International Journal of Engineering Research and General Science Volume 4, Issue 2, March-April, 2016

ISSN 2091-2730

Investigations on Mechanical properties of AL 8011 reinforced with micro B4C

/ Red Mud by Stir Casting Method
C. KARTHIKKUMAR1, R. BARANIRAJAN2, I. PREMNAUTH3, P. MANIMARAN4
1, 2, 3 Students, Department of Mechanical Engineering, Christ College of Engg. And Technology, Puducherry, India

4 Assistant Professor, Department of Mechanical Engineering, Christ College of Engg. And Technology, Puducherry, India

Abstract- Aluminium metal matrix composites are emerging as the most versatile materials for unique structural, automotive,
aviation, aerospace, defense, marine applications and other structural applications. Because of their excellent interfusion of properties.
The potency of Aluminium Matrix Composite can be elevated, when it is reinforced with ceramic particles, which leads the Metal
Matrix to elevate their mechanical properties to the reduced weight ratio. In this research a Hybrid Metal Matrix Composite of
aluminium alloy is reinforced in conjunction with Boron Carbide of grain size of <10µm and Red Mud of grain size 150µm by using
stir casting technique. In which, Red Mud is one of the major dreck material extracted from the bauxite ore of the Alumina during
Bayer’s Process. Red Mud is contemplated as a dangerous material regarding with NBR 10004/2004, which has been treated under the
room condition as a reinforcement with Aluminum Metal Matrix. The samples were casted by varying the proportions in weight
percentage by stir casting route. The samples are exposed to tensile, compression, micro hardness test and the dispersion of B4C and
Red Mud in the AMCs was observed in the micrographs. The results prevailed from the mechanical characterization shows the
considerable elevation in strength and hardness of the Hybrid Metal Matrix Composite by reducing the weight ratio of the hybrid
reinforcements.

Keywords: . Stir casting, hybrid composite, red mud, B4C

INTRODUCTION
Stir casting is one of the best methods which is widely used worldwide for preparing particle reinforced aluminium matrix
composites (PR-ALMC’s)in order to produce the complex shapes easily and at a low cost. According to the type morphology and
reinforcement, the AMC’s are produced by different methods such as stir casting, squeeze casting, spray depositing and powder
metallurgy. The above stir casting methods can be categorized under liquid stir casting and solid stir casting. In this investigation we
have followed liquid stir casting method to reduce the cost. It involves the incorporation of dispersed phase into a molten metal
matrix, followed by its solidification. These aluminium matrix composites are drawing more attention in aviation, aerospace,
automobiles and many structural applications due to their good wear resistance with the extraordinary hardness.

Addition of reinforcement to the AMC’s can increase the strength of particle reinforced aluminium matrix which imparts good
mechanical properties. Addition of reinforcement to the matrix in the stir casting process is a challenging process specially where
there is moisture present in the reinforcement materials. Hence the red mud is dried in hot sun for 15 hours [1]. At first B4C is added to
the AMC, where B4C is a robust material having excellent chemical and thermal stability, High hardness and low density [2]. It is
mostly used in nuclear industries due to their good capabilities of absorbing neutrons without creating long living radio nuclides. They
are applicable in bullet proof vests, armor tanks, etc. Red mud is the extra ordinary wastage residue produced during the production of
Alumina by Bayer’s process. It is a insoluble product generated after the digestion from the sodium hydroxide at the higher
temperature and the higher pressure which gives the residue of the bauxite which is known as the Red Mud.

EXPERIMENTAL PROCEDURE
The fabrication of aluminium 8011-B4C-red mud compositions are used in this study and it was carried by stir casting method. In this,
firstly the Al 8011 alloy in the form of 25mm diameter rods were placed in a clay graphite crucible. Then it is heated in muffle furnace
to the desired temperature of 850 oC. Before the Al is melted, the B4C of < 10µm is heated in another crucible to the temperature of
250 oC to remove moisture. Red mud is sieved for 150µm for second reinforcement. Then the particulates were mixed into the molten
metal. The molten metal was covered with a degassing agent and with the flux to improve the quality of casting and to increase the
casting speed of the aluminium 8011. The mixture was stirred by a mechanical stirrer for 5-10 min at a speed of 60 rpm. The
temperature of the furnace remains constant at 850 oC during the addition of reinforcement particles.

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International Journal of Engineering Research and General Science Volume 4, Issue 2, March-April, 2016
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Figure 1. Stir Casting setup for fabrication of (Al8011/ B 4C/ Red Mud)

Then the molten aluminium metal matrix is poured in the preheated die for the preparation of specimen according to the ASTM
standard. Same procedure is followed to fabricate AMC’s with 1-5% of B4C and red mud simultaneously. The stir casting set up used
for producing composite specimen and the composite castings are shown.

Table 1. Process parameters used for Stir Casting

Parameters Units Value

o
Temperature of Melt C 850
Preheated temperature of B4C Particles oC 250
o
Preheated temperature of die C 400
Spindle Speed rpm 60
Stirring time min 10-15
Powder feed rate g/s 0.8-1.2

EXPERIMENTAL MATERIALS
The following evaluation is associated with the characterization of mechanical properties on Al – Boron Carbide and Red Mud
Metal Matrix Composite (MMC) of Aluminium alloy of grade 8011 with the addition of varying weight percentage composition of
Boron Carbide and the Red Mud particles by Stir Casting Method. The properties were tested under the laboratory conditions.
Variations in the properties are taken into a consideration.

For achievement of the above, a desired experimental setup was prepared to facilitate the preparation samples for the required
specification, according to ASTM standards. The experiment was carried out by preparing the samples of varying percentage
composition to predict the mechanical properties as well as to measure the Micro Hardness. An analyzed study of a Micro Structure
had been conducted by the Optical Microscope to verify the dispersion of hybrid reinforcements.

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PREPARATION OF CASTING DIE

Initially the die was made up of a low metal which can be corroded easily within a interval of time. Hence the die was surface
finished by using emery papers without damaging the size of ASTM standard. After removing the rusts from the casting die, the die
was made to preheated to the temperature of 400 oC for a constant time. Then clamped with two clamps vertically for the regular
preparation of the samples without any voids.

Figure 2. Die used for Stir Casting

TESTS PERFORMED

 Tensile Test
 Compression Test
 Micro Hardness Test (BHN)
 Microstructure

Before initializing the testing, the samples were machined to the particular size according to the ASTM standards. Tested samples are
being undergone Microstructure testing’s by using De- Wintor Inverted Trinocular Metallurgical Microscope.

TENSILE TEST

The ultimate tensile strength of various compositions was measured using 5 ton capacity servo hydraulic universal testing
machine. Testing of the specimens was in the parallel direction of the applied load. In a stress- strain graph the initial portion of the
curve is a straight line and it represents the proportionality of varying stress to strain values according to Hooke's law. When the load
is increased continuously, in which the stress of the composite is no more proportional to the strain of the following composite. UTS is
the maximum stress that a specimen can bear before its fracture due to the load and its original area. All the tests were conducted
according to the ASTM E8-82 standards. The tensile specimens of diameter 16 mm and gauge length 100 mm were prepared by Stir
Casting method. Six specimens were tested and the average values of the ultimate tensile strength and Elongation were measured.

Figure 3. Specimens which undergone Tensile Test.

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International Journal of Engineering Research and General Science Volume 4, Issue 2, March-April, 2016
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HARDNESS TEST

Hardness test were conducted to find the resistance of plastic deformation of the composites under static or dynamic loads. The
micro Vickers Hardness test is used in this present study to examine the hardness of the specimen. In this test the ball indenter of
0.5mm diameter is made to be tested by applying a load of 0.5 Kg for 20 seconds for each specimen. The averages of four varying
positions of the specimen were considered as the highest hardness number.

Figure 4. Prepared specimens for Vickers Hardness Test

COMPRESSION TEST

Compression test was carried out using a standard 5 ton capacity universal testing machine. Compression tests were conducted
on specimens of 15 mm diameter and 60 mm length machined from the casted composites, by applying the loads gradually; the
corresponding strains of the following composite were measured until failure of the specimen. The tests were made according to
ASTM E9 at room temperature.

Figure 5. Specimens which were undergone for Compression Test

MICROSTRUCTURE

The microstructures of the varying composites are shown below for the presence of hybrid reinforcements in the Aluminium
matrix composites. The Microstructure is studied by using De- Wintor Inverted Trinocular Metallurgical Microscope. The samples
with the both highest and lowest value for tensile and compression strength were studied for microstructure. The OM revealed the
presence of B4C in the layer of the aluminium matrix and the Red Mud is sedimented in between the matrix which is made the
composites to increase its strength.

100X HF 200X HF 500X HF

Figure 6. Pure Al without reinforcements

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International Journal of Engineering Research and General Science Volume 4, Issue 2, March-April, 2016
ISSN 2091-2730

100X HF 200X HF 500X HF

Figure 7. 94% Al + 3% B4C + 3% Red Mud

100X HF 200X HF 500X HF

Figure 8. 94% Al + 3% B4C + 3% Red Mud

RESULT AND DISCUSSION

Table 2. Mechanical properties of Al/ Red mud and B4C composite

Varying Wt% Tensile Hardness Yield Compression Elongation

Composition Strength Strength strength
Mpa BHN Mpa Mpa %
Pure Al
65.315 37.5 57.441 66.426 18
94% Al + 5% B4C +
1% Red Mud 67.543 39.6 55.226 71.141 9.2
94% Al + 4% B4C +
2% Red Mud
71.044 36.6 46.932 61.826 12
94% Al + 3% B4C +
3% Red Mud
77.024 45.4 59.973 76.877 22
94% Al + 2% B4C +
2% Red Mud
72.038 43.7 52.613 65.164 12
94% Al + 1% B4C +
5% Red Mud
70.872 43.4 51.973 70.271 8

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Variation in Tensile Strength

78 77
76
Tensile Strength in Mpa

74
72
72 71
70
70
68 67
66 65
64
62
60
58
pure Al 94% Al + 5% B4C94% Al + 4% B4C94% Al + 3% B4C94% Al + 2% B4C94% Al + 1% B4C
+ 1% Red Mud + 2% Red Mud + 3% Red Mud + 2% Red Mud + 5% Red Mud

Fig.9 graph shows the variation in tensile strength from 5-1% of B4C and 1-5% Red mud composite

Variation in Compression Strength

80 76
71 70
70 66 65
Compression Strength in Mpa

61
60

50

40

30

20

10

0
pure Al 94% Al + 5% B4C94% Al + 4% B4C94% Al + 3% B4C94% Al + 2% B4C94% Al + 1% B4C
+ 1% Red Mud + 2% Red Mud + 3% Red Mud + 2% Red Mud + 5% Red Mud

Fig.10 graph shows the variation in Compression strength from 5-1% of B4C and 1-5% Red mud composite

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variation in hardness number

50
45 43.7
45 43.4
Vickers Hardness Number

39.6
40 37.5 36.6
35
30
25
20
15
10
5
0
pure Al 94% Al + 5% 94% Al + 4% 94% Al + 3% 94% Al + 2% 94% Al + 1%
B4C + 1% Red B4C + 2% Red B4C + 3% Red B4C + 2% Red B4C + 5% Red
Mud Mud Mud Mud Mud

Fig.11 graph shows the variation in Hardness Number from 5-1% of B4C and 1-5% Red mud composite

It has been observed that at 94% Al + 3%B4C + 3% Red Mud, there is a considerable increased values in almost all the mechanical
properties of the following hybrid composite.

CONCLUSION

Red mud is the waste generated product from alumina plant which can be successfully used as a reinforcing material to produce the
particle reinforced aluminium matrix composites (PR-ALMC’s) component to be used in the casting environment. It can be successfully used
in the place of conventional aluminium intensive materials, and also by saving the usage of about 10 percent of matrix material could be
achieved.

There is a good dispersion of red mud in aluminium matrix which improves the hardness of the matrix material of the hybrid
composite. The effect is increase in interfacial area between the matrix material and the red mud particles leading to increase in strength
appreciably. From this study that the oxide phases like Al2O3, Fe2O3, TiO2 etc. have been dispersed uniformly in the interfacial areas of the
aluminium matrix thus strengthening the result.

The general conclusion which is revealed from the present work is that by the combination of a matrix material with reinforcement
such as B4C and Red mud particles, it improves mechanical properties like tensile, compression strength, hardness and yield strength. The
microstructure studies also indicate the presence of Aluminium dendrite structure with the fine inter metallic particles of B 4C and Red mud
reinforced in between interfacial areas of the matrix.

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