International Journal of Mechanical and Production

Engineering Research and Development (IJMPERD)

ISSN (P): 2249–6890; ISSN (E): 2249–8001
Vol. 10, Issue 2, Apr 2020, 237–246
© TJPRC Pvt. Ltd.

MECHANICAL BEHAVIOR OF GRAPHITE/GRANITE PARTICLES REINFORCED

Al-Si ALLOY BASED COMPOSITES BY STIR CASTING ROUTE
1 2 3
MOSES DAYAN G, JAMI RAMESH & M. GOPI KRISHNA
1,2
Research Scholar, Department of Mechanical, Acharya Nagarjuna University, Guntur, A.P. India
3
Assistant Professor, Department of Mechanical, Acharya Nagarjuna University, Guntur, A.P. India
ABSTRACT

Al-Si alloy reinforced with the particulates of granite acquired from cutting of rock stones along with the graphite
particles have good mechanical properties. The composite materials were prepared with various weight proportions of the
strengthening particles to evaluate the mechanical characteristics. This has been achieved by manufacturing by stir
casting method, hardness, density studies of tensile and compression on both alloys and composites were completed.
Better durability and tensile properties for each composite were observed. Conveyance of rock and graphite particles in
aluminum alloy matrix improves hardness of lattice material.

KEYWORDS: Al-Si alloy, Granite Particles, Graphite, X-Ray Diffraction and Energy Dispersive Spectroscopy.

Original Article
Received: Jan 15, 2020; Accepted: Feb 05, 2020; Published: Feb 29, 2020; Paper Id.: IJMPERDAPR202021

NOMENCLATURE:-

ρMMC = composite density

m= composite mass

m1= composite mass in distilled water

ρH2O= distilled water density

Vr = reinforcement weight ratio

ρr = reinforcement density

ρc = density of composite

ρm =density of the unreinforced alloy

1. INTRODUCTION

With the advent of specified reinforcements the aluminum matrix composites are becoming ravishing materials for
advanced aerospace and despite their properties car structures can be customized [1, 2]. At the elevated
temperatures, many materials fails to perform the modulus property and by substituting these with the composite
materials the mechanical properties can be enhanced. To enhance the MMC’s properties of normally reinforced
particles of order in microns are used. Flyash is the lowest density and conservative fortification reachable in mass
amounts which is obtained as a byproduct in power plants. Hassan S.F et al. [3] examined the scanning electron
micrographs of SiC as strengthening particle in metal matrix composites manufactured by secondary processing and

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238 Moses Dayan G, Jami Ramesh & M. Gopi Krishna

recognized higher strain to fracture values for the deformed material and further more sinter forged test castigated the
higher value of flexible modulus and ultimate rigidity because of the molecule fracture because of crack. Kwok et al [4]
reported that coalesce of hard particles in Al-Si alloy deteriorates the crystal bonding and results in evacuating of the SiC
particles. The cross-section stressing in the neighboring regions of the particles will lessen the degree of plastic
disfigurement that these zones can experience, which will make them increasingly sensitive against breaking. These splits
will allow the lattice to be removed from the combining regions of the particles, subsequently diminishing the quality of
the interfacial bond. Attempts have been made in the present work to obtain excellent properties of high specific strength
with good wear-resistant properties.

2. EXPERIMENTAL WORK
2.1. Refinement of Granite Powder

Table 1: Chemical Composition of Granite Powder

Constituents Weight Percentage
Al2O3 14.4
CaO 1.82
MgO 0.71
SiO2 72.4
K 2O 4.12
Na2O 3.69
Fe2O3 1.22

The granite particle was taken as strengthening material and obtained from local stone crushing units. The as
received granite particles chemical composition of the powder was given in table 1. 500 grams of granite powder was taken
in a graphite crucible and preheated for 4 hours at 850oC in the muffle furnace to determine the ignition loss. Preheated
granite particles were washed with distilled water after cooling to room temperature and then heated at 120oC for a
duration of 48 hours to make it dry. Initially, granite powder is greyish in color and after processing it turns to brikish as
shown in Figure 1. The processed granite powder is sieved with meshes of 100 to 350 of sieve shaker for 15 minutes and
results show that over 70 percent by weight remained in-200 + 350 mesh with an average particle size of 53 µm, this size
was chosen as a strengthening for the development of hybrid composite.

(a) (b)
Figure 1: (a) Granite powder Initial Condition (b)Granite Powder After Refinement.

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Mechanical Behavior of Graphite/Granite Particles Reinforced 239
Al-Si Alloy Based Composites by Stir Casting Route

2.2.X-Ray Diffraction Pattern

X-ray diffractometer is used to classify the mineralogical components in a Sheifert Model URD 65, which operates with
Cu-Kα radiation for a 2θ variation from 5º to 65º. The x-ray diffraction pattern of granite 50-53 µm is as shown in the
figure 2 shows the compounds consisting of mineral amphibolic (hornblende), feldspar (microcline, albite, and anorthite)
and quartz. The peaks depicted with MI (miller indices) represent the characteristic granite peaks (ICDD CARD No:
C000560159). Different peaks may be a result of another period of any antecedent materials or pollutions or may be a
direct result of any type of middle stage. The normal molecule size determined by Scherrer's formula is 9.0006 AOfigure 2
shows XRD of granite powder.

Figure 2: X-Ray Diffraction Pattern of Granite

Powder.

2.3.Fabrication of Metal Matrix Composites

In this study, aluminum-based hybrid composites containing various mixtures of granite and graphite particles addition of
53µm reinforcements were effectively manufactured by vortex method. Table 2 shows the composition of aluminium-
silicon alloy.

Table 2: Chemical Composition of Al-Si Alloy, wt. %.

Si Mg Cu Fe Ti Al
6.5 0.4 0.05 0.09 0.06 Balance

Al-Si alloy is melted in electric furnace by using graphite crucible. The arrangement for the stir cast is depicted in
figure 3, when the temperature reaches 7700C a pool was created. The preheated granite and graphite particulates were first
mixed into the Al-Si melt in different weight percentages of 2% graphite and 2% granite in first case and by keeping the
graphite reinforcement as constant the granite weight percentage is increased to 4%. To ensure uniform distribution of
strengthening particles in the pool, a cone shaped object is utilized .To prevent the oxidation inert gas preferably argon is
impinged around the melt and fingers were casted in a permanent die as shown in figure4.

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240 Moses Dayan G, Jami Ramesh & M. Gopi Krishna

Figure 3: Experimental Setup of Stir Casting.

Figure 4: Fabrication of Fingers.

2.4. Hardness Analysis

Vickers micro hardness tester (Model: VHS 5B-Banbros) is used to find the hardness of the composites and base alloy by
taking 10 readings on an average.

2.5. Density Analysis

By using the technique of Archimedes drainage method the densities of composites and base alloy were found by using the
relation:

ρMMC =

And by using the concept of rule of mixtures the analytical density calculations was done using following relation.

ρc= Vr ρr + (1-Vr)ρm

3. RESULTS AND DISCUSSIONS

3.1. Microstructural Study

To evaluate the morphological changes and elemental analysis of the composites and base alloy, a Scanning electron
microscopy was used. Figure 5 (a),(b),(c),(d) illustrates the Al-Si alloy SEM micrograph in which needle particles indicates
Si, graphite and granite particles are identified and displayed in magnified view.

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Mechanical Behavior of Graphite/Granite Particles Reinforced 241
Al-Si Alloy Based Composites by Stir Casting Route

Figure 5: (a) SEM Micrograph Al-Si Alloy (b) SEM Micrograph of Graphite Particles (c) Particle
Distribution in Low Resolution (d)SEM Micrograph of Granite Particles.

3.2.Energy Dispersive Spectroscopy Analysis

Figure 6 (a), (b) shows the existence of Silicon, Aluminium,and Magnesium in the matrix phase obtained from the EDS
composite spectrum, silicon and other components in composite-reinforced graphite granite as shown in figure 7 (a), (b).
Also no contamination had taken place because of argon gas shielding continuously and no oxygen traces were found in
the matrix.

Figure 6: (a), (b) Energy Dispersive Spectrum of Al-Si Alloy.

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242 Moses Dayan G, Jami Ramesh & M. Gopi Krishna

Figure 7: (a), (b) Energy Dispersive Spectrum of Graphite and Granite Composite.

3.3. Density and Hardness Studies

Table 3 shows the standard analytical and experimental density values for the base alloy and the subsequent composites. It
was observed that the addition to the Al-Si alloy matrix of 2 percent graphite and 4 percent granite particles significantly
decreases the density of the resulting composites compared to the base alloy.

Table 3: Analytical and Measured Densities of Al-Si Alloy and

Composites
Density (g/cm3)
S. No Sample
Analytical Measured
1. Al-Si alloy 2.8 2.8
2. 2% graphite composite 1 2.79 2.76
2% graphite + 4%
3. 2.76 2.73
granite composite 2

Figure 8: Hardness Values of Composite Samples.

With the increase in the percentage of graphite and granite particulates the densities of the composites decreases
as shown in table 3. The observed densities are therefore lower than the values derived from theoretical calculations. A
material's hardness is a physical criterion which indicates the ability to withstand local plastic deformation. The Figure 8
indicates that composite 1 and composite 2 hardness increased to 110 and 135 VHN from 84 VHN in Al-Si alloy. This
could be attributed to the Si and Al2O3 and silica predominant pieces that are strong in nature. M.G. Krishna et.al.[5, 6 ]
reported similar findings.

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Mechanical Behavior of Graphite/Granite Particles Reinforced 243
Al-Si Alloy Based Composites by Stir Casting Route

3.4.Tensile Studies

Using INSTRON tensile testing machine, elastic properties of manufactured composites were determined according to
ASTM, E-8 standards as shown in figure 9 (a) and plotting has done repeatedly. Table 4 shows the tensile behavior of the
composite and figure 10(a), (b) shows the specimens before and after fracture. The composite with 2% graphite and 2%
granite (C2) shows an increased ultimate and yield strength relative to the base matrix and an improvement is also seen in
the modulus of elasticity.

Figure 9: Tensile Test on Sample.

Figure 10: (a) Composite Specimens Before Tensile Test (b) Tensile Specimens After Fracture.

From Table 4, it is found that the tensile strength of the composites is greater than their base matrix. Maleq et al.
[7] reported that the responsible mechanism for the marvels incorporates load transfer from the alloy phase to the particle
which has high strength and stiffness.

Table 4: Tensile Strength of Al-Si Metal Matrix Composites

Ultimate Tensile Young’s
Yield Strength
Alloy and Composites Strength (UTS) Modulus,
(MPa)
(MPa) GPa
Al-Si alloy 65.09 102.30 9.7
C1 (2% Graphite) 86.31 128.07 16.2
C2 (2% Gaphite+2%Granite) 88.44 170.71 16.6
C3 (2% Gaphite+4%Granite) 86.87 148.17 15

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244 Moses Dayan G, Jami Ramesh & M. Gopi Krishna

The fracture behavior and tensile deformation of the 6061 alloys reinforced with silicon carbide was studied by
Lloyd [8] stated that the elastic modules of intermittently strengthened composites were supposed to work as a fraction of
the reinforcement volume. Lorca and Gonzalez[10] stated that, with the rise in the volume fraction of the reinforcement,
the UTS, yield strength and the Elastic composite modulus improved, while the ductility decreased. Because of the
constraints imposed on the deformation induced by the presence of hard and brittle Al2O3particles in the soft and ductile
6061 Al alloy matrix higher applied stress is needed to set off plastic deformation in the matrix. Figure 11(a) indicates a
crack for alloy Al-Si alloy and figure 11(b, c) shows that the typical character of a fracture with no apparent dimple and
tear ridge structures is observed for 2 per cent graphite and granite hybrid fractured specimens. It can be seen that the
addition of graphite and granite particles into matrix alloy increases the elastic strength. This was due to the hard granite
particle shape at the edge used in this study. And they also stated that the increase in the load borne by the
particulates during the plastic shear at the starting phase was due partly to the strain hardening of the neighbouring
matrix, which is relatively ductile in nature. Several authors[11-12 ] reported inundated stress relaxation from broken
particles allowing stress transfer to surrounding particles resulting in increased particle fracture. They also concluded
that the final fracturing of the composites happens through a ductile process involving the nucleation and
development of the matrix voids, which leads to the final coalescence of the larger voids that exist around the broken
particles.

Figure 11: (a) SEM Micrograph of Al- Si Alloy

(b),(c) SEM Micrographs of Fractured Graphite, Granite Composite

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Mechanical Behavior of Graphite/Granite Particles Reinforced 245
Al-Si Alloy Based Composites by Stir Casting Route

4. CONCLUSIONS

Al-Si alloy combined with hybrid graphite and granite particulate composites was produced successfully using vortex. The
strengthening particles were evenly distributed in the matrix phase. The SEM results show a strong interfacial bonding,
which clearly shows that the composites did not contain discontinuities and voids.

REFERENCES

1. R.J. Arsenault, Metal Matrix Composites; Mechanisms and Properties, 1991(Academic Press, SanDiego).

2. Kahtri et al, Fundamentals of metal-matrix composites, S.Suresh, A. Mortensen and A. Needleman, B-H publications1993.

3. Hassan S.F, Gupta, M, Development of high strength magnesium copper based hybrid composites with enhanced tensile
properties, Materials Science and Technology, 19 (2003)253-259.

4. NG Deng, CJ, Yu, P, Kwok, WY, Aravind, M, Ng, DHL, Chan, SLI, Formation of Mg-Mg2Cu nanostructured eutectic in Mg-
based metal matrix composite, Journal of Materials Research, 188. (2003) 1934-1942.

5. M.Gopi Krishna,Mechanical behavior of fly ash/SiC particles reinforced Al-Zn alloy-based metal matrix composites
fabricated by stir casting method, Journal of Materials research technology – Volume 8, Issue 1, January–March 2019, Pages
737-744.

6. M.GopiKrishna. Influence of wear parameters on friction performance of A356 aluminum –graphite/ granite particles
reinforced metal matrix hybrid composites, 5, 2019.

7. M A Maleque, A A Adebisi, and N IzzatiAnalysis of Fracture Mechanism for Al-Mg/SiCp Composite Materials, in:
Proceedings of ICMAAE- 16, IOP Conf. Series: Materials Science and Engineering 184 (2017) 012031.

8. D.J. Lloyd, Aspects of fracture in particulate reinforced metal matrixcomposites, Acta Metall. Mater. 39(1991) 59–71.

9. J.Llorca, C.Gonzalez, Microstructural factors controlling the strength and ductility of particle-reinforcedmetal-matrix
composites, J. Mech. Phys. Solids 46 (1998)1–28.

10. P.K.Rohatgi, R.Q.Guo, P. Huang, S.Ray, Friction and abrasion resistance of cast Aluminiumalloy–flyash composites, Metall.
Mater. Trans. A 28A (1997) 245–250.

11. N.R.M.R. Bhargava, I. Samajdar, S. Ranganathan, M.K. Surappa, Role of coldwork and SiCrein forcements on the b0 /b
precipitation in Al-10Mg alloy, Met.Mat. Trans A 29A (1998)2835–2842.

AUTHOR’S PROFILE

G. Moses Dayan is a Research Scholar in Mechanical Engineering Department, Acharya Nagarjuna University, Guntur,
A.P. He has finished his M.E and research area includes material characterization and surface engineering of
nanomaterials.

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246 Moses Dayan G, Jami Ramesh & M. Gopi Krishna

J. Ramesh is a Research Scholar in Mechanical Engineering Department, Acharya Nagarjuna University, Guntur, A.P.
Research area includes material characterization.

Dr. M. GopiKrishna obtained Ph.D. from Andhra University, A.P, Published more than 75 research papers in reputed
journals. Completed one major research project and currently guiding 8 Ph.D. scholars. Life time member in Society for
failure analysis.

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