Effect of Sic Particles On Mechanical Properties of Aluminium Adc12 Composite Through Stir Casting Process

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Effect of SiC Particles on Mechanical Properties of

Aluminium ADC12 Composite through Stir Casting


Process

Abstract. A study of ADC 12 (Al-Si aluminium alloy) composite is conducted as the more sustainable option of
material in the automotive industry due to its durability, good elastic modulus, thermal stability, wear resistance, and
high strength properties. This research is performed to identify and recognize the effect from the addition of SiC
reinforce on the metal composite with aluminium act as the matrix. In this study, the composite will be fabricated
through a stir casting process where stirring is performed mechanically with a stirrer 4 times, 10 seconds each time
with 2 seconds interval between them. Then, 1, 3, 5, 7 to 10 vol% SiC was added to each of the composite, the
addition of 5%, 0,04%wt strontium, and 0,15%wt TiB were believed to enhance wettability, modify the silicon
eutectic phase, and acts as the grain refiner respectively. The result obtained in this research showed an increase in
hardness ADC12 composite with higher SiC content, but the result showed an optimum tensile strength is at 3 vol%
SiC. Thus, It is believed that strengthening and weakening factors from the reinforcing particle and metal matrix
could neutralize the effect of each other until the optimum point of 3% (volume fraction) SiC exhibits the maximum
toughness, with tensile strength and hardness values of 236 MPa and 46 HRB respectively.

INTRODUCTION
Metal matrix composite is considered as one of the most reliable materials, especially for the automotive
industry due to the metal matrix's basic properties which were modified by the reinforcement[1]. Among all
materials, aluminum is one of the most widely used matrix material for composite due to its low density,
ductility, and thermal conductivity[2]. However, the reinforcement for aluminum matrix composite should be
able to complement wear resistivity and other certain properties qualifications[3]. Aluminum ADC 12 has been
chosen as a matrix because of its lightweight, ductility, low thermal resistance, and corrosion resistance. SiC as
reinforcement has a high melting point, high hardness value, and good wear resistance. Aluminium ADC12 with
SiC reinforcement has increased physical and mechanical properties such as better wear resistance, lower
thermal coefficient, higher corrosion resistance, better resistance to creep at high temperatures, and better
fatigue resistance[4]. Reinforcement is not the only contributing factor in enhancing composite. The addition of
wetting agents such as magnesium and silicone is also important to strengthen the interface between and matrix
and reinforce[5]. Good interface bonding means good wettability shown by the surface energy of reinforcement
is higher than the matrix. The surface energy between reinforcement and matrix can be determined by using the
Young Equation:

γSA – γLS = γLA.cosθ (1)

where γSA, γLA, γLS is the surface tension of solid surface, liquid surface, and solid–liquid interface,
respectively.
However, the presence of alumina oxide layer can decrease the wettability between reinforcement particles
and aluminium matrix. One way to increase the wettability is by using other element such as magnesium while
increasing the hardness of a material by forming the Mg 2Si phase [6]. Fabrication process used in the present
study is stir casting method. The process was chosen because it’s relatively economical and not complicated [7].
The stir casting manufacturing of the composite tends to form dendritic microstructure which results in the
lowering of some mechanical properties [8]. Titanium boron in the form of Al-5Ti-1B was added to suppress
dendritic grain growth and producing finer and equiaxed grain. The existence of boron from Al-5Ti-1B also acts
as an intermetallic stabilizer by forming the boride layer[9]. Strontium modifier (Al-15Sr) was also added to
transform the coarse eutectic silicone into a more fibrous and dispersed form[10].
In this work, various SiC reinforcement volume fractions: 1%Vol; 3%Vol; 5%Vol; 7%Vol; and 10%Vol
were added to examine the effects of different SiC content to the composite’s properties.
EXPERIMENTAL

Composite Fabrication

ADC12 was heated at 800oC until molten state was obtained. Prior to casting, SiC was also heated at 950 oC
for 1 hour as pre-treatment. After pre-treatment, SiC was added to the ADC12 melt, followed by stirring with a
mechanical stirrer 4 times, 10 seconds each time with 2 seconds interval between them. Addition of Mg ingot,
TiB, and Sr was conducted subsequetly, followed by another stirring. Argon degassing was conducted for 2
minutes before pouring the melt to the casting die. The casting die was previously coated with zirconia and
preheated at 350oC for 2-3 minutes to suppress thermal shock.

Composite Testing

All composite samples were prepared for mechanical properties testing (i.e. tensile test, hardness test, and
abrasion test) and microstructural analysis. Microstructure analysis was conducted using optical microscope
(OM), after samples were ground, polished, and etched using 0.5% hydrofluoric acid (HF) for 8-10 seconds.
The utilized mechanical properties tests apparatuses were UTM GOTECH AL-7000 LA 10 tensile test
machine with ASTM E8 standard, Rockwell B hardness tester with ASTM E18 standard, and OGOSHI model
abrasion test machine with ASTM G99 standard. The density of each sample was also measured using
Archimedes Method. All mechanical tests were conducted at room temperature.

RESULT AND DISCUSSION

Microstructural Analysis of TiB and Sr Modified ADC12/SiC Composite


The microstructure of the composite mainly contains α-Al, Eutectic Si, and Mg 2Si intermetallic as shown
Figure. 1. As shown in Table. 1, the SiC reinforcement composition was increased, but some of the amounts did
not reach the number targeted. This phenomenon can be caused by the fading mechanism that happens because
of the long period of holding time in the casting process and lack of stirring.
TABLE 1. Al ADC12 alloy composition determined by OES
SiC vt%
Element
1 3 5 7 10
Al 70,8 71 68,9 66,7 64,62
Si 11,4 12,1 12,7 15,22 17,132
Fe 0,8 0,76 1,55 1,2 1,92
Cu 2,55 2,45 2,92 2,34 2,94
Mg 5,27 6,4 5,19 5,4 5,72
Ni 0,09 0,16 0,06 0,2 0,13
Zn 0,82 0,04 0,84 0,28 0,76
Ti 0,068 0,07 0,084 0,08 0,078
B 0,0052 0,0043 0,0068 0,0049 0,005

The phase identification of the ADC 12 and the composites is shown in Fig. 1 and predicted by the
solidification path on the ternary phase diagram [11]. The light colored region is the base metal (-Al) whereas
that with grey color is Al2Cu with porous morphology and can be formed through the reaction:

L  Al + Si + Al2Cu (2)

The addition of Mg as wetting agent forms MgAl 2O4 known as Spinel phase as seen in Fig.2. MgAl 2O4 can
increase the bond of the interphase. The black Chinese script microstructure can also be seen on the Fig.1
known as binary Mg2Si, whereas the blocky microstructure known as primary Mg 2Si that also can be formed by
the addition of magnesium as wetting agent trough reaction[12]:
L Al + Si + Mg2Si (3)

All of the phases identified in optical microscope observation were confirmed in the XRD patterns shown in
Fig. 2.

FIGURE 1. Phase identification in composite microstructure using an optical microscope with 1000 magnification.

FIGURE 2. XRD patterns of ADC 12/SiC Composite

EDX testing performed at six different points is shown in Fig. 3. The results of analysis by EDX at spot 1
indicate a low Mg content with Al dominant indicating the absence of the spinel phase, but only the content of
the matrix. Spot 2 contains Mg along with Al and has a needle-like shape. Accordingly, spot 2 is identified as
Binary Mg2Si phase. Similar element content can be seen at spot 3 but has a different shape which is likely
primary Mg2Si.

FIGURE 3. SEM imaging (left) and EDS result (right)


Mechanical Properties Analysis of TiB and Sr Modified ADC12/SiC Composite

Tensile Strength Elongation


Ultimate Tensile Strength
250 8%
200 6%

Elongation
150
4%
100
50 2%
0 0%
1% 3% 5% 7% 10% 1% 3% 5% 7% 10%
%vf Reinforce SiC %vf Reinforce SiC

FIGURE 4. Ultimate tensile strength (left) and elongation (right) of composite

Ultimate tensile strength (UTS) data of composite with the variation of SiC reinforce contents are shown in
Fig. 4. Composite with 3%Vol reinforcement achieves the highest ultimate tensile strength. The highest UTS
value shows the optimum content of SiC reinforcement. As the SiC reinforcement increases the strength up to 3
vol%, ductility and hardness of composite decrease and increase respectively. It can be concluded that the
strengthening and weakening factors of the matrix and reinforcement can neutralize each other up to the 3%Vol
composition which is the optimum point for obtaining maximum tensile strength. Afterwards, the addition of
SiC reinforce particles will reduce the tensile strength of the composite.
This is in accordance with a research by Mazahery et. al. which states the addition of the SiC volume
fraction will increase the yield strength and UTS to the SiC amplifier composition by 3.5 vt%. [13].

Hardness Wear Rate


60 0.01
50 0.01
Wear Rate (mm3/mm)
Hardness (HRB)

40
0.01
30
0
20
10 0
0 0
1% 3% 5% 7% 10% 1% 3% 5% 7% 10%
%vf Reinforce SiC %vf Reinforce SiC

FIGURE 5. Hardness (left) and Wear Rate (right) of composite

From Fig. 5, it can be seen that the the addition of SiC reinforce will cause an increase in material hardness
up to 56.3 HRB on the composition of the 10 %Vol reinforce. M. H. Al Rashed et al [14] also obtained similar
results, wherewith each addition of the SiC reinforcement, there would be an increase in composite hardness.
This is due to the increase of SiC content. The more interfaces formed between the matrix and the SiC
reinforcement increases the blockage for dislocation movements resulting in the need for more force to deform
the composite. Dislocation movements in the composite needs to move around the SiC reinforcement to
continue moving thus increasing the force needed. This phenomenon is called orowan looping.
From Fig. 5, it can be seen that the wear rate at each addition of the reinforcing composition tends to
decrease. More interfaces are formed between the ADC 12 matrix and the SiC reinforce and will hold the rate of
dislocation mobility so that the material will be unlikely to deform. Research conducted by M. H. Al Rashed et
al also obtained similar results with SiC volume fraction of 5%, 10%, and 20%, of which the addition of SiC
reinforce increases the wear resistance[14].

CONCLUSION

The phases formed on the ADC 12 / SiC composite with the addition of the modifier Sr and Grain refiner
TiB are α-Al phase, primary Mg 2Si, binary eutectic Mg2Si, β phase (Al5FeSi) and Al2Cu. The addition of SiC
particles can improve the mechanical properties of the composite material with the mechanism of load transfer
effect and orowan looping. SiC reinforcing particles will increase the hardness of the composite and will be
balanced with the ductile nature of the matrix to an optimum condition. The optimal composition is found in the
composite material with the addition of SiC reinforcement particles at 3%Vol because it has a high tensile test
value and optimum hardness and ductility ratio resulting a tougher material is obtained. The addition of the Sr
element which acts as a modifier can improve mechanical properties by modifying the dendritic growth of the α-
Al phase in Al-Si alloys and the Mg 2Si phase. Then, the addition of TiB grain refiner will initiate α-Aluminum
nucleation on the composite material and cause even distribution of SiC reinforcing particles. With the addition
of Mg to the composite also produces MgAl 2O4 compound or often called a spinnel, this compound can increase
the ability of the reinforcement with the matrix so that the impact on increasing mechanical properties.

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