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Experimental Investigation On Mechanical Properties and Wear Characteristics OF A390-SIC-B C Hybrid Composite

The document describes an experimental investigation of the mechanical properties and wear characteristics of an A390-SiC-B4C hybrid composite. The composite was produced by stir casting A390 alloy reinforced with 6% silicon carbide (SiC) and varying amounts (3%, 6%, 9%) of boron carbide (B4C). Tests were conducted to measure the hardness, tensile strength, and wear resistance of the composite and compare to the unreinforced A390 alloy. Preliminary results showed over 35% improvement in hardness for the composite compared to the alloy. However, tensile strength and wear resistance results were not obtained for the composites. Further work is needed to fully characterize the mechanical properties and wear behavior of

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Rahul Sanjayan
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82 views6 pages

Experimental Investigation On Mechanical Properties and Wear Characteristics OF A390-SIC-B C Hybrid Composite

The document describes an experimental investigation of the mechanical properties and wear characteristics of an A390-SiC-B4C hybrid composite. The composite was produced by stir casting A390 alloy reinforced with 6% silicon carbide (SiC) and varying amounts (3%, 6%, 9%) of boron carbide (B4C). Tests were conducted to measure the hardness, tensile strength, and wear resistance of the composite and compare to the unreinforced A390 alloy. Preliminary results showed over 35% improvement in hardness for the composite compared to the alloy. However, tensile strength and wear resistance results were not obtained for the composites. Further work is needed to fully characterize the mechanical properties and wear behavior of

Uploaded by

Rahul Sanjayan
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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EXPERIMENTAL INVESTIGATION

ON MECHANICAL PROPERTIES
AND WEAR CHARACTERISTICS
OF A390-SIC-B4C HYBRID
COMPOSITE

GUIDED BY
DR.AMBILIKUMAR C K SUBMITTED BY
ASSOSIATE PROFESSOR RAHUL SANJAYAN
MECHANICAL ENGINEERING TCR18MEPE09
GEC THRISSUR M.Tech Mechanical Engineering (PE)
GEC THRISSUR
1. Abstract
Aluminium metal matrix composites are widely used due to low density, corrosion resistance,
mechanical properties, availability, ease of manufacturing, cost effectiveness etc. The
purpose of this thesis is to compare and experimentally investigate the wear characteristics
and mechanical properties of aluminium A390-SiC-B4C composite, which have been done by
stir casting. The weight percentages of SiC is 6% by weight and B 4C is 3%,6%,9%. A390
reinforced with SiC and B4C is used in aerospace, automotive industry in the manufacturing
of disc brakes, cylinder liners etc. Here A390-6% SiC- B4C (3%,6%,9%), castings are done
and compared on the basis of wear characteristics and mechanical properties. Composites of
A390 shows an increase in wear resistance when it compared with A390 alloy. As the B 4C
content in A390-SiC- B4C composite increases, wear rate decreases. Thus the further addition
of B4C enhances the wear resistance and hardness of the material.

2.Introduction
Aluminium matrix composites (AMCs) are potential materials for various applications due to
their good physical and mechanical properties. The addition of reinforcements into the
metallic matrix improves the stiffness, specific strength, wear, creep and fatigue properties
compared to the conventional engineering materials. Aluminium MMCs are widely used in
aircraft, aerospace, automobiles and various other fields. The reinforcements should be stable
in the given working temperature and non-reactive too. The most commonly used
reinforcements are Silicon Carbide (SiC) and Aluminium Oxide (Al₂O₃). SiC reinforcement
increases the tensile strength, hardness, density and wear resistance of Al and its alloys. The
particle distribution plays a very vital role in the properties of the AMC and is improved by
intensive shearing. Al₂O₃ reinforcement has good compressive strength and wear resistance.
Boron Carbide is one of hardest known elements. It has high elastic modulus and fracture
toughness. The addition of Boron Carbide (B4C) in Al matrix increases the hardness, but does
not improve the wear resistance significantly.

In this project, A390 which is an alloy of aluminium is reinforced with Silicon Carbide(SiC p)
[6 wt%] and Boron Carbide(B4C) [3,6,9 wt%] .The wear characteristics and mechanical
properties of A390 alloy reinforced with silicon carbide and boron carbide is analysed and
compared with A390 alloy.

1
3. OBJECTIVES
1. To cast A390 alloy.
2. To cast A390 alloy reinforced with Silicon Carbide (6 wt%) and boron carbide(3,6,9 wt
%).
3. Study hardness of A390-SiC-B4C composite.
4. Study wear characteristics of A390-SiC-B4C composite.
5. Study tensile properties of A390-SiC-B4C composite.

4. METHODOLOGY
5.1. Casting of A390 alloy
A390 alloy composed of Al6061(75.65%), Si(18%), Cu(5%), Fe(0.5%), Mg(0.45%),
Ti(0.2%), Zn(0.1%), Mn(0.1%) is casted using oil fired tilting furnace.

5.2. Pre-processing of SiC particles, B4C particle, A390 alloy and mould parts.
5.3. To prepare the composite by stir casting process
5.4. Conducting hardness test by Vickers hardness testing machin
5.5. Conducting wear test by pin on disc tribometer according to ASTM standard
5.6. Conducting tensile strength using UTM as per ASTM standards
5.7. Compare the results

6. Work Done Till Date

6.1. Casting of A390 alloy

Charge calculation

Table: Weight of consecutive elements in 3kg of AA6061


Al Cu Mg Si Fe Mn Total
Composition(%) 97.4 0.1 0.9 0.7 0.6 0.3 100
Composition(gram) 2922 3 27 21 18 9 3000

Table: Required composition of A390 alloy(wt%)


Al Si Cu Mg Fe Mn

75.2 18 5 0.9 0.06 0.03

2
For 3000 grams of AA6061 add
 550 grams of Al-50%Cu master alloy (275 grams of each Al and Cu)
 1930 grams of Al-50%Si master alloy (965 grams of each Al and Si)
 Total weight = 3000+550+1930 = 5480 grams
 Total weight of Si = 21+965 = 986 grams
 Total weight of Cu = 3+275 = 278 grams
986
 % composition of Si = ×100=17.99 ≈18 %
5480
278
 % composition of Cu = ×100=5.072≈ 5 %
5480
5.2. Preparation of Composite
 A390 alloy is power hammered and broken into pieces
 A390 is weighed and heated in the electric furnace associated with stir casting
machine to a temperature of 750°C
 Reinforcing materials SiC and B4C are weighed and preheated using a Muffle Furnace
at 500°C for 30 mins
 Molten A390 alloy at 750°C is stirred at 350 rpm, preheated reinforcing materials are
added to it
 After completing the addition of reinforcement materials, the mixture is stirred for 10-
15 mins
 The mixture is then transferred to a metallic mould preheated to 250°C to reduce
thermal shock
 Same procedure is followed to cast aluminium composite with SiC(6 wt%) and
varying B4C wt% (3%,6% and 9%)
5.3. Micro Hardness Test
 Specimens for micro hardness test are cut down from the composite samples
 Specimens were polished using double disc polishing machine
 Micro hardness is measured using HM200A series Vickers hardness testing machine
 The hardness of the composites was measured at a distance of 1, 3, 6, 9, 12.5 mm
from the outer periphery region (edge)
 Five indentations were taken for each location in the sample and the average value
was reported as hardness

3
Hardness(HV)
160

140

120

100
Hardness(HV)
80

60

40

20

0
A390 alloy A390+6%SiC+3%B4C A390+6%SiC+6%B4C A390+6%SiC+9%B4C

 More than 35% improvement in micro hardness

5.4. Tensile Test


 The tension test was conducted on the specimens using a universal testing machine as
per ASTM E8M04 standard
 The 1200 grit grinding SiC paper was used to polish the test specimens in order to
decrease the machining scratches and the effects of surface defects on the sample
 Tensile strength of A390 alloy – 187 MPa
 Tensile strength of A390-SiC(6%)-B4C(3%) composite – not obtained
 Tensile strength of A390-SiC(6%)-B4C(6%) composite – not obtained
 Tensile strength of A390-SiC(6%)-B4C(6%) composite – not obtained

5.5. Wear Characteristics


 Unidirectional dry sliding wear tests using a pin-on-disc tribometer with a flat tipped
pin and a disc were carried out
 Wear resistance of A390 alloy at 9.81N – 0.61 *103 m/mm3
 Wear resistance of A390 alloy at 29.43N – 0.37 *103 m/mm3
 Wear resistance of A390 alloy at 49.05N – 0.17 *103 m/mm3
 Wear resistance of A390-SiC(6%)-B4C(3%) composite – not obtained
 Wear resistance of A390-SiC(6%)-B4C(6%) composite – not obtained
 Wear resistance of A390-SiC(6%)-B4C(6%) composite – not obtained

4
5.6. Microstructure Characterization
 Microstructure of A390 alloy – obtained
 Microstructure of A390-SiC(6%)-B4C(3%) composite – not obtained
 Microstructure of A390-SiC(6%)-B4C(6%) composite – not obtained
 Microstructure of A390-SiC(6%)-B4C(9%) composite – not obtained

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