International Journal of Engineering Trends and Technology (IJETT) – Volume 59 Issue 3 – May 2018

Experimental Investigation of Mechanical

Properties of Pure Al-Sic Metal Matrix
Composite by Stir Casting Method
Redankamma Yenumula 1, Srinivasulu Dorasila2, CV Ramana Murthy Naidu S3, Rambabu Kalpukuri4
1
Student, Department of Mechanical Engineering, Kallam Haranadha Reddy Institute of Technology, Guntur,
Andhra Pradesh, India.
2
Associate Professor, Kallam Haranadha Reddy Institute of Technology, Guntur, Andhra Pradesh India..
3
Professor & HOD Department of Mechanical Engineering, Kallam Haranadha Reddy Institute of Technology,
Guntur, Andhra Pradesh India..
4
Assistant Professor, NRI Institute of Technology, Guntur, Andhra Pradesh India.

Abstract - Inexorably Metal matrix composites required. Composite Technology combines the most
(MMCs) improved equities including high important properties of the components together in
mechanical properties compared to unreinforced order to obtain a material with overall properties
alloys. There has been an increasing interest in suitable for the design of the engineering part
composites comprise low density and low cost required. Generally the continuous phase is referred
reinforcements. Amid various incohesive to as the matrix, while the scattered phase is called
dispersoids used. The unbiased of this experimental the reinforcement. A lot of work was done in this
investigation is to produce pure aluminium, as a subject for the last decades since the production
base material it is reinforced with the following advances was highly touched by composites where
additives each time (silicon carbide Sic,) with you can tailor material properties as you need by
different volume fractions. Liquid state mixing mixing two peculiar materials without chemical
proficiency was plugging away for the different reaction. Some of composites are of metallic
integral. A thermocouple is used for checking matrices with ceramics additives to have what we
temperature recurrently whilst unite. To diminish call metal matrix composite (MMC), and some
gas bubbles at the final cast degasser was combined polymeric matrices (PMC) and excess are of ceramic
to the content of the composite whilst unite. After matrices (CMC).
liquefying and whilst, fluxes were poured in metallic The melting point of aluminium is high ample to
mould then we got a cast from which specimens for satisfy many application exaction, yet low ample to
numerous tests were prepared. In each case the restore composite processing reasonably convenient.
mechanical properties were steadfast. The sic is It can hold a diversity of reinforcing agents [1].
accession with matrix alloy, it increases the ultimate A number of more reinforcing materials such as illite
tensile strength & the hardness, and decreased clay, , Zirconium, graphite etc have been assimilated
elongation of the composites in comparison with in Al using molten metal method. The key drawback
particular of the matrix. Waxing wt% of Sic, of this method is the poor wet ability of ceramic
increased their strengthening effect but sic is the particles with liquid Al alloys,[6-8]. Wet ability can
most effective strengthening particulates, for higher be defined as the ability of a liquid to spread on a
hardness, strength and grain size reduction. On the solid surface, and it represents the extent of
other hand, it decreases ductility and toughness. confidential contact between a liquid and a solid [24],
Further the Vickers hardness test, heat treatment and this build up the drift of reinforcement cluster.
process and microstructures were performed on This serve as a great challenge of producing cast
specimen. The best result has been obtained at 20% metal matrix composites. This would normally result
weight fraction of sic with pure aluminium. in poor distribution of the particles, high porosity
content, and low mechanical properties. For that we
Keywords: Al-Sic, stir casting, Vickers hardness need improve the wet ability of matrix with additives.
test, heat treatment, microstructure. For improving wet ability of Sic studies proved a
high efficiency of wet ability improvement by
I. INTRODUCTION: accession of silicon or magnesium.
It is very important to study the The confinement and trading of the particulates are
composite materials because it is the material for very important in production of composites
advanced technology, high temperature application materials. Mg0 addition improves the retention and
where high strength / stiffness to-weight ratio is distribution of Al2O3within the matrix [8],[9].

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 International Journal of Engineering Trends and Technology (IJETT) – Volume 59 Issue 3 – May 2018

Stirring was useful to obtain arrange of particulate II. EXPERIMENTAL PROCEDURE:

percentages [10]. J. Has him et al. For the preparation of the Aluminium
silicon carbide alloy by using mass basis ratio of
The results was found that the Sic
100:0,100:5,100:7.5, 100:10, 100:15, and 100:20 are
particles rounded in the matrix & the composites of
prepared. Figure illustrates the raw materials and
the porosity content was mostly progressed by the
samples of Aluminium Silicon Carbide material.
milled composite powder injecting rather of the melt
Stir- casting was used here in preparing
of untreated-Sic particles. Casting was done instead
composite samples. In this method the silicon
of fully liquid state from semisolid state had related
carbide particles was homogenously in the
effects. By injecting milled composite powders, the
aluminium microstructure by the established of
average size of Sic particles assimilated into the
eddy in molten metallic. Stir casting improved the
matrix was also significantly reduced from about 7
mechanical and physical properties of the aluminium
to 2 μm. The ultimate tensile strength, yield strength
matrix in the process of silicon carbide particles pull
and elongation of Al/5 vol.%SiCp composite
through molten metallic & dispersed them
manufactured by compo casting of the (Al–Sic)
homogenously. Matrix material cut into small pieces
injected melt were increased by 91%, 103% and
to attain the required weight according to
132%, respectively, manufactured by stir casting of
reinforcement silicon carbide particles weight
the untreated-SiCp injected melt [25], compared to
fraction (0, 5, 7.5,10,15, and 20 wt. %)[silicon
those of the composite. W. Zhou et al. studied a
carbide powder- (50- 100μm)- supplied from
composites based on two aluminium alloys (A536
dhanlaksimi Chemicals Ltd (Vijayawada).
and 6061) reinforced with 10% or 20% volume of
The samples of Pre-weighted were putted in
fraction Sic particles were produced by gravity
alumina pots, and then the samples were inserted in
casting and a unique two-step mixing method was
Carbolite tube furnace setting at 500°C to ensure
applied strongly to improve the wet ability and
that melting the sample. These were provide the
distribution of the particles. The Sic particles were
homogeneity of the silicon carbide particles added
noticed to be located principally in the inter-dendrite
through molten aluminium, the electrical mixer was
regions, and a thermal lag model is proposed to
inserted in to the alumina pot which is kept in the
explain the concentration of particles [21].
Carbolite tube furnace at 500°C . So the Molten
K. R. Suresh et al. studied wear and aluminium was stirred at (800 r.p.m.) to get suitable
tensile properties of aluminium composites vortex. Later on the silicon carbide particles were
fabricated by squeeze casting method and correct added in to molten metal. This process was followed
rigid particulate distribution. The squeeze cast to the distribution through modify reinforcement
composites show peak strength of 216 MP a particles of the molten aluminium.
showing an increase of 11.6% in tensile strength. The silicon carbide particles were pulled
The matrix bond should strongly with the inward the molten metal and it was uniformly
reinforcement but should not be chemically touched distributed due to the vortex effect. Molten
by adverse reactions. Proper matrix and aluminium was stirred for (0- 4 min.) until the
reinforcement selection will promote part aluminium of the molten becomes slurry. Than the
formability by various processes [13]. slurry was poured into the suitable stainless steel
mould box, which is preheated at 150°C to prevent
Reinforcement,as either continuous or sudden cooling effect for slurry. This process was
discontinuous may constitute 10 to 60 vol % of the
repeated several times according to reinforcement
composite [14].The aim of this study was to probe particles ratio. It was noted obviously increasing the
the production of Al-MMC using a modified liquid slurry viscosity especially at 9wt% of silicon carbide
state mixing called stir casting method. The
particles. This phenomenon requires long stirring
technique was examined by employing the ceramic time to overcome the difficulties in the casting
particulates of Sic to aluminium in the liquid state process
where casting temperature and heating temperature
was serious after some trials to achieve two targets:
 High ample to add the additives and mix it
properly and then cast before the aluminum
starts to solidify.
 Not too high so that it may scorch the
better of the additives before mixing them with the
matrix and not to take a lot of time to solidify after
casting so that the particulates may establish in the
bottom of the mould due to gravity.
After that mixing properly and casting
specimens, subjected to various micro-structural and
Fig: 1.Composite (Al+Sic) without machining
mechanical tests consideration.

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 International Journal of Engineering Trends and Technology (IJETT) – Volume 59 Issue 3 – May 2018

Machining the components by using lathe

machine up to required dimensions.

Fig: 3 Vickers testing machine

Fig: 2. Machined Composite Material.
Specimens for various tests were prepared The machined components are polished by
from each melt. For tensile test samples was emery paper up to good surface finish.
prepared according to ASTM-E8-95a and impact test
samples were prepared according to the ASTM E23.

Composite Alloy

1 100g(AL)+5g(SIC)
2 100g(AL)+7.5g(SIC)
3 100g(AL)+10g(SIC)
4 100g(AL)+15g(SIC) Fig: 4. Emery paper polishing

5 100g(AL)+20g(SIC)
Table 1: Each Specimens total weight
The above table shows the different
weightages of silicon carbide is mixed with
aluminium. The each composition is made two
components. The below figure is raw material of
silicon carbide is divided in to required weightages.

III. WITHOUT HEAT TREATMENT

PROPERTICES
Fig: 5. Double disc polishing

HARDNESS VALUES
After that by using double disc polishing machine to
S.No Material polish the component up to mirror finish.
Trail Trail
Average
I II
200
Vickrs hardness

AI- 150
1 121 110 115.5
10wt%Si,5.0wt%Sic
AI- 100
2 136 122 129
10wt%Si,7.5wt%Sic
50 HV
AI-
3 140 139 139.5
10wt%Si,10wt%Sic 0
AI-
4
10wt%Si,15wt%Sic
143 169 156 0 10 20 30
AI- Comtent particulate composite %
5 171 183 177
10wt%Si,20wt%Sic
Table 2: Hardness Values
Fig: 6. Vickers hardness measurement graph.

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 International Journal of Engineering Trends and Technology (IJETT) – Volume 59 Issue 3 – May 2018

The results of the Vickers hardness Fig 10: 100% AL of 7.5% SIC and Magnification: 100X
measurements are shown in graph. It increases with
increasing wt% of the particulates used in this work.
1.3 MICROSTRUCTURES OF AL-SIC:

Fig11: 100% AL of 7.5% SIC and Magnification: 200X

The silicon carbide reduces the density of
Fig 7: Metallurgical microscope the aluminum and improves its stiffness and wear
The following figures are different resistance. The toughness and ductility are reduced
combination and magnification of Al-sic by the ceramics. These alloys have found
microstructures .we had chosen 500X and 200X applications in advanced bicycle frames, racing
magnification of lens(where 500X and 200X are size horse shoes and formula one racing car brakes.
of lens that are used for magnification process)

Fig 12: 100% AL of 10% SIC and Magnification: 100X

Fig 8: 100% AL of 5% SIC and Magnification: 100X

Fig 9: 100% AL of 5% SIC and Magnification: 200X Fig13: 100% AL of 10% SIC and Magnification: 200X
The microstructures have two main You can see similar alloys and images of
constituents. The darker gray particles are grains of microstructures at other magnifications in the
silicon carbide (sic).they are dispersed through a internal microscope.
matrix of aluminium.you can see the individual
grains of the aluminum.

Fig14: 100% AL of 15% SIC and Magnification: 100X

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 International Journal of Engineering Trends and Technology (IJETT) – Volume 59 Issue 3 – May 2018

HARDNESS VALUES
S.No Material
Trail
Trail I Average
II
AI-
1 95.68 90.97 93.325
10wt%Si,5.0wt%Sic
AI-
2 93.06 98.33 95.695
10wt%Si,7.5wt%Sic
Fig15:100% AL of 15% SIC and Magnification: 200X AI-
3 98.25 98.92 98.585
10wt%Si,10wt%Sic
AI-
4 103.3 101.2 102.25
10wt%Si,15wt%Sic
AI-
5 137.5 133.2 135.35
10wt%Si,20wt%Sic
Table3: Hardness Values

150

Vickrs hardness 100

Fig16: 100% AL of 20% SIC and Magnification: 100X

50
HV

0
0 10 20 30

Comtent particulate composite %

Fig19: Vickers’s hardness measurement graph.

Fig17: 100% AL of 20% SIC and Magnification: 200X The results of the Vickers hardness
measurements are shown in graph. It increases with
IV. WITH HEAT TREATMENT increasing wt% of the particulates used in this work.
PROPERTICES These increases can be related -as mentioned before-
to the interaction of the dislocations with the
particulates and grain refinement with increasing
wt% of the particulates.

V. MICROSTRUCTURES OF AL-SIC:

The following figures are different

combination and magnification of Al-sic
microstructures .we had chosen 500X and 200X
magnification of lens(where 500X and 200X are size
of lens that are used for magnification process)

Fig18: furnaces
Go to the heat treatment process kept
the components on the furnace at a temperature
of 1800c and cooling on room temperature.
Once again conduct the hardness and
microstructures of the specimens.

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 International Journal of Engineering Trends and Technology (IJETT) – Volume 59 Issue 3 – May 2018

Fig20:100% AL of 5% SIC and Magnification: 100X

Fig25: 100% AL of 10% SIC and Magnification: 200X

Fig21:100% AL of 5% SIC and Magnification: 200X
You can see similar alloys and images of
The microstructures have two main microstructures at other magnifications in the
constituents. The darker gray particles are grains of internal microscope.
silicon carbide (sic).they are dispersed through a
matrix of aluminium.you can see the individual
grains of the aluminum.

Fig26:100% AL of 15% SIC and Magnification: 100X

Fig22: 100% AL of 7.5% SIC and Magnification: 100X

Fig27: 100% AL of 15% SIC and Magnification: 200X

Fig23: 100% AL of 7.5% SIC and Magnification: 200X

The silicon carbide reduces the density of

the aluminum and improves its stiffness and wear
resistance. The toughness and ductility are reduced
by the ceramics. These alloys have found
applications in advanced bicycle frames, racing
horse shoes and formula one racing car brakes. Fig28: 1.4.9 100% AL of 20% SIC and Magnification: 100X

Fig24:100% AL of 10% SIC and Magnification: 100X Fig29: 100% AL of 20% SIC and Magnification: 200X

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 International Journal of Engineering Trends and Technology (IJETT) – Volume 59 Issue 3 – May 2018

[8] Abdul-Lattif, N.I., Kheder, A.R.I. & Goel, S.K., J. Materials

After conducting the heat treatment process Science, 22 (1985), P. 466-472.
to seen the microstructures are of the specimens the [9] Mcevoy, A.J., Williams, R.H. & Higginbotham, L.G., J.
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[10] Lioyd, D.J., Composite Science Technology, vol. 35 (1989)
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Volume 255, 2003, Pages 638-642.
aluminum carry proved a good proxy for cast
[13] Zaid, A.I.O., "Role of Manufacturing Process Parameters on
iron. the Characteristics of Aluminum Metal Matrix Composites AL-
 After steel Aluminum is the most used metal. MCC". Proc. 8th International Symposium on Advanced
 in the Earth’s crust Aluminum is the most Materials. ISAM-2003, Islamabad, Pakistan, (2003).
commonly occurring metal. [14] Foltz, J.V. & Blackmon, C.M., Metal-Matrix Composites.
 Aluminum is 100% revocable without losing ASM Handbook: Composites, 1(21), 903-912. (2001)
any of its natural characteristics. [15] The Principles of Materials Selection for Engineering
Design, Pat l. Mangonon, prentice hall, 1999.
 Al-SiC has the maximum strength-to-weight
[16] Huang, Y.D., Froyen, L., Wevers, M., "Quality Control &
ratio of any metal. Nondestructive Tests in Metal Matrix Composites, MMC-Assess
 For applications where magnetism charges to Consortium", Thematic Network, Institute of Materials Science &
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times it is the most strengthening "Effects of SiC Volume Fraction and Aluminum Particulate Size
particulates for increasing hardness, grain on Interfacial Reactions in SiC Nano-Particulate Reinforced
size reduction and strength. While it Aluminum Matrix Composites", Journal of Alloys and
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decreases the toughness and ductility.
[21] W. Zhou and Z.M. Xu. , "Survey on wetting of SiC by
 The accession of Sic particulates into the molten metals", Ceramics International, volume 36, (2010) 1177–
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yield strength, the hardness and decreases
elongation of the composites in analogy
with those of the matrix alloy.
 The grain size of the matrix was compared
with the before particulate addition, it was
High reduction in grain size of MMC’s. It
is affected by the presence of the
particulates in the matrix alloy where they
act as grain nucleation cites.

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