy ◽

Matrix Composites ◽

Boron Carbide B4c ◽

Weight Proportion

The developments in the area of aerospace, advancing activities in aircraft field and automotive industry emerges the exploit of new materials. In such applications, the role of Metal Matrix Composites (MMCs) is inevitable. In the proposed article, the fabrication of Al (6351) alloy reinforced with SiC and varying weight proportion of Boron Carbide (B4C) was done through stir casting process. The characterization of prepared composite materials is evaluated to ensure the homogeneous distribution of reinforced particulates in Al matrix. The existence of alloying elements and their mapping is done through EDS. Moreover, the enhancement of physical and mechanical behavior of the fabricated composites is also discussed in detail.

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MICROSTRUCTURAL ANALYSIS, MICROHARDNESS AND COMPRESSIVE BEHAVIOUR OF DUAL REINFORCED PARTICLES ADC-12 ALLOY COMPOSITE

International Journal of Engineering Technologies and Management Research ◽

10.29121/ijetmr.v1.i1.2015.23 ◽

2020 ◽

Vol 1 (1) ◽

pp. 23-34 ◽

Cited By ~ 1

Author(s):

Surendra Patel ◽

Raman Nateriya ◽

G. Dixit

Keyword(s):

Mechanical Properties ◽

Silicon Carbide ◽

Compressive Strength ◽

Volume Fraction ◽

Microstructural Analysis ◽

Stir Casting ◽

Alloy Composite ◽

Compressive Properties ◽

Zircon Sand ◽

Hybrid Reinforcement

The aim of this study was to determine the compressive properties of silicon carbide (SiC) and zircon sand (ZrSiO4) particulate reinforced with ADC-12 alloy, ADC-12 alloy composite. In this experimental study, SiC and ZrSiO4 particulates reinforced with ADC-12 alloy composite were manufactured by stir casting methods. Compressive properties of these composite materials were investigated by different weight percentages of dual reinforcement combinations (9+3) %, (6+6) %, (3+9) %wt. silicon carbide (SiC) and zircon sand (ZrSiO4)respectively, The compressive tests were conducted to determine compressive strength and young’s modulus to investigate the effects of reinforce materials on different combinations of weight percentages. The outcome of the investigations reveals that the tensile strength of composites reinforced by Zircon sand (ZrSiO4) and silicon carbide particles with a total reinforcement 12% wt, and in this hybrid reinforcement the variations (9+3) %, (6+6) %, (3+9) % were taken in to account for investigating the properties such as density, compressivestrength and hardness of the composites synthesized by Stir casting technique, also compared between each other’s. The mechanical properties evaluation reveals variations in hardness and the compressive strength values with the composite combinations. From the experimental studies, the optimum volume fraction of hybrid reinforcement in ADC-12 alloy on the basis of microstructure and mechanical properties it is found that the (6+6) wt.% combination.

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Effect of stirrer design on microstructure of MWCNT and Al alloy by stir casting process

Advances in Materials and Processing Technologies ◽

10.1080/2374068x.2020.1731156 ◽

2020 ◽

Vol 6 (2) ◽

pp. 320-327

Author(s):

Ashish Kumar ◽

Ravindra Singh Rana ◽

Rajesh Purohit

Keyword(s):

Casting Process ◽

Stir Casting ◽

Al Alloy

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

INCAS BULLETIN ◽

10.13111/2066-8201.2020.12.2.15 ◽

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.

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A Numerical Study on Stir Casting Process in a Metal Matrix Composite Using CFD Approach

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.1119.533 ◽

2015 ◽

Vol 1119 ◽

pp. 533-541 ◽

Cited By ~ 2

Author(s):

Joseph George ◽

Sheeja Janardhanan ◽

T.M. Sijo

Keyword(s):

Silicon Carbide ◽

Metal Matrix Composite ◽

Matrix Composite ◽

Metal Matrix ◽

Numerical Study ◽

Rotational Velocity ◽

Casting Process ◽

Stir Casting ◽

Ansys Fluent ◽

Casting Technique

This work brings out the numerical simulation of the stir casting technique for aluminium silicon carbide Metal Matrix Composite (MMC) in a closed crucible and the effect of the blade geometry and rotational velocity on solidification of the metal matrix composite has been predictedusing Computational Fluid Dynamics (CFD) approach. The material used in the crucible is silicon carbide in aluminiummetal matrix. Geometric modelling and meshing have been carried out using ANSYS ICEM CFD. Computer simulations have been carried using the commercial CFD package, ANSYS FLUENT. The calculations used 2-D discrete phase, solidification and melting model and enthalpy method. Mushy state mixing, indicative of the solidification patterns have been studied to predict the most suitable ratio of crucible to blade dimensions and speed of stirring to obtain the most uniform type of solidification which in turn induces some enhanced mechanical properties to the casting.

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Fabrication and characterization of Al6063/SiC composites using electromagnetic stir casting process

Proceedings of the Institution of Mechanical Engineers Part E Journal of Process Mechanical Engineering ◽

10.1177/09544089211045796 ◽

2021 ◽

pp. 095440892110457

Author(s):

Farhan A Shamim ◽

Akshay Dvivedi ◽

Pradeep Kumar

Keyword(s):

Silicon Carbide ◽

Tensile Strength ◽

Metal Matrix Composites ◽

Metal Matrix ◽

Casting Process ◽

Stir Casting ◽

Matrix Composites ◽

X Ray ◽

Electromagnetic Stir Casting ◽

Al6063 Alloy

In this work, metal matrix composites were fabricated using the electromagnetic stir casting process by adding 5 and 10 wt% silicon carbide in Al6063 alloy. Hardness, ultimate tensile strength, and yield strength of the developed Al6063/SiC/5p metal matrix composites have been improved by 17%, 18%, and 37%, respectively, in comparison with Al6063 alloy. Further, an improvement of 25%, 37%, and 71% in hardness, ultimate tensile strength, and yield strength, respectively, have been noted for Al6063/SiC/10p metal matrix composite in comparison with the Al6063 alloy. Results revealed that the hardness and strength of metal matrix composites were increased with silicon carbide addition in Al6063 alloy. The presence of different elements in metal matrix composites was identified by energy-dispersive X-ray spectroscopy and X-ray diffraction techniques. Energy-dispersive X-ray spectroscopy was used for elemental mapping observation of the metal matrix composites. Uniform distribution of reinforcement particles in the matrix with improved mechanical properties of metal matrix composites proved the adequacy of the electromagnetic stir casting process. The presence of facets and dimples in fractographs indicated the mixed mode of fracture. The average percentage porosity presented in Al6063/silicon carbide/5p and Al6063/SiC/10p metal matrix composites was found to be 4.68% and 5.22%, respectively.

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