Effect of Process Parameter of Stir Casting On Metal Matrix Composites

International Journal of Science and Research (IJSR)
ISSN (Online): 2319-7064
Effect of Process Parameter of Stir Casting on Metal Matrix Composites

Shubham Mathur1, Alok Barnawal2
1, 2
Mechanical Engineering, Integral University, Mechanical Engineering, Dasauli, P.O. Bas-ha Kursi Road, Lucknow 226026, India
Abstract: In the present study a modest attempt has been made to develop aluminum based silicon carbide particulate Metal Matrix
Composites(MMC) with an objective to develop a conventional low cost method of producing MMCs and to obtain homogenous dispersion of ceramic material. Desired improvements in properties including specific strength, hardness and impact can be achieved by intelligently selecting the reinforcement materials, their size, and shape and volume fraction. It has been observed that melting and pouring conditions have directly or indirectly effect on mechanical properties of cast materials as hardness, percentage elongation, percentage reduction in diameter, toughness and so on. The knowledge of melting temperature of metals and alloys is necessary to estimate their corresponding pouring temperature.
Keywords: Metal Matrix Composites MMCs, Cu, Silicon Carbide (SiC), SPSS, Stir, Pouring Temperature, UTM, Hardness.
1. Introduction
The increase in strength of composites due to smaller reinforcement particle size has been reported by many authors. Statistically, larger flaws and more defects are more likely to exist in larger particles and, therefore, will deteriorate the strength of composites when compared with the composites containing smaller particles. The smaller grain size in the composites containing smaller reinforcement particles can also contribute to the increase in strength. The mechanical properties such as hardness, impact and strength is increase when grit size of reinforcement of SiC particle increase. One of the major challenge when processing on 4% Cu + 5% SiC with balanced Aluminum Metal Matrix Composites are achieving a homogeneous distribution of reinforcement in the matrix as it has a strong impact on the properties and the quality of the material. Among discontinuous metal matrix composites, stir casting is generally accepted as a particularly promising route, currently practiced commercially. Its advantages lie in its simplicity, flexibility and applicability to large quantity production. It is also attractive because, in principle, it allows a conventional metal processing route to be used, and hence minimizes the final cost of the product. The cost of preparing composites material using a casting method is about onethird to half that of competitive methods, and for high volume production, it is projected that the cost will fall to one-tenth. In general, the solidification synthesis of metal matrix composites involves producing a melt of the selected matrix material followed by the introduction of a reinforcement material into the melt, obtaining a suitable dispersion.
MMC. The mixing equipment for this stage consisted of a driving motor capable of producing a rotation speed within the range of 600rpm, a control part for the vertical movement of the impeller and a transfer tube used for introducing the ceramic powders in the melt. Balanced aluminium alloy with copper were melted in graphite crucibles. At the same time the SiC particulate was preheated in a muffle furnace set at 1100C for approximately 2 hour to remove surface impurities and assist in the adsorption of gases. The ceramic particles were then poured slowly and continuously into the molten metal and the melt was continuously stirred at 600 rpm.
Figure 2.1: Schematic View of Experimental Set Up Chemical Reaction Metal matrix composites (Al+4%Cu+5%SiC) In preparing metal matrix composites by the stir casting method, there are several factors that need considerable attention, including the difficulty of achieving a uniform distribution of the reinforcement material, wettability between the two main substances, porosity in the cast metal matrix composites, and chemical reactions between the reinforcement material and the matrix alloy.
2. Experimentation
An open hearth furnace was used for melting and mixing the materials in flat bottom, cylindrical graphite crucible. The fabrication process is conventional mechanical stirring for the distributive mixing of the reinforcement in the matrix. For the work, a new stir caster was developed to fabricate
Paper ID: 02013656
Volume 2 Issue 12, December 2013 www.ijsr.net
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3. Methodology
First of all, the balanced aluminium with 4% Cu was melted in a graphite crucible in an open hearth furnace. After automatic mechanical mixing is carried out for about 3 minutes at normal stirring rate 600 rpm and then poured into sand mould with pouring temperature 700C, 725C and 750C respectively. After that the balanced Al+4%Cu and 5% SiC (400-grit) were took. For this, the base metal Al+4%Cu were preheated at 450C for 3 hours in a electrical resistance muffle furnace before and mixing the SiC particles were preheated at 1100C for 2 hours in a electrical resistance muffle furnace to remove the moisture and surface oxidized.
The variations of Izod impact with pouring temperatures are shown in fig-4.2. The impact is increases initially for all composites with pouring temperature at 700C. It latter attained its maximum value of all material types at pouring temperature 725C. After that it falls sharply at the pouring temperature 750C. From the figure, it can be observed that the impact of the composite material-2 (Al + 4% Cu + 5% SiC) is higher than the base matrix material-1 (Al + 4% Cu). Thereafter, the increasing impact with increasing the grit sizes of SiC particles. The maximum impact attained when the reinforcement was 800-grit at pouring temperature 725 C. Table 1: Showing variation in MP-BHN-UTS with Change in Poring Temperature
Pouring Impact Hardness Serial no. Temperature (C) Strength(MP) (BHN) 1. 700 26.00 41.00 2. 725 29.56 41.96 3. 750 24.45 39.87 UTS 164.00 175.00 162.34
4. Observations of Process Parameters

A. BHN Test The hardness testing was carried out for all composite specimens. The hardness of the specimen determined by Brinell hardness testing machine with 250 kg load and 5 mm diameter steel ball indenter. The detention time for the hardness measurement was 1 minute.
Figure 2.2: Specimen after BHT B. Impact Strength Izod impact strength testing is standard method of determining impact strength. Izod impact test were conducted on notched sample. Standard square impact test specimen measured 75 mm x 10 mm x 10 mm with notch depth of 2 mm and a notch of angle of 45. The machine could provide a range of impact energies from 0 to 164 Joule. The mass of the hammer was 22 kg. It was carried out for all specimens respectively. C. Tensile Strength Tensile strength is defined as a stress, which is measured as force per unit area. In the SI system, the unit is Pascal (Pa) or Newtons per square metre (N/m). For tensile test, we used Universal Testing Machine. The testing involves taking a sample with a fixed cross-section area, and then pulling it with a controlled, gradually increasing force until the sample changes shape or breaks. The tensile test was carried out for all specimens respectively. The maximum capacity of U.T.M is 400 KN.
Graph A: Hardness vs. Poring Temperature
5. Result
The effects of input (independent) variables as pouring temperatures (700C, 725C and 750C) and material types (varying with grit size of SiC particles) on output (dependent) variables as hardness, impact strength and ultimate tensile strength, statistically analysis were performed by using SPSS 17.0.
Graph B: Impact vs. Poring Temperature
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ISSN (Online): 2319-7064 [4] Chawla N., Chawla KK, (2006), Metal matrix composites in ground transportation. JOM, 58(11) pp. 67-70. [5] Clyne TW, Withers PJ, (1993), An introduction to metal matrix composites, 1st edition. Cambridge: Cambridge University Press. [6] Creese R., (1990), Introduction to manufacturing process and materials Marcel Dekker Inc. [7] Dieter G., (1961), Mechanical Metallurgy, McGrawHill, pp. 237-248, 132-137. [8] Geiger AI and Walker JA, (1991), The processing and properties of discontinuously reinforced aluminium composite. JOM vol. 48, pp. 8-15. [9] Gruzleski J. et. al., (1990), Treatment of liquid Al-Si alloys, AFS, Inc. [10] Hashim J, Looney L, Hashmi MSJ (1999). Metal Matrix Composites: Production by the Stir casting method. Journal of Materials Processing Technology, 92-93 pp. 1-7 [11] Hull D, Clyne TW (1996). An introduction to composite materials, 2nd edition, Cambridge, UK: Cambridge University Press. [12] Ibrahim IA, Mohamed FA, (1991), Particulate reinforced metal matrix composites A review. Journal of Materials Science, vol. 26, pp. 1137-1156. [13] Jit N, Tyagi A, (2011), Properties of (A384.1)1-x [(SiC)p] x Composites by Keeping Particle Size at 0.220 m. WCE, London, vol. 3. [14] Jokhiyo M, Panhvar M, (2010), Manufacturing of aluminium composite material using stir casting process. Mehran University Research Journal of Engineering & Technology, volume 30, NO. 1, January, 2011. [15] Kaufman J, (2004), Aluminium Alloy Casting Properties, Processes and Applications, ASM International, Materials Park, USA. [16] Kelly A (1989). Concise Encyclopedia of Composite Materials, Oxfrod, UK: Pergamon Press. [17] Kumar G, Rao C, (2011), Mechanical and tribological behavior of particulate reinforced aluminium metal matrix composites a review, Journal of Minerals & Materials Characterization & Engineering, Vol. 10, No.1, pp.59-91, 2011. [18] Matthews FL, Rawlings RD (1994). Composite Materials: Engineering and Science
Graph C: UTS vs. Pouring Temperature Variation in the UTS with Different Pouring Temperature.
6. Conclusions
The significant conclusions of the studies carried out on balanced (Al + 4% Cu + 5% SiC) composites are as follows: Cast balanced (Al + 4% Cu + 5% SiC) composites were prepared successfully using liquid metallurgy techniques (stir rout). Hardness of the composites found increased with increased grit size of SiC. Impact (Izod) of the composites found increased with increased grit size of SiC. The tensile strength of the composites found increased with increased grit size of SiC. The pouring temperature at 725C which gave the best optimum value of hardness, impact strength and ultimate tensile strength. When the pouring rate kept constant at 2.5 cm/s for all composites.
7. Scope for Future work

We only consider three grit sizes (400, 600, and 800); chances may be that with further reduction in grit size mechanical properties of composite may decline. We added only 5% SiC, however with further addition of SiC particles mechanical properties may improved as investigated by Singla M. (2009) for Al and SiC casting. Wear resistance may be the parameter which defines the hardness and abrasive property of composite is the scope for future work. Experiments are performed on open hearth furnace chances of inclusion and blow holes may measure.
Author Profile
Shubham Mathur, I am currently pursuing Bachelor of Technology in Mechanical Engineering Final year Student from Integral University, Lucknow, India. I'm a creative thinker. I like to explore alternative solutions to problems and have an open mind about what will work best. I am a keen learner. I have inclination towards solving practical industrial problems. Enthusiasm towards new endeavors and passion towards my work are my motivational factors. I like to commit myself towards my work. I love the challenges of my life and believe that they help me to learn something new and improve myself as well. Alok Barnawal, I am a very passionate man when it comes to applying knowledge to real world problems. I am a good leader, with excellent communication skills. I'm a people person. I really enjoy meeting and working with a lot of different people. I'm a perfectionist. I'm a creative thinker. I like exploring alternative solutions to problems and have an open mind about what will work best. I enjoy solving
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References
[1] Basavarajappa S, Dinesh A, (2004), Mechanical properties of MMCS- an experimental investigation, ISRS, 20-22. [2] Behera R, Dutta A, (2011), Role of SiCp on the solidification rate and forgeability of stir cast LM6/SiCp MMCs, International Journal of Scientific & Engineering Research, Volume 2, Issue 1, January-2011 [3] Chawla KK, (1998), Composite Materials, 2nd edition. New York: Springer.
Paper ID: 02013656

problems, troubleshooting issues, and coming up with solutions in a timely manner believe in honesty and try to get my tasks more organized. Humility and ambition is what I always follow.
Paper ID: 02013656
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International Journal of Science and Research (IJSR)

ISSN (Online): 2319-7064