19Mepn6601-Innovative and Creative Project: in Partial Fulfillment For The Award of The Degree of
19Mepn6601-Innovative and Creative Project: in Partial Fulfillment For The Award of The Degree of
19Mepn6601-Innovative and Creative Project: in Partial Fulfillment For The Award of The Degree of
5V COMPOSITE REINFORCE
WITH WC AND CHARACTERIZE ITS
EFFECT:METALLURGIAL AND
CORROSION
Submitted by
DHIANESHWAR.K (19BME001)
DARSHAN.S.P (19BME009)
RESHMAA.S.V (19BME013)
im
Mechanical Engineering
BONAFIDE CERTIFICATE
DHIANESHWAR.K (19BME001)
DARSHAN.S.P (19BME009)
RESHMAA.S.V (19BME013)
Submitted for the Autonomous End Semester Examination Project viva-voce held on
.
We wish to thank our Principal Dr. A. Rathinavelu, M.Tech., Ph.D., for his
motivation.
It is also our primary duty to thank our Project guide Dr. T. Ramkumar,
M.E., Ph.D., Assistant Professor (S.G.), Mechanical Engineering, who is back bone of
all our project activities, for his constant guidance and encouragement, which kept us
fast and pro-active in our work. It is their enthusiasm and patience that have borne
fruit in the end.
ABSTRACT
Titanium alloys are used in airframe structures, landing gear components, and jet engine parts
for their unique combination of properties: moderate density, high strengths, long fatigue life,
fracture toughness, creep strength, and excellent resistance to corrosion and oxidation. The aim
of this project is to develop a material with less weight and more wear resistance and analyze
the suitability of the developed materials for aerospace applications. Composite specimens
are fabricated using Microwave Sintering technique considering Titanium as matrix
and WC as particulate Micro hardness of Ti-WC composites are determined. Wear
tests are conducted using Pin on Disc apparatus for Ti-WC composite specimens.
Wear rate for different loads and speeds are analyzed. The morphology structure of Ti-
WC composites are analyzed before and after wear test using SEM studies. Composition
Ti-WC composite specimens are verified using EDAX analysis. The corrosion behavior of
Ti-WC composite specimens are investigated using TAFEL exploration and SEM analysis.
The developed Titanium-based composite materials have less weight, more wear and
corrosion resistance. Hence, these composite materials are better applicant materials for the
Aerospace applications.
i
TABLE OF CONTENTS
ABSTRACT ......................................................................................................................................i
1. INTRODUCTION… ..................................................................................................... 1
1.1 Composite Materials… ................................................................................................. 2
1.1.1 Polymer Matrix Composites… ................................................................................ 2
1.1.2 Metal Matrix Composites… .................................................................................... 3
1.1.3 Ceramic Matrix Composites… ................................................................................ 3
2. LITERATURE REVIEW .............................................................................................. 5
2.1 Objectives… ................................................................................................................. 8
3. METHADOLOGY ........................................................................................................ 9
3.1 Powder Metallurgy ....................................................................................................... 9
3.2 Selection of Composites ............................................................................................. 10
3.3 Sintering ..................................................................................................................... 11
3.3.1 Advantages of Sintering ........................................................................................... 12
3.4 Microstructure............................................................................................................ 13
3.4.1 Scanning Electron Microscope .............................................................................. 13
3.5 Energy Dispersive X-ray Analysis .............................................................................. 16
3.6 X-Ray Power Diffraction ............................................................................................ 17
3.7 Wear Test… ............................................................................................................... 19
3.7.1 Pin On Disc ............................................................................................................ 19
4. RESULTS AND DISCUSSION .................................................................................. 22
4.1 Wear Rate… ............................................................................................................... 22
4.2 Co-Efficient Of Friction .............................................................................................23
4.3 Porosity and Relative Density..................................................................................... 24
4.4 TAFEL Graph… ......................................................................................................... 25
4.5 SEM Results .............................................................................................................. 26
4.6 EDAX Mapping of SEM Images… ........................................................................... 29
5. CONCLUSION .......................................................................................................... 31
6. REFERENCES ............................................................................................................ 32
ii
LIST OF FIGURES
Figure 1 Powder Metallurgy Process… ............................................................................. 9
Figure 2 Photographic image of Sintering Furnace ........................................................... 11
Figure.3 Photographic image of SEM… ........................................................................... 13
Figure 8 Wear rate of the Composites with Respect to Load (N) ....................................22
Figure 9 Wear rate of the Composites with Respect to Sliding
iii
LIST OF TABLES
Table I Chemical Composition of Ti Grade 9 .................................................................. 10
iv
LIST OF ABBREVIATIONS
FF - Friction Factor
WR - Wear Rate
WL - Wear loss
v
1. INTRODUCTION
1
1.1 Composite Materials
2
regain its properties during cooling, facilitating applications of conventional compress
techniques to mould the compounds.
Most metals and alloys make good matrices. However, practically, the choices
for low temperature applications are not many. Only light metals are responsive, with
their low density proving an advantage. Titanium, Aluminium and magnesium are the
popular matrix metals currently in vogue, which are particularly useful for aircraft
applications. If metallic matrix materials have to offer high strength, they require high
modulus reinforcements. The strength-to weight ratios of resulting composites can be
higher than most alloys. The melting point, physical and mechanical properties of the
composite at various temperatures determine the service temperature of composites.
Most metals, ceramics and compounds can be used with matrices of low melting point
alloys. The choice of reinforcements becomes more stunted with increase in the
melting temperature of matrix materials.
Ceramics can be described as solid materials which exhibit very strong ionic
bonding in general and in few cases covalent bonding. High melting points, good
corrosion resistance, stability at elevated temperatures and high compressive strength,
render ceramic-based matrix materials a favourite for applications requiring a
structural material that doesn’t give way at temperatures above 1500ºC. Naturally,
ceramic matrices are the obvious choice for high temperature applications. High
modulus of elasticity and low tensile strain, which most ceramics possess, has
3
combined to cause the failure of attempts to add reinforcements to obtain strength
improvement. This is because at the stress levels at which ceramics rupture, there is
insufficient elongation of the matrix which keeps composite from transferring an
effective quantum of load to the reinforcement and the composite may fail unless the
percentage of fiber volume is high enough. A material is reinforcement to utilize the
higher tensile strength of the fiber, to produce an increase in load bearing capacity of
the matrix. Addition of high-strength fiber to a weaker ceramic has not always been
successful and often the resultant composite has proved to be weaker.
4
2. LITERATURE REVIEW
S. Gollapudi et al. (2008) [1] has discussed the creep mechanisms were elucidated
in the light of standard creep models supported by the substructures studied by
transmission electron microscopy. Microstructural observations along with
parametric variations of creep rates were useful in identifying the underlying
deformation mechanisms.
E.M. Ruiz-Navas etal. (2012) [2] has discussed that Ti-3Al-2.5V powders
produced by the blending elemental or the master alloy addition approaches are
suitable for obtaining almost fully dense materials whenprocessed by vacuum hot-
pressing
L. Bolzoni et al. (2012) [3] has discussed the Mechanical properties such as
hardness and flexural strength similar to those of the respective wrought materials
are easily obtained
P.G. Esteban et al. (2012) [4] has discussed the Various relative densities between
83% and 95% pore structures and grain sizes can be obtained by selecting a proper
sintering temperature, but when thealloying elements have to diffuse to homogenise
the composition, a minimum temperature of 1100 1C should be selected
L. Bolzoni et al. (2013) [5] has discussed the ductility is lowered due to the residual
porosity and the relatively high amount interstitials dissolved. Moreover, thermal
conductivity and electrical resistivity values similar to those of the wrought alloy by
processing the Ti-3Al-2.5V alloy by means of pressing and sintering
Kopac J et al. (2013) [6] has discussed the Liquid or gas nitrogen has been able to
decrease the friction coefficient and material transfer when Ti6Al4V and uncoated
carbide pins were used, while a significant improvement has been noted for
Inconel718 and TiN coated pins.
5
E. Gordo et al. (2014) [7] has discussed the Higher hardness and ultimate tensile
strength can easily be obtained whereas care must be taken to keep high ductility
Anil K et al. (2014) [8] has discussed the experimental results of a recent study on
built-up welded beams are presented in this paper with the primary objective of
enabling design, facilitating fabrication, and implementation of large structural
members forpotential applications in the structural and defense-industry.
Juanjuan Qi et al. (2020) [9] has discussed the Friction and wear tests were
conducted under both room and elevated temperature. Mg MMCs exhibited
outstanding anti-wear and self-lubricating properties in addition to enhanced
mechanical strength.
F.V. Vodolazskiy et al. (2020) [10] has discussed the increase in total content of
alloying elements in investigated alloys contributes to decrease of CTE value as
well as to raise of volume effect of polymorphic transformation upon heating to the
temperature range of occurring of α + β→ β- transformation.
F. Yang et al. (2020) [11] has discussed that it is found that high relative density
values and chemical homogeneity are achieved regardless of the sintering technique
or chemistry of the alloy. Both wrought-equivalent and low-cost Fe-bearing powder
metallurgy Ti alloys were analyzed.
M., Gupta et al. (2021) [12] has discussed that this is a high strength alloy, which
leads to large values of cutting force, a low thermal conductivity causes the
appearance of high cutting temperatures. Dry machining is very useful for
sustainability and clean manufacturing, as it has minimal environmental impact
Sharma S et al. (2021) [13] has discussed the mechanical characteristics like tensile-
strength, flexural-strength, toughness, hardness, scratch adhesion, percent-porosity
and density were studied. A drum type wear apparatus was utilized to evaluate the
6
percentage of wear-loss in different compositions using different loads and it was
found that the wear-loss decreases linearly as the muscovite percentage was
increased.
McDonald A et al. (2021) [14] has discussed the mechanisms contributing to the
material removal and the influence of different parameters on these mechanisms
were evaluated. The effects of the WC particle size and volume fraction on the
scratch depth and worn volume of the composite were also analysed.
7
2.1 Objectives
• To fabricate the titanium grade 9 by reinforcing with WC through powder
metallurgy route.
8
3. METHODOLOGY
3.1 Powder Metallurgy
Powder metallurgy is the process of blending fine powdered materials, pressing them
into a desired shape or form (compacting), and then heating the compressed material
in a controlled atmosphere to bond the material (sintering). Figure 1 shows the detail
powder metallurgy process.
• Powder manufacture/purchase
• Powder blending.
• Compacting.
• Sintering.
9
3.2 Selection of Composition
Titanium
Balance (92 to 95%)
Aluminum
3
Vanadium
2.5
Iron
≤0.25
Carbon
≤0.05
Hydrogen
≤ 0.015
Oxygen
≤0.12
Nitrogen
≤0.02
Tungsten Carbide
Tungsten carbide is a dense, metal like substance, light gray with a bluish tinge that
decomposes, rather than melts, at 2,600° C (4,700° F). It is prepared by heating
powdered tungsten with carbon black in the presence of hydrogen at 1,400°–1,600° C
(2,550°–2,900° F).
10
Specimen Calculation:
m
�=
�
3.3 Sintering
Sintering is static when a metal powder under certain external
conditions may exhibit coalescence, and yet reverts to its normal behavior when
such conditions are removed. In most cases, the density of a collection of grains
increases as material flows into voids, causing a decrease in overall volume. Mass
movements that occur during sintering consist of the reduction of total porosity
by repacking, followed by material transport due to evaporation and condensation
from diffusion. In the final stages, metal atoms move along crystal boundaries to
the walls of internal pores, redistributing mass from the internal bulk of the object
and smoothing pore walls. Surface tension is the driving force for this movement.
A typical inert Sintering Oven is shown in Figure 2.
11
A special form of sintering (which is still considered part of powder
metallurgy) is liquid-state sintering in which at least one but not all elements are
in a liquid state. Liquid-state sintering is required for making cemented carbide or
tungsten carbide. Sintered bronze in particular is frequently used as a material for
bearings, since its porosity allows lubricants to flow through it or remain captured
within it. Sintered copper may be used as a wicking structure in certain types of
heat pipe construction, where the porosity allows a liquid agent to move through
the porous material via capillary action. For materials that have high melting
points such as molybdenum, tungsten, rhenium, tantalum, osmium and carbon,
sintering is one of the few viable manufacturing processes. In these cases, very low
porosity is desirable and can often be achieved. Sintered metal powder is used to
make frangible shotgun shells called breaching rounds, as used by military and
SWAT teams to quickly force entry into a locked room. These shotgun shells are
designed to destroy door deadbolts, locks and hinges without risking lives by
ricocheting or by flying on at lethal speed through the door. They work by
destroying the object they hit and then dispersing into a relatively harmless
powder. Sintered bronze and stainless steel are used as filter materials in
applications requiring high temperature resistance while retaining the ability to
regenerate the filter element. For example, sintered stainless steel elements are
employed for filtering steam in food and pharmaceutical applications, and sintered
bronze in aircraft hydraulic systems. The Sintering process is carried out in
Dr.Mahalingam College of Engineering and Technology, Pollachi, Tamil Nadu.
The use of microwave energy for materials processing has major potential
and real advantages over conventional heating. These include:
12
Fine microstructures and hence improved mechanical properties and better
product performance
3.4 Microstructure
Due to the very narrow electron beam, SEM micrographs have a large
depth of field yielding a characteristic three-dimensional appearance useful for
understanding the surface structure of a sample. This is exemplified by the
micrograph of pollen shown above. A wide range of magnifications is possible,
from about 10 times (about equivalent to that of a powerful hand-lens) to more
14
than 500,000 times, about 250 times the magnification limit of the best light
microscopes.
16
specimen, complementary techniques are available, typically Infra-red (FTIR)
Microscopy, RAMAN Microscopy, Nuclear Magnetic Resonance Spectroscopy
(NMR) and Surface Analysis (X-ray photoelectron spectroscopy (XPS) or Time-of-
Flight Secondary Ion Mass Spectrometry (SIMS)).
X-ray powder diffraction (XRD) is a rapid analytical technique primarily used for
phase identification of a crystalline material and can provide information on unit
cell dimensions. The analyzed material is finely ground, homogenized, and average
bulk composition is determined.
17
X-ray diffractometers consist of three basic elements: An X-ray tube, a sample holder,
and an X-ray detector. The Rays generated are shown in Figure 4.
18
Figure 5 Sample XRD Graph
The geometry of an X-ray diffractometer is such that the sample rotates in the path
of the collimated X-ray beam at an angle θ while the X-ray detector is mounted on
an arm to collect the diffracted X-rays and rotates at an angle of 2θ. The instrument
used to maintain the angle and rotate the sample is termed a goniometer.
For typical powder patterns, data is collected at 2θ from ~5° to 70°, angles that are
preset in the X-ray scan.
The XRD was taken in Alagappa Chettiar College of Engineering and
Technology, Karaikudi, Tamil Nadu.
19
Figure 6 Pin on Disc Apparatus
The amount of wear in any system will, in general, depend upon the number of
system factors such as the applied load, machine characteristics, sliding speed, sliding
distance, the environment, and the material properties. The value of any wear test method
lies in predicting the relative ranking of material combinations. Since the pin-on- disk test
method does not attempt to duplicate all the conditions that may be experienced in service
(for example; lubrication, load, pressure, contact geometry, removal of wear debris, and
presence of corrosive environment), there is no endurance that the test will predict the
wear rate of a given material under conditions differing from those in the test.
20
Figure 7 Schematic Diagram of Pin on Disc
The disk was made of EN31 steel with hardness of 62 HRC. The diameter of the
sliding track on the disk surface was 100 mm. The wear tests were performed under dry
sliding conditions with the load (10 N – 25 N), rotational speed (100-200 rpm) and
sliding speed (10 m/s).
Wear rate is calculated by,
Wear rate (mm3/m) = Volume loss /Sliding distance
The wear tests were carried out in Dr. Mahalingam College of Engineering and
Technology, Pollachi, Tamil Nadu.
21
4. RESULTS AND DISCUSSION
The wear rate of the composite samples are carried out in the Pin on Disc Wear Testing
machine under various loads and sliding velocity is taken and the average is taken for
accuracy. The wear rate results are shown below.
Figure 8 Wear rate of the composites Figure 9 Wear rate of the composites
with respect to load (N) with respect to Sliding velocity (m/s)
The Figure 8 shows the wear rate of the composites with respect to load applied. With
the increase in load from 10 N to 30 N the wear rate of the composites increases. It
also shows that the maximum wear rate was recorded for pure Ti-3Al-2.5V at a load
of 30N and the minimum was recorded for Ti-3Al-2.5V+2WC at a load of 10 N.
The Figure 9 shows the wear rate of the composites with respect to sliding velocity.
The sliding velocity was varied from 5 m/s to 25 m/s. It also shows that the maximum
wear rate was recorded for pure Ti-3Al-2.5V at a sliding velocity of 5m/s and the
minimum was recorded for Ti-3Al-2.5V+2WC at a sliding velocity of 25 m/s.
22
4.2 Co-efficient of friction
The Co-efficient of friction of the composite samples are carried out in the Pin on
Disc Wear Testing machine under various loads and sliding velocity is taken and
the average is taken for accuracy. The wear rate results are shown below.
The Figure 10 shows the Friction co-efficient of the composites with respect to Load
(N) applied. With the increase in load from 10 N to 30 N the friction co-efficient of
the composites increases. It also shows that the maximum friction co-efficient was
recorded for pure Ti-3Al-2.5V at a load of 30N and the minimum was recorded for Ti-
3Al-2.5V+2WC at a load of 10 N.
The Figure 11 shows the Friction co-efficient of the composites with respect to
sliding velocity (m/s). With the increase in sliding velocity from the friction co-
efficient of the composites increases. It also shows that the maximum friction co-
efficient was recorded for pure Ti-3Al-2.5V at a sliding velocity of 5 m/s and the
minimum was recorded for Ti-3Al-2.5V+2WC at a sliding velocity of 25 m/s.
23
4.3 Porosity and Relative density
The porosity and Relative density of the composite samples are calculated by
Archimedes Principle. The values are shown in the below.
The Figure 12 shows the porosity and relative density graph of the composite samples.
The porosity % of the composite Ti-3Al-2.5V+2WC is minimum and has the value of
0.04%. As well as the composite Ti-3Al-2.5V+2WC has maximum relative density
value of 0.98.
24
4.4 TAFEL Graph
The TAFEL graph is drawn the relationship between the current generated from the
electrochemical cell and the potential of the specific metal. The TAFEL graph for the
composite samples is made from the values obtained from the TAFEL experiment and
it is shown in figure 13.
The figure 13 shows that the Ecorr value of the composite Ti-3Al-2.5V+1.5WC is
greater than the other composite samples. The corrosion rate of the composite Ti-
3Al-2.5V+1.5WC is lower when compared to the other composite samples. The
value obtained from the TAFEL exploration is display in Table II.
25
Table II Corrosion rate of the composite samples
SPECIMEN CORROSION
COMPOSITION RATE (mil/year)
Ti-3Al-2.5V(PURE) 3.110e+001
Ti-3Al-2.5V+0.5WC 1.761e+002
Ti-3Al-2.5V+1WC 2.295e+001
Ti-3Al-2.5V+1.5WC 5.384e+001
Ti-3Al-2.5V+2WC 7.374e+001
26
Figure 15 SEM image of Ti-3Al-2.5V+0.5 WC alloy.
27
Figure 17 SEM image of Ti-3Al-2.5V+1.5 WC alloy.
28
4.6 EDAX Mapping of SEM Samples
Figure 19 EDAX mapping of pure titanium grade 9 alloy after corrosion test.
Figure 19 shows the composition of the Pure Titanium grade 9 alloy. There is a peak of
titanium in between 4.0 keV to 5.0 keV. There is a peak of Fe in between 6.0 keV to
7.0 keV and between 0.0 keV to 1.1 keV with low intensity. Then the peak of
Aluminium in between 1.0 keV to 2.0 keV with low intensity.
29
Figure 20 EDAX mapping of titanium grade 9 alloy reinforced with WC
after corrosion test
Figure 20 shows the composition of the reinforced Titanium grade 9 alloy with
Tungsten Carbide. There is a peak of titanium in between 4.4 keV to 5.5 keV. There is
a peak of vanadium in between 0.0 keV to 1.1 keV and between 4.4 keV to 5.5 keV
with low intensity. Then the peak of Aluminium in between 1.1 keV to 2.2 keV with
low intensity. There is a peak of W in between 1.3 keV to 2.6 keV and a peak of C in
between 1.1 keV to 2.2 keV with low intensity.
30
5. CONCLUSION
31
6. REFERENCES
[2] L. Bolzoni, E.M. Ruiz-Navas, ―E. Gordo, (2012), ―Influence of vacuum hot-
pressing temperature on the microstructure and mechanical properties of
Tie3Ale2.5V alloy obtained by blended elemental and master alloy addition
powders‖, Department of Materials Science, vol.30, pp.28911.
32
[8] Patnaik, Anil K. Poondla, Narendra Menzemer, Craig C. Srivatsan, T.S
(2014) ―Understanding the mechanical response of built-up welded beams
made from commercially pure titanium and a titanium alloy‖, Materials Science
and Engineering: A, vol.590, pp.390-400 .
[9] Zhu, Juanjuan Qi, Jiahui Guan, Dikai Ma, Le Dwyer-Joyce, Rob (2020),
―Tribological behaviour of self-lubricating Mg matrix composites reinforced
with silicon carbide and tungsten disulfide‖, Tribology International,vol.146,
pp.106253.
33