development and characterization of nanoparticle metal

International Journal of Scientific Research and Innovative Technology ISSN: 2313-3759 Vol. 4 No. 8; August 2017

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Review Article (2017) Development and Characterization of Nanoparticle Metal Matrix Composites: A Review Muhammad Arshad Chaudhry1, Liaqat Ali2, Khalid Mahmood Ghauri2 1Ph.D Research Scholar, Department of Metallurgical and Materials Engineering, University of Engineering & Technology, Lahore, Pakistan 2Professor Dr. Department of Metallurgical and Materials Engineering, University of Engineering & Technology, Lahore, Pakistan Corresponding Author: [email protected] Abstract: A composite material consists of at least two or more physically and chemically separate phases, one being a metal and other may be a ceramic. In recent years, Al and its alloys based cast MMCs have gained a great importance in the fields of engineering and technology due to improved properties such as high strength, low CTE, good fatigue resistance and lower creep rate than unreinforced materials. The present research is aimed for Development of nano particle Metal Matrix Composites by using stir casting process and subsequent characterization for analyzing the microstructure and mechanical properties. MMCs play a vital role in the present day industrial and engineering sectors like Automotive, Aerospace, Defense and Industrial Infrastructure. Al alloy / SiC nano particle composites using stir casting method are light weight along with high strength and toughness. It has various advantages such as simple, flexible and could be made economical if applicable to large quantity production with enhanced efficiency of the engineering systems. Nano Composite has nano particles with average particle size of 45-55nm. Its properties include mechanical, electrical and thermal which depends upon the materials composition used. The properties and microstructures are governed by type and size of reinforcement, nature of bonding and process of production. Recent focus is on reinforcing aluminum matrix with much smaller particles, submicron or nano sized range, is one of the key factor in producing high performance composites with enhanced mechanical properties. Keywords: Al-Cu alloy, SiCnp, Stir Casting, Characterization.


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1. Introduction in Sequence of Events MMC is produced using Stir Casting by selecting metal matrix of required grade and the dispersion of the reinforcement material. In order to form a vortex, stirring is carried out vigorously in which reinforcing materials are inserted from the vortex side. The reinforcement particles along with all impurities drag to form the vortex. The air is entrapped by the vortex into the melt. Due to increased viscosity of the slurry, it is difficult to remove the air from the melt [1]. The Particle distribution in the melt depends upon the viscosity of the slurry, particle wetting, particle settling rate, effective mixing, agglomeration breakup and minimum gas entrapment [2]. The Metal matrices have a useful combination of properties such as high strength, ductility and high temperature resistance but sometimes have low stiffness, whereas ceramics are stiff and strong though brittle [3]. It is well known fact that Liquid phase process has capability to develop producing of intricate profiles having light weight [4]. Al and its alloys have preferable dispersing of SiC due to its high melting point (23000C), high stiffness (480 GPa), good thermal stability, high hardness (9.7 Mohs), great resistance to chemical attack at room temperature, low density (3.21 gm/cm3) and low thermal coefficient of expansion (4.7 x 10-6 K-1). That’s why, SiC has proved competitive reinforcing material with wider applications in industries [5]. Al Metal Matrix Composites (AMMCs) are produced by dispersing SiC, Al 203 and B4C having micron or nano sized into Al alloy matrix. [6]. Al Metal Matrix Nano Composites (AMMNCs) reinforced by nano scale particulates are widely used in industry such as automotive and aerospace [7]. Stir casting method has some limitations of poor wettability which enhances the tendency of agglomeration of reinforcement material. The wettability of SiC and Al2O3 may be improved by adding Si or Mg [8]. The objective of the present study was to investigate the influence of the stir casting process parameters like heating temperature with holding time for uniform distribution of SiC particles and obtain mechanical properties such as TS, ductility, impact and hardness behavior [9]. Current researches reveal that the dispersing of nanoparitcles into the Al matrix improve the hardness, yield and UTS substantially whereas the ductility is retained. It was observed that yield strength of A356 alloy

having 50% improvement with 2.0 wt% nano particle [10]. Al is widely used because of its easy availability, high strength to weight ratio, easy machinablity, durability, ductility and malleability [11]. Stir casting is the type of vortex heating with stirring method in which the raw material gets homogeneously mixed with each other at controlled temperature rate [12]. It is well known that MMCs being light weight, hard and abrasion resistant are widely used for high temperature and speed parts such as pistons, axles, high speed wheels and so on [13]. Decrease in the reinforcement particle size from micron to nano sized increases the tendency of particles clustering and agglomeration but having good strength. Homogenous particle distribution improves mechanical properties [14]. Al Metal Matrix Nano Composites (AMMNCs) have gained considered importance because of dispersion of nano particles in the host matrix to achieve superior mechanical properties [15]. Al alloys having light weight, good stiffness, corrosion resistance and improved mechanical properties etc [16]. Al alloys are mostly attractive due to their low density, good thermal & electrical properties and having good damping capacity [17]. Stir casting method is used to achieve a suitable dispersion. It has some advantages such as simple, flexible, economical and applicable to large quantity production [18]. Al alloy reinforced with particulates composites are achieving great importance due to their low cost, isotropic in nature and useful for secondary processing [19]. The development of Al alloy / Al2O3 reinforced (MMNCs) is important for such applications in aerospace, jet engine exit vanes, blade sleeves of helicopters, parts of space shuttle, piston and cylinder liners, brake drums and discs [20]. Cast Al alloy matrices have higher specific strength, specific modulus and good wear resistance [21]. Al alloys are preferred engineering materials in automobile and aviation industries for various high performance components [22]. Al alloys reinforced with Al2O3 have been used in automobile, aerospace, aircraft etc. due to their high strength- to-weight ratio, good cast ability and better tribological properties [23]. The dispersion of SiC into


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Al matrix is constrained due to more %age of Si. It is noted that viscosity of the molten metal increases because of the addition of nano SiC particles [24]. Stir Casting is one of the most economical, simple casting route for the production of AMMCs [25]. Composite materials have more potential for replacing of widely used steel and Al. They have many times better performance [26]. Al matrix composites reinforced with SiC have structural and non-structural applications both at room and high temperatures. [27]. A MMC is an engineered material by combining the metal (matrix) and ceramic hard particles (reinforcement) in order to obtain required properties [28]. Al metal matrix composites have specific use due to low cost, ease in fabrication, recyclability and isotropic characteristics [29]. Al alloys are used for engineering applications at moderate temperature [30]. In the production of composite with desired properties, important factors like nature of metal matrix and choice, the kind of reinforced particulates and the process involve, must be standardized [31]. By using casting method, the cost of composite production is about 1/3 to 1/2 and for high volume production, it falls to 1/10 [32]. Normally, Al and its alloys solidify in columnar structure having large grain size with less mechanical properties. The addition of Cu in Al alloy, there is a substantial improvement in mechanical properties and microstructure [33]. There is a dire need of modern development of advanced engineering materials for various engineering applications. [34]. In order to obtain better properties, hybrid MMCs have more than one type, shape and size of reinforcement are utilized. Hybrid MMCs possess better and improved properties being, combined advantages of their constituent reinforcements [35]. During the last three decades, Al based composite has been creating an interest in materials science and engineering sector for the development of high performance components in the fields of automobile, medical, aerospace, defense, marine, sports and recreation [36]. Al and its alloys in the form of MMCs are widely used in aircraft, aerospace, automobiles and various other fields [37]. It is desirable that the composite material be economical for the mass production [38]. Aluminum MMC exhibits better mechanical properties than unreinforced Al alloys. Al is only second to steel, when it comes to automobile body frame, with 5xxx and 6xxx series on the lead [39]. Stir

casting method is most suitable for large quantity production of composite [40]. The development of Aluminum Metal Matrix Nano Composites (AMMNCs) is most considered material for high temperature applications, due to their excellent mechanical properties, increased performance and weight saving for more reduction of fuel consumption [41]. Stir casting process has certain characterized features such as simple and low cost technology, dispersion phase may not more than 30 vol %, inhomogenous distribution of reinforced particles, might be clusters of dispersed particles and possibility of gravity segregation of dispersed phase because of difference in the densities of matrix and dispersed phases. Rheocasting / compocasting is the method in which matrix in semi solid state is used to improve the distribution of dispersed phase [42]. There are various factors such as the nature and type of reinforcement material, its particle size and weight or volume fraction, the processing conditions, secondary forming and heat treatment processes, which affect the properties of MMCs. [43]. In order to obtain optimum mechanical properties of composite material, high level of homogenous distribution is required. Therefore, the important parameters controlling the process must be identified and corrected so as to attain a better quality composite [44]. There has been emerging a huge demand from automotive sector due to light weight with reduced fuel consumption [45]. There can be further enhanced the properties of MMCs by adding the nano sized reinforcement particles. The uniform distribution of nano particles in the molten metal is entirely difficult. It is because of high viscosity, poor wettability and large surface to volume ratio. These factors create clustering and agglomeration which may be overcomed by using the ultrasonic cavitations to breakup the clustered fine particles and disperse more uniformly in liquids. It enhances the wettability between the alloy melts and reinforcement particles [46]. The advantages of stir casting lies in its simplicity, flexibility and applicability on large scale production. [47]. Application of nano sized ceramic particles strengthens the MMCs while maintain good ductility, high temperature creep resistance and better fatigue strength [48]. During


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the last three decades, MMCs have improved specific strength, stiffness, wear, fatigue and creep properties than to conventional engineering materials [49]. MMC with less than 100 nm size, it can be termed as Metal Matrix Nano Composite (MMNC) and it shows far superior mechanical properties than conventional MMC. The grain refinement increases the ductility, weight %age elongation, UTS, impact strength and hardness [50]. The operational parameters of stir casting process such as mold preheating temperature, stirring speed, pouring temperature and stirring time are optimized to obtain better properties [51]. With the development of MMC, It is possible to produce large volume of complex shape components at high production rates along with producing near net shapes by the foundry techniques [52]. For the investigation on the effects of coating on particles, there were considered main parameters of stirring like stirring speed and temperature to produce the composite. The objective of the present study was to fabricate Al 2024 / SiC nano composite with Al and Cu pure coating using stir casting process and the effects of coating on microstructure. [53]. In order to develop light weight high performance Al composite materials should have combined metallic properties such as ductility and toughness with ceramic properties of high strength and modulus. The final properties depend on interface strength between the matrix and reinforced particles. There are various manufacturing variables which affect the final properties including matrix alloy, particle volume fraction, its size and heat treatment [54]. Because of the attractive properties, MMCs are being considered for a wide range of applications in shuttles, commercials airlines, electronic substrates, automobiles and golf clubs [55]. The various reinforced materials used as nanocomposite are Al203, illmenite, SiC, etc. Al is widely used as matrix material due to its high wear resistance and high strength to weight ratio [56]. During these days with the modern development, an application for the composites goes on increasing for various engineering materials. To meet such demand, MMC is one of the dependable source. Al is important not only because of its availability but also of its immense properties. The reinforcement used such as SiC, composites have become as a class of materials suitable for various applications. [57]. Al metal matrix composite is a combination of Al metal

alloy having properties like high strength, ductility and high temperature resistance and SiC ceramic materials which are stiff and strong, though brittle [58]. Al metal matrix composites are low density having improved mechanical properties like high strength toughness, fatigue and wear resistance. It is an ideal material for automotive and aerospace sectors for the construction of light weight structures and engine parts which enhances the fuel efficiency of the systems [59]. In order to enhance the mechanical properties of Al metal matrix nano composites, hybridization technique is used which improves the ultimate efficiency and performance of the nanocomposites [60]. 2. Comparison of Experimental Techniques and Findings J. Hashim (2001) studied by using A359, SiC and Mg. Placed A359 & SiC and Mg particles in a graphite crucible. Heated in an inert atmosphere of N gas at a rate of 3 cc / min. inside the rig, controlled temperature inside the rig was kept below 750 0C to minimize the chemical reactions between substances. Stirring in two steps process was used. Firstly it took place in semi solid state while secondly, when the slurry was remelted at 50-70 0C above liquidus to form full liquid. It was stirred at 100 rpm with placement of stirrer at 20% from the bottom of the rig. Poured the full liquid slurry into the mold die of graphite having cavity of dia 20 mm and length 150 mm. It was concluded that main problem of low wettability be enhanced by heat treating of SiC particles and can be ensured uniform distribution of particles by re-stirring process to disperse the SiC particles [1]. S. Naher et al. (2004) studied by using A356 and SiC particles. A356 and SiC particles were placed in the crucible under N gas in a furnace in order to reduce the oxidation problem at high temperature. The crucible was heated above liquidus to 630 0C for 130 min till it becomes complete liquid. Stirring was started at semi-solid state during cooling till it was stabilized with an appropriate stirring level. The full liquid slurry was then poured into mold to cast test sample. It was concluded that full dispersion of SiC particles into the Al matrix was achieved in the semi solid state [2]. S. B. Prabu et al. (2006) studied by using A384 and SiC


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powder (60 µm). Melted weighed quantity of A384 in a graphite crucible at 100 0C above liquidus to get full liquid which was stirred at 500-700 rpm to form the vortex. MS impeller coated with Zircon was used to minimize the dissolution of blades in molten metal. A mechanical stirrer was used to agitate the molten metal to create turbulence motion. The stirring speed was maintained at 500-600-700 rpm. The preheated SiC powder (60 µm) at 800 0C for 2 hrs, was then dispersed at a constant rate into the route of the vortex. On oxidation of SiCp, SiO2 layer improve the incorporation of SiCp into the molten Al / SiC slurry. Stirring was continusely made for different combination of processing conditions by varying the stirring time and stirring speed at 5, 10, 15 min at 500, 600, 700 rpm respectively. Then poured the molten metal into MS steel die (preheated to 300 0C. It was concluded that at lower speed and lower stir time, clustering was accord at some sites. Similarly, it was found better distribution of SiC particles at higher speed of 600 rpm and stirrer time of 10 min. it was found that better hardness was at 600 rpm and 10 min [3]. S. D & N. Nageswara (2010) investigated by using A356 and SiC particles (34 nm). A356 alloy was melted in an electric resistance furnace at 700 0C. Added preheated SiC (34 nm size) particles into the melt from the top which was protected by argon gas. A stirrer was used at 750 rpm for 3 min. composites with different wt% of 0.1, 0.2, 0.3, 0.4 & 0.5 nano sized were fabricated. Processed the melts for 6 min for every 0.1 wt% increment. The composite melt was poured into MS permanent mold for casting of test samples. composite melt was poured into MS permanent mold for casting of test samples. It was concluded that tensile strength, hardness increased by increasing wt% of nano particles and decreased in ductility. The use of nanoparticles by top-down approach is permissible. However, it is advised to use nano particles produced by bottom- up approach for fabrication of nano particles in view of ductility retention with the uniform increase of tensile properties [4]. S. Amirkhanlou and N. B. Niroumand (2011) studied by using A356 and Sip (8, 80 & 40 µm). A356 alloy was melted in a graphite crucible to 700 0C for 2 min. Melt was stirred at 500 rpm and SiC particles were injected

using pure Argon gas. Thereafter slurry was slowly cool down at 4.2 0C per min to 650 0C (full liquid) and then to 607 0C (semi-solid). Added 1 wt% Mg to the melt to increase the wettability between the matrix and the reinforcement particles. Poured the composite melt in the steel die for sample casting. It was concluded that by using semisolid state (compocasting) with 8 to 3 um particle size. Porosity content was also decreased considerably [5]. M. H. Zamani and H. Baharvandi (2011) studied by using A356, Al203, 10% volume ZrO2 nano particles. Smelted Al356 ingot and added 3 gm keryolite to the molten metal in an electric resistance furnace having the graphite crucible. . Stirred molten metal at 420 rpm for 14 min and added nano particles (80 nm) wrapped in Al foils at 850 0C. Test specimens were cast in preheated steel mold to avoid temperature drop. Prepared test samples for microstrucctural and mechanical analysis. It was concluded that by increasing the reinforcement content, density decreased while yield, UTS and compressive strength increased. Ductility of the composite was low because of high porosity content [6]. E. S. Y. El-Kady et al. (2011) studied by using A356 and Al2O3 (200 & 60 nm). A356 alloy was melted at 680 0C in a graphite crucible in an electric resistance furnace. After complete melting and degassing by Argon gas of the alloy, allowed the alloy to cool to the semisolid state at 602 0C. Started stirring at 1000 rpm. Before stirring the nanoparticles (200 and 60 nm) after heating to 400 0C for 2 hrs, added into the vortex (upto 5 wt %). After complete addition of SiCnp, stop the stirring and poured into preheated tool steel mold. Before testing, MMC heat treated at T6 (solution treated) at 540 0C for 3 hrs. Then quenched in cold water and aged at 160 0C for 11 hrs. It was concluded that Al 356/Al2O3 MMNC, containing upto 3 wt% of 60 nm Al2O 3 showed better thermal conductivity than the MMNCs containing 200 nm nano particles [7]. A. R. I Kheder et al. (2011) studied by using Al and SiC (50 um), Al2O3 (60 um) & MgO (50 um). Melted Al in a graphite crucible to 900 0C. Pre heated ceramic particles (SiC 50 um, Al 2 O 3 60 um, MgO 50 um) to 300 0C before adding into the molten Al. Added different wt% of particles to the melt and stirred. Then continuous stirring


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at 400-500 rpm for 15 to 20 min to achieve uniform distribution of particles until 700 0C. After degassing, poured the melt into preheated mold die for sample casting of size 15 x 8 x 1 cm. Opened cooled mold after 10 min. Prepared tensile test samples as per ASTM-E8-95a and impact test samples as per ASTM E23. It was concluded that by adding SiC, Al 2 O 3 and MgO particles significantly increased the YS, UTS & hardness and decreased elongation (ductility) of composites. Improved mechanical properties by increasing wt% of particles increases, but decreases ductility and toughness [8]. G.G Sozhamannan etl (2012) investigated the effect of processing parameters on MMCs by stir casting process. Al-11Si-Mg alloy was heated in a graphite crucible at 700 0C, 750 0C, 800 0C, 850 0C and 900 0C. Preheated SiC (40 um) particles at 1000 0C for 2 hours. 10 vol % SiC was dispersed in the melt. The designed 4 blade stirrer was used for continuous stirring to obtain homogenous distribution. Stirring was carried out at 450 rpm for 10, 20 & 30 min by using argon gas to avoid oxidation of metal matrix. After completion the stirring process, the melt was poured in the preheated (300 0C) mold die for sample casting. It was concluded that because of homogenous distribution of reinforced SiC particles, there was an increase of TS, impact strength and hardness [9]. B. S. Kumar and L. Ramesh (2012) studied by using A357 and SiCnp (18 µm & 50 nm). Heated SiCnp (50 nm) to 1000 0C. Placed weighed quantity of A357 alloy (Al/SiC= 1.66) in the crucible to 740 0C (above liquidus temp.) and added 1 wt% Mg in powder form as wetting agent. Supplied N gas in the crucible. Connected Shaft to stir the slurry. Poured and allowed the slurry to flow into a mold. Ensured non-mixing of composites floating on the surface of the melt. Inserted powder mixture into an Al foil by forming of a packet and added into molten metal of crucible. Melted packet of powder mixture and particles started to distribute around the sample. It was concluded that the addition of 3.5 vol. % of nano particle resulted in significant improvement in hardness, YS & UTS of composites [10]. J. J. Rino et al. (2012) reviewed on the stir casting which is a liquid state method of fabrication for composite materials. In this method a dispersed phase (ceramic particles) is mixed with a molten metal matrix by using mechanical stirring. The liquid composite material is then cast by conventional casting methods.

It was concluded that with the addition of hybrid reinforcement instead of single reinforcement the hardness, toughness, strength, corrosion resistance and wear resistance of the composite is increased considerably [11]. A. D. Sable and Dr. S. Deshmukh (2012) studied by using Al and SiCp. Preheated the scrap of Al (99.41%) for 3-4 hrs at 450 0C and SiC powder (320 grit size) at 900 0C. Mixed both and placed in graphite crucible and put into the coal fired furnace at 760 0C. Stirred the mixture to form slurry for casting of molds and solidified into bars. Prepared the test samples by varying the SiC 5%, 10%, 15%, 20%, 25% & 30%. It was concluded that hardness, impact strength improved by increasing SiC particle at 25 w% of 320 grit size [12]. A. D. Sable and Dr. S. Deshmukh (2012) studied by using Al and SiCp. Preheated scrap of Al (99.41%) for 3 to 4 hours at 450 0C and SiC powder (320 grit) at 900 0C. Mechanically mixed both the preheated mixtures with each other. This metal matrix Al-SiC is then poured into the graphite crucible and put into the coal fired furnace at 760 0C. Increased the furnace temperature above the composites completely melt the Al scrap and then cooled down just below the components temperature and keep it in a semi-solid state. Added at this stage the preheated SiC p with manually mixed with each other. On completion of manual mixing then carried out automatic stirring for 10 min with normal 400 rpm. Controlled temperature rate of coal fired furnace at 750 0C in final mixing process. After completion of the process, the slurry is taken into the sand mold within 30 sec allow it to solidify for sampling. It was concluded that these metal matrices are very popular with improved mechanical properties, economical and beneficial for the modern engineering fields [13]. A. Mazahery et al. (2012) studied by using A356 (16 µm) and SiC (50 nm). Melting of Al alloy and additions of particulates were performed in a resistance heating furnace. Placed the Al ingot in a graphite crucible and heated to 750 0C. Protected the melt by N gas poured composite slurry into preheated die cavity. Preheated the graphite lubricated die and rams to 350 0C to avoid premature chilling.


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Microstructural characterization was carried out using optical microscope. Brinell hardness of the sample was measured on the polished samples. [14]. S. Chatterjee and A. B. Mallick (2013) studied by using Al, TiO2 (20 nm) & Mg. Prepared Al3Ti reinforced Al based MMNCs. Used TiO2 powder, Al (99.5% pure) and Mg as starting material. The tubes (filled up Al tubes of length 4 cm) were preheated at 500 0C and immersed into molten Al (containing 2wt% Mg) at 900 OC. stirrer the melt vigorously and poured into cast iron metal molds of size 200 mm x 10 mm x 30 mm. It was concluded that the strength and hardness of the composite is controlled by the degree of grain refinement [15]. A. Jailani and S. M. Tajuddin (2013) studied by using Al alloy and SiCp. Set the impeller at the angle of 30 0 and speed of 50 rpm. Melted Al alloy in induction furnace then mixed 10 wt% SiC reinforcements. Stirred SiC reinforced Al alloys for 15-20 min. Poured the composite melt into the mold to prepare test specimens. It was concluded that during lower speed and lower stir time particle clustering occurred in some sites and some sites were without SiC inclusion. It was found that better homogenous distribution of SiC (10 wt%) in the Al matrix was because of increased stirring speed at 100 rpm and stirring time for 10% found that better mechanical properties of composite was obtained from 10% SiC, 100 rpm and 30 0 blade angle [16]. B. M. Viswanatha et al. (2013) studied by using A356 and SiCp & Grp. Preheated SiCp and Graphite for 2hrs to oxidize the surfaces. Melted A356 alloy in graphite crucible using electric resistance furnace. Then added slowly the reinforcements into the crucible. Mixed Mg 1 wt% to enhance the wettability between reinforcement and matrix alloy. Added hexachloroethane (C 2 Cl 6 ) tablets which decompose to form AlCl 3 gas bubbles. After sufficient mixing by stirrer, stirred at speed of 500-600 rpm for 10 min. Poured the slurry into preheated mold to avoid the formation of porosity. It was concluded that A356 hybrid composites have been successfully fabricated by stir casting route with uniform distribution of SiCp and graphite. Hardness increased significantly with addition of SiCp by 9% while tensile strength improved by 5% with an addition of 3 wt% of SiCp

and Grp [17]. K. L. Meena et al. (2013) analyzed by using Al 6063 and SiCp. Preheated Al 6063 to 450 0C before melting for 2 hrs. Melted Al 6063 in clay-graphite crucible. Preheated SiC particles at 1100 0C for 1.5 hrs to improve wetting properties. Melted the matrix at 750 0C, cooled down below the melting temperature to keep the slurry in semi solid state. Added the preheated SiC particles and mixed mechanically. Reheated the composite slurry to full liquid state and carried out mechanical mixing for 20 min at 200 rpm. Mixed in the final stage at 760 0C to control at 740 0C. Poured the melt into the preheated molds (size 40 mm dia x 170 mm long). It was concluded that by increasing reinforced particulates increased homogeneous distribution of SiC particle and also increased UTS, YS, hardness and decreased elongation% (ductility) and impact strength with maximum value at 20% wt of 400 mesh size [18]. D. Singla and S. R. Mediratta (2013) evaluated by using Al 7075, Fly Ash & Mg. Fly ash is heat treated in the induction furnace at 600 0C. Ethanol solution is also added at 50 0C and stir for some time. Melted Al 7075 in an electric resistance furnace. Added preheated fly ash into it. Added Mg to increase the wettability. A stirrer is used for better mixing of all materials. Also used hexachloroethane tablets as solid degasser. Poured the molten composite material into the preheated sand mold for casting the test samples. It was concluded that TS, hardness and toughness increased with increasing as fly ash contents and showed best results with 30 wt% content. Density is decreased with increasing fly ash contents [19]. V. Kumar et al. (2013) studied by using AA 2218 and Al2O3. Melted Al alloy 2218 at 850 0C by adding Al2O3 using stirrer at different speed in the preheated solid state. Addition of Al2O3 is used to increase the mechanical strength, hardness and toughness. It was concluded that the distribution of Al2O3 is uniform and non-uniform also at the different speeds and there is the change in the mechanical properties [20]. Gopi K. R. et al. (2013) studied by using Al 6061 and


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ZrO2 / Grp. Melted Al 6061 alloy in a graphite crucible at 756 0C using hexachloroethane degassing tablets. Stirring device having SS rod with 4 blades (1mm thick) mounted radial on the rotating rod at 50 angled to the radial horizontal rotational plane. Added Zircon sand & graphite particles on %age weight of Al alloy from 2-10% (with increment of 2%). Stirred molten alloy at 400 rpm for 1 min. Added preheated nanoparticles (ZrO2 & graphite particles) at 200 0C for 3-5 min. to ensure complete insersion of particles. Poured molten metal into preheated mold die. It was concluded that there was an average of 35% improvement in the wear resistance at 400 rpm and 30% at 800 rpm [21]. P. Phutane et al. (2013) studied by using Al alloy and SiCp (25 um). Superheated Al-HE-30 over its melting temperature and then lowering of temperature below the liquidus temperature to keep the matrix alloy in the semisolid state. Introduced the preheated SiC particles (25 um) at 800 0C into the slurry and mixed with 3% and 5%. Increased the composite slurry temperature to obtain full liquid state. Continued the stirring for 10 min at 500 rpm. Superheated the melt above 760 0C and poured at 700 0C into preheated permanent metallic molds. It was concluded that by increasing wt% of SiC particles increased TS, YS & hardness while decreased ductility. Also showed fairly uniform distribution of SiC particles [22]. D. K. Koli et al. (2013) reviewed by using A356 and Al2O3 (50 nm). Melted matrix Al 356 in an electric resistance furnace above its liquidus temp 750 0C. Stirred the molten metal thoroughly to form a vortex. Added preheated reinforcement particles Al 2 O 3 with 1.5 vol. % to 800 OC. Poured the melt for casting of test samples. It was concluded that porosity increased with increasing particle content at both casting temp (800 & 900 0C.) Increased nearly 92% in hardness, 57% in TS as compared to commercially pure Al [23]. Dr. G. Nandipati et al. (2013) investigated by using Al 2024 and B4Cnp (50 nm). Melted Al 2024 alloy in an EN-8 steel crucible placed in an electric resistance furnace at 638 0C. Added B4C nano particles (50 nm) at various wt% (0.1, 0.2, 0.3, 0.4, 0.5, 1.0, 1.5, 2.0 %) to the melt during stirring process. Added Argon gas during melting to protect molten metal from atmospheric air. Poured melt in a mold die of size 200 x 130 x 9 mm3 to cast plates. Heat treated as-cast

plates (solutionized at 560 0C for 1hr) and aged at 160 0C for 12 hrs. Prepared tensile specimens as per ASTM-E8 standards. Processed heat treated plates through rolling to remove the casting defects & porosity. It was concluded that MMNCs have fine and more homogeneous microstructure with increase of wt% of B4Cnp. Hardness, UTS, YS increased by 14%, 6% & 11% respectively. Ultrasonic nonlinear affects efficiently disperse nanoparticles into molten alloy by enhancing their wettability [24]. L. Rasidhar et al. (2013) studied by using Al alloy and FeTiO3 nano particles (57 nm). Melted weighed amount of alloy to 750 0C. Added weighed % of FeTiO 3 nano particles 57 nm (1, 2, 3, 4 & 5 %) to the melt. Packed the powder in Al foil as a packet. Melted packets of nano particles and distributed around the molten alloy. Stirred melt at 650-700 rpm for 10-15 min. Maintained the temp at 850 0C during stirring and supplied Argon gas to the crucible. Al alloy reinforced melt with nano particles is poured into a preheated permanent MS mold. It was concluded that nano particles were evenly distributed. TS & hardness increased maximum at 5wt% [25]. J. Shree P. K et al. (2013) reviewed by using A6061 and SiCp. Charged A6061 alloy billet into the furnace to 750 0C & degassed by passing hexachloroethane (C 2 Cl 6 ) solid degasser. Allowed melt to cool to 600 0C to a semisolid state. Added preheated SiC particles at 600-800 0C for 2 hrs to the melt and performed manual stirring of slurry for 20 min. Reheated composite slurry and maintained at a temp of 750-760 0C. Performed mechanical stirring for 10 min at 400 rpm. Casted samples at a pouring temp of 720 0C. After degassing the molten metal, poured into permanent molds. It was concluded that 20% improvement in yield strength, low CTE, high modulus of elasticity and more wear resistance [26]. N. S. Abtan (2013) investigated by using Al and SiCp (63 um). Preheated Si particles to 7000C before adding to melt to avoid high drop of Al melt temp. Melted Al at 900 0C and added preheated SiC (63 um) with 0, 5, 10, 15, 20 wt% & Si element 10 wt% to overcome problem of poor wettability of SiCp. Stirred the melt to form vortex until the particles were completely wetted. Reheated the composite slurry to 750 0C by electrical


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resistance furnace. Poured the composite slurry in metal mold of dimension dia15 x 100 mm long. Prepared test specimens of dia 10 x 10 mm for micro structure, and hardness and dia 10 x 20 mm for impact and resistance tests. It was concluded that addition of Si to Al improved the wettability between SiCp and Al. Also TS, YS and hardness increased but decreased impact strength due to decrease of ductility by added SiCp [27]. A. Kumar et al. (2013) studied by using A359 & Al2O3. Melted A359 to 730 -750 0C. Stirred the melt and added preheated-Al2O3 particles at about 800 0C. Stirring speed of stirrer kept at 300 rpm. Performed experiments with varying wt% from 2% to 8 % in steps of 2%. It was concluded that tensile strength and hardness increases with increase in weight fraction of Al203. Microstructural observation indicates good particle matrix interface bonding with smaller grain size [28]. R. S Rana et al. (2013) studied by using A5083 & SiCnp. Placed small pieces of Al ingot into a graphite crucible. Melted the A5083 alloy to 760 0C, added flux coveral 11 and degassed with dry N gas of grade 1. Added preheated SiC nano particles (40 nm) with different wt% in the melt. Stirred the alloy melt and prepared different wt% of SiC particles such as 1, 2, 3, 4 & 5%. Poured melt into preheated MS die in the form of cylindrical rod (20mm dia & 200 mm length). Prepared standard samples for tensile strength, compressive strength, hardness & microstructural analysis. It was concluded that porosity could be decreased significantly by ultrasonic treatment and N degassing. TS, CS & hardness increased with increase in wt% of SiC nano particles. It is maximum at 4% nano particles while elongation of MMC remains almost same [29]. A. R. N. Abed and I. R. Ibrahim (2013) studied by using Al 7075 and Al203 nano particles. Charged 500 gm of Al7075 alloy into the graphite crucible and melted to 650 0C. Cleaned the melt from the slag by overheating of the melt 50 0C above the liquidus temperature. Mixed by an impeller with a speed about 300 rpm at 650 0C in semi-solid condition. Stirred the slurry for 20 min. Poured in a 100 x 120 x 14 mm steel mold. It was concluded that the addition of ceramic nanoparticles

to the Al alloy enhances its properties. Increased stirring time reduces agglomeration of added particles. Heat treatment refines grain size and consequently enhances mechanical properties. Increasing wt% increases mechanical properties for certain limit and drop down. Reducing capsule particle content and increasing its thickness lead to reduction in particles agglomerations [30]. B. P. Samal et al. (2013) studied by using Al and SiCp. Melted Al ingot at 800 0C. Charged the capsule/ bullet with pieces of Mg chips or SiC particulates. Mixed at stirring speed of 500 rpm. Charged the bullet prepared by SiC particulates (10 wt%) into the alloy melt Poured the uniform mixed melt of MMC into preheated mold of fire bricks. Prepared the test sample. It was concluded that by adding reinforcement particles, YS, UTS and elastic modulus increased by 49%, 31% & 24% respectively. The % of elongation decreased by 68%. Higher ductility is possibly due to finer grains [31]. S. Mathur and A. Baranawal (2013) studied by using Al alloy and SiCp. Preheated base Al metal at 450 0C for 3 hrs in an electric resistance muffle furnace. Melted Al-4 % Cu in a graphite crucible. Mixed preheated SiC particles at 1100 0C for 2 hrs at stirring rate of 600 rpm for 3 min in an electrical resistance furnace. Poured and casted molten composite at 700-725 0C into molds. It was concluded that TS, hardness and impact strength increased with increasing grit size of SiC. [32]. A. Mittal and R. Muni (2013) studied by using Al6061 and RHA / Cu. Put Al 6061 into graphite crucible to melt to 750 0C. Prepared RHA as reinforcement (preheated to 850 0C for 1 hr before mixing). Added at the same time 3wt% of Mg to improve wettability. Melted Cu metal cuttings to 1100 0C. Stirred the melt at 600 rpm. Added slowly preheated RHA particles at constant rate of 5gm/sec for 5 min. Poured composite melt into preheated molds (550 0C for 20 min) to obtain uniform solidification. Produced samples of composites with 8, 16, 24 & 32 wt% RHA with Cu and without copper particles. It was concluded that strength and hardness increased by increasing RHA and Cu contents can lead to production of economic composites [33]. R. G. Bhandare and N. P. M. Sonawane (2013) studied by using Al alloy and Al2O3 / SiC / Graphite. Placed empty crucible in the muffle to set at temp of 5000C and then


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upto 900 0C. Put cleanedrequired quantity of Al alloy in the crucible for melting. N gas is used as inert gas. Used powder mixture of Al 2 O 3 , SiC & graphite (320 mesh) and 1wt% of Mg. Heated reinforcements at a temperature of 500 0C for ½ hr. Started stirring after 2 min from 0-300 rpm at a temp of 630 OC to achieve semi solid which is below the melting temp of the matrix. Poured preheated reinforcements in semi solid stage to enhance wettability & reduces the particle settling. Maintained flow rate of reinforcements at 0.5 gm /sec with dispersion time of 5 min. Stirred semi solid slurry for 5 min and reheated to hold at 900 0C to make sure full liquid slurry. Poured molten composite slurry in the preheated metallic mold (500 0C) keeping uniform flow of slurry. It was concluded that uniform dispersion of reinforcement particles achieved at 450 or 600 blade angle with 4 blades. Achieved good wettability at operating temperature of 6300C semi solid stage. Preheated molds helped in reducing porosity and increased mechanical properties [34]. T. Rajmoham et al. (2013) Evaluated by using aluminum alloy, Al 356 and SiC particles with size of 25 um and mica with average size of 45 um. Melted Al alloy in an electric furnace. Preheated Mica and SiC to 620 0C and were added to the molten metal at 750 0C and stirred continuously. Performed the stirring at 500 rpm for 5-7 min. Added Mg during stirring to increase the wetting. Poured the melt into mold for casting of samples. It was concluded that the stir casting method is found to be suitable to fabricate the hybrid aluminum–mica reinforced metal matrix composites. The strength and hardness is found maximum with Al/10 SiC-3 mica composites [35]. K. K. Alaneme et al. (2013) studied by using aluminum matrix reinforced with SiC and BLA. Two steps stir casting process was adopted by charging the determined amount of BLA and SiC. Preheated separately the BLA and SiC particles at a temperature of 250 0C. Charged Al alloy and heated to 750 0C. Allowed the melt to cool to semi solid state at 600 0C. Charged preheated BLA and SiCp with 0.1 wt% Mg and stirred for 5-10 min. Superheated the composite slurry to 600 0C. Performed second stirring at 400 rpm for 10 min. Poured the melt for casting of samples. It was concluded that the hardness, ultimate tensile strength (UTS), and percent elongation of the hybrid composites decreased with increase in BLA content. The fracture

toughness of the hybrid composites was observed to be superior to that of the single reinforced Al-10 wt% SiC composite. [36]. B. V. Ramnath et al. (2014) reviewed by using Al-Si alloy and Al2O3p. Preheated Al 2 O 3 reinforcement particles. Melted Al-Si alloy at 700 0C. In a graphite crucible using an electric resistance furnace at 700 0C. Mixed the Al 2 O 3 reinforcing particles in molten Al melt and stirred at 900 rpm, stirring time 5 min and particle addition rate 5 gm/min at pressure of 6 MPa. Poured the composite melt to 700 0C into preheated mold at 550 0C. Solidified the molds to room temp to get test specimens. It was concluded that SiC reinforced Al MMCs have higher wear resistance than Al 2 O 3 & B4C are most suitable for brake drums. Addition of ZrO 2 and fly ash reinforcement increases wear resistance and compressive strength. Found that Al MMCs reinforced with Diamond Fiber exhibited high thermal conductivity and a low thermal expansion co-efficient [37]. Raghavendra N. and V S Ramamurthy (2014) studied by using Al 7075 and Al2O3p. Cut sizeable pieces of Al 7075 and placed inside the graphite crucible. Collected Al 2 O 3 powder in sieve size 100 mesh (149 u), 140 mesh (105 u) & 200 mesh (74 u). Weighed quantity of Al 7075 is heated to 720 0C. Al03 powder is also heated to 350 0C and added to the melt. Stirred the melt for 5 min. Poured the melt into the sand mold. Cast the rods of dia 20 X 200 mm long. It was concluded that mechanical properties are controlled by the parameters such as processing route, reinforcement size, weight fraction and temp of melt. The temp of 700-720 OC be maintained to avoid agglomeration and clustering. Hardness and wear rate increases with reduced particle size [38]. P. O. Babalola et al. (2014) reviewed by using Al 6061 and SiCp. Melted Al 6061 alloy in a graphite crucible to 670 0C and then stirred at 500 rpm. Added SiCp of 10 vol.% to the matrix alloy. Argon was used as a carrier gas. Slurry was cast into a steel die placed below the furnace. It was concluded that stir casting process is predominant because it is cost effective and processing parameters could be readily varied and monitored. Specimens from stir casting showed high hardness and fine grains in the


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microstructures [39]. S. Haque et al. (2014) studied by using Al 6061-Cu and SiCp. Preheated billet of Al-Cu alloy at 450 0C for 40 min. Also preheated SiC particles at 1100 0C for 2 hrs. Melted Al 6061-Cu alloy in a graphite crucible. Furnace temp was first raised above the liquidus to melt. Cooled down the slurry to semi solid state. Added the preheated SiCp and mixed manually and the slurry was reheated to a fully liquid state. Then automatic mechanical stirring was carried out for 10 min at 200-600 rpm. Maintain the final mixing furnace temperature within 800 0C. Poured composite slurry in a sand mold to get standard test specimens. It was concluded that wear rates are high at high stirring speed above 600 rpm. Also high wear at high pouring temp 775 0C for Al 6061-4% Cu and 5% SiC MMC. [40]. Vinoth M. A. et al. (2014) studied by using Al-Si alloy and SiCp / Cenosphere. Melted weighed quantity of Al-Si alloy in clay-graphite crucible at 750-800 0C. Added hexachloroethane pallets to remove the atmosphere gases particularly H. Preheated measured quantity of SiC and cenosphere at 450 0C for 3-4 hrs to remove gases and moisture. Added preheated particles at 10-30 gm/min into the melt. Stirred the mix with speed range of 350-890 rpm for 8-10 min. Preheated the mold and applied choco powder in mold to avoid shrinkage of casting material. Poured and casted the required samples. It was concluded that TS, CS & hardness increased with increasing reinforced particles. Best TS obtained at 15% wt of cenophere and 3% wt of SiC. [41]. Tony Thomas. A et al. (2014) developed the feeding and stirring mechanism for AMCs. Preheated Al alloy was melted in a crucible at 900 0C for 2.5 hrs. Preheated SiC particles were dispersed in the matrix at 600 rpm for 10 min. The molten MMC was poured in the mold for sample casting. It was concluded that by using modified feeding and stirring mechanism, homogenous distribution of SiC particles was ensured. There was an increase of about 34 % elongation %age and 31% BHN. [42]. G. Sutradhar et al. (2014) studied by using LM 6 aluminum alloy reinforced with SiC particles. Melted the LM 6 in a resistance furnace. Added 3 wt% Mg to the melt because Mg forms strong bonding. Preheated SiC particles at

850-900 0C. and added to the melt and mechanically stirred at 750 0C at 400-500 rpm. Poured the melt at 745 0C for test samples. It was concluded that TS, impact strength and hardness increases with increase in reinforcement ratio whereas elongation decreases with increase of particle wt%age. [43]. B. V. Ramnath et al. (2014) evaluated by using Al alloy matrix with Al2O3 and B4C. Melted the Al alloy (95%) ingot in the graphite crucible. Preheated the ingot for 3-4 hr at 550 0C. Also preheated the B4C and Al2 O3 powders to 400 0C in the respective containers. Heated the crucible with Al alloy to 830 0C. Stirred vigorously at 550 rpm for 10 min resulted to obtain uniform distribution of reinforcements at 830 0C. Poured the melt for sample casting. It was concluded that the tensile strength, flexural strength, impact strength and hardness of the MMCs has improved values than that of Al alloy (LM 25) [44]. Mr. Praveen. G et al. (2014) studied by using Al alloy matrix reinforced with MgO nano particles. Reinforced Al alloy with MgO was stirred at 100 rpm for 15-30 min. Poured the melt at 850 0C for casting of samples into the MS mold die. It was concluded that hardness and wear resistance increases with increase in wt% of nano particles. [45]. L. Poovazhagan et al. (2014) studied by using SiC nano particulates reinforced Al matrix nano composites. Melted AA6061 at 680 0C for 10 min. Stirred mechanically alloy melt and added slowly SICnp to the molten metal. Poured the melt at v 800 0C into preheated steel die. Prepared the sample of dia 20 mm and 120 mm length. It was concluded that tensile strength and hardness increases with increase of values %age of SiC nano particle [46]. M. T. Alam and A. H. Ansari (2014) studied by using Al matrix reinforced with SiC particles. The side- blow converted furnace was used to melt Al at 680 0C. A digital thermocouple was used to measure temperature of molten metal directly in the graphite crucible. Added silicon carbide particles in the molten metal and mixed by stirring at 300 rpm for 30 seconds.


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Prepared the MS steel die as per ASTM standard. Die is cuboids in shape which is in 2 pieces of sizes 7 in. x 7 in. x 1.5 in. and 7 in. x 7 in. x 0.75 in. It was concluded that the hardness improves with an increase of SiC upto 30% and then it decreases with the further increase in the %age of SiC [47]. H. R Ezatpour et al. (2014) investigated by using Al alloy 6061(50 um) and Al203 nanoparticles (40 nm). Melted Al alloy at 750 0C. Injection time of nanoparticles was 10-30 min. Stirred the melt at 450 rpm for 15 min to produce homogenous mixture. Poured at 700 0C for casting of samples. It was concluded that mechanical properties shows greater strength and hardness for four blade stirrer than two blade and fine blade [48]. T. Q. Hashmi (2014) reviewed by using reference of Sozhamannan et al [7]. Produced the samples at 600 0C, 750 0C and 800 0C and found uniform distribution of particles and dendritic structure with no large pores. It was also observed that increasing temperature to 850 0C to 900 0C, there were enhanced pores and particles clustering. Hardness increased with increase in temperature of 750 0C 800 0C at 20 min holding time [49]. A. Kumar et al. (2015) studied by using Al matrix reinforced with Al2O3 nano composites. Melted the pure Al in the furnace to 700 0C. Removed the slag with the help of slick and then graphite rod was taken out so that molten metal flow towards the mold. Casting was also made without ultrasonic vibration to compare the results of castings with ultrasonic vibration. It was concluded that ultrasonic mold vibration has a good effect on the microstructure and properties of casting being fine grain than casting without ultrasonic vibration. Casting with ultrasonic vibration has microhardness value 48.21 Hv and ultimate tensile strength 68.01 MPa [50]. B. Pavithran et al. (2015) studied by using Al alloy matrix reinforced with SiC (50 um) and graphite particles (60 um). Melted Al 6061 in a furnace and stirred vigorously, after effective degassing with solid C2 Cl6. Addition of wetting promoters into the melt enhances the particle distribution and its bonding with the matrix. Carried out the hybridization by simultaneously introducing both the reinforcements into the matrix alloy while stirring. Added the reinforcements at 700 0C in semi molten state while

stirring at 300 rpm for 17 min. Preheated the reinforcements to a temperature of 500 0C for 1 hr to oxidize and to prevent the decrease in temperature of the molten metal during addition of reinforcements. Poured the molten composite into preheated cast iron mold at 400 0C. It was concluded that tensile strength of the composite increases linearly with the addition of both SiC and graphite reinforcements, whereas hardness improves with the SiC addition and shows decreasing trend with the graphite particle reinforcement. Wear rate of the developed HMMC has decreased with the addition of both SiC and graphite reinforcement [51]. Phaniphushana M. V et al. (2015) evaluated by using Al 6061 matrix reinforced with Fe2O3 particles. Melted the matrix material Al 6061 alloy to 750 0C in a graphite crucible. Stirred the molten metal at 300-350 rpm. Added scum powder (Alkaline powder) to the crucible to remove the slag and flux. Added preheated Fe203 powder to the melt slowly. Continued the stirring for 5-10 min and added degassing tablet (C2 Cl6) to remove the gasses. Poured the melt into the preheated die for sample casting. It was concluded that microstructure reveals uniform distribution of the reinforcement particles. The hardness and tensile strength increases with increase of %age of reinforcement [52]. P. Melali et al. (2015) fabricated high strength Al base alloy composites reinforced with SiC nanoparticles coated with Al and Cu. Two types of powders of pure Al (type A) and pure Cu (type B) were produced by mechanical milling process with size of 60 um each. SiC nano powder of size 50 nm was used in 1 weight % as reinforcement. Mechanical milling was made at 900 rpm for 1 hr with steel ball of 10 mm dia. Al 2024 alloy of about 450 gm with 18 gm of Al and Cu powders were added separately to the melt. To separate molds were used for each composite. The melt temperature was 750 0C and stirred at 512 rpm for 6 min. Poured the melt to MS mold for sample casting. It is to be noted that each stir casting process be held under inert atmosphere. It was concluded that Al coated particles because of their lower melting point causes higher wettability and uniform distribution of particles in the matrix. Also the dispersed particles act as grain refiner results in fine grain. As a


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result of high temperature difference between master powder and melt, there occurs high nucleation rate in melt. This form spherical and rosset-shaped grains. This phenomena can reduce the viscosity of melt during casting process [53]. S. Dhanasekaran et al. (2015) investigated by using Al 356 alloy, SiC (15-20 um) and Al203 (15-20 um). Melted Al356 in an electric resistance furnace at 800 0C. Preheated SiC and Al203 particles to 250 0C for 30 min. Liquid metal was degassed by C2Cl6 and the temperature was maintained at 750 0C. The melt was stirred at 200 rpm for 5 min. Also Mg 1 % was added to improve the wettability of the particles. In order to ensure proper mixing, stirring at 200 rpm for another 10 min was maintained and then poured into the mold for casting of samples. It was concluded that TS, YS increases with increase in vol fraction of SiC and Al203 particles. It was investigated that 20 % SiC increases 16 % increase in TS while 10 % Al 203 increases 19 % increase in TS [54]. S. K. Thandalam et al. (2015) reviewed the research investigated by Das et al. who reported the incorporation of zircon particles of different sizes and amount into Al-4.5 wt% Cu alloy melt using stir casting process. It was observed that courser particles of sizes 90 and 135 um were dispersed up to 30 wt% while finer particles of sizes 15 and 65 um could be dispersed upto 20 wt% [55]. M. Vykuntarao et al. (2015) reviewed the research/ investigation of Haisu (16) et al. how fabricated nano sized ceramic particles reinforced Al matrix composites. In Al2024/Al203 nano particle prepared by solid-liquid mixed casting combined with ultrasonic treatment. Supersaturated the matrix at 750 0C and held for 15 min. Added powdered Al / Al203 particles to the melt and stirrered. Dipped an ultrasonic probe in the melt and sonicated for 5 min. Solid-liquid casting method decreased the agglomeration of Al203 nano particles whereas ultrasonic treatment improved the distribution of particle and refined the grain structure. There was an increase in the UTS and YS of nano composites. Factors affecting the composites fabricated by stir casting are uniform distribution of reinforcement materials wettability, porosity and chemical reactions between matrix and reinforcement particles. Process parameters are stirring speed, stirring temperature, reinforcement preheat temperature, stirring time, preheated temperature of the mold and powder feed rate [56].

K. K. Paul and Sijo MT (2015) studied by using Aluminum LM6 and SiC (20 um). Al alloy was preheated at 450 0C for 3 to 4 hours. Preheated SiC at 900 0C for 2 hrs. Set the temperature of furnace to 620 0C. Added preheated SiC particles. SS stirrer with 4 blades was used for stirring operation. Achieved uniform semi solid stage by stirring at 600 rpm. Pouring of preheated reinforcement at the semi solid stage of the matrix enhances the wettability of reinforcements, reduces the particles settling at the bottom of the crucible. After stirring for 10 min at semi solid stage, reheated the slurry and hold at 900 0C to make slurry in liquid state. Lowered the stirrer rpm gradually to the zero. Poured the molten composite slurry into the metallic mold which was preheated at 500 0C to ensure the molten slurry state throughout the pouring. The test specimens required for analysis were machined to cylindrical specimens and were then ground in successive steps using SiC abrasive papers of various grit sizes. The micro structures of the samples were observed to study the particle distribution. A section was cut from the castings for microstructure analysis. The specimens were ground thoroughly by using emery papers for certain time by using 300, 600, 900 grit papers and then polishing it with applying a paste. The samples were then mechanically polished and etched by Kaller’s reagent to obtain the accurate contrast structure. The casting procedure was examined under the light optical microscope under 100 X resolution to determine the reinforcement pattern and cast structure. Tensile Test samples were prepared according to ASTM E 08. Hardness Test was conducted with 250 kg load and 5 mm dia steel ball indenter [57]. Jamaluddin Hindi et al. (2015) studied by using Al 6063 and SiC particles using stir casting process. Al 6063 was melted in an electric resistance furnace and SiC (200-300 mesh) with 2, 4 & 6 wt% reinforcement dispersed to produce homogenous slurry by using mechanical stirrer. Poured the composite melt into the metallic mold die for casting of samples. It was concluded that TS & hardness increases with increase of SiC wt% whereas ductility decreases. Impact strength initially increases and then decrease with the addition of SiC. The microstructure indicates better distribution of SiC in the matrix [58].


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S.B. Rayjadhav and Dr. V. R. Naik (2016) developed and characterized Al 6061-SiC MMCs by stir casting process. Al 6061 was melted at 820 0C in an electric resistance furnace. The preheated SiC (60-90 um) at 800 0C for 1 hr was added in the melt. The stirring of the melt was continued for 20-40 sec. The melt was maintained at 750 0C and poured in the mold for sample casting. It was concluded that hardness increases with increase in SiC particles. The microstructure indicates uniform distribution of SiC particles [59]. Kalidindi Sita Rama Raju et al. (2016) studied mechanical properties of Al metal matrix nanocomposites by hybridization technique. Al-4 % Cu alloy was melted at 700 0C. Al powder (75 um) and CNTs (9 nm in dia and 5 um in length) as primary and secondary launching vehicles respectively, were preheated to 200 0C. The mixtures were then stirred at 200 rpm for 4 min in a two-step stirrer. The whole setup was maintained under an argon gas environment. A Boron Nitrate coating was used to all the surfaces exposing to the casting environment to avoid iron contamination. 1.5 wt% Al203 (13 nm) is used as ultra-fine reinforced nano particles. It was concluded that launching vehicles methodology significantly enhances the distribution of reinforcements and ultimately the strength of the composite by using the secondary launching vehicle CNTs, the strengthening of composite is observed as better technique with improvement of ductility [60]. Muhammad Arshad Chaudhry et al. (2017) reviewed on Development and Characterization of nano Particle Metal Matrix Composites (Stir Casting) and prepared a standard operating procedure for development and characterization of nano particle metal matrix composites [61]. The designed SOP is being described here under: A. Development � Preheat the Al Alloy at 450 0C for 3-4 hours and SiC Nano Particles at 800-900 0C for 2 hours before melting � Charge 1500 gm of Al Alloy into the stainless steel crucible and melting in an electric resistance furnace by heating upto 700 0C

� Clean the melt from the slag by overheating of the melt 50 0C above the liquidus temperature � Maintain furnace temperature at 800 0C and degas the melt by passing hexachloroethane (C 2 Cl 6 ) solid degasser � Allow melt to cool to 700 0C to a semi solid state � Add preheated SiC Nano particles at 700 0C to the melt and perform stirring at 300 rpm for 20 minutes. � Add Mg 1 wt% as wetting agent in the melt � Reheat the composite slurry and maintain at a temp of 750-760 0C � Perform mechanical stirring for 10 minutes at 400 rpm B. Sample Casting � Preheat steel mold die (En 31) at 550 0C for 20 minutes � Cast test sample bars of dia 20 mm and length 180 mm at pouring temperature of 750 0C C. Machining of Test Samples � Machine the test samples to perform tensile test as per ASTM-E 8-95a, brinell hardness test, charpy impact test, density measurement, metallographic test D. Heat Treatment � Heat treat the machined test samples at 530 0C for 3 hours � Quench the test samples in H2 O at room temperature � Age at 180 0C for 5 hours and then air cool at room temperature E. Sample Preparation � Prepare heat treated specimens for microstructural observation by grinding using emery paper # 0, 400, 600, 1000, 1500 � Polish the ground samples using diamond paste # 6 micron and 1 micron � Etch the polished test samples using keller’s reagent


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for 10-30 second � Prepare test samples of size dia 20 mm and height 20 mm for microstructural evaluation and hardness � Prepare test samples of size 10 mm x 10 mm x 55 mm with V-notch 2 mm deep at 450 for charpy impact test as per ASTM-E 23 � Prepare tensile test samples of gauge dia 6 mm, gauge length 32 mm and shoulder dia 10 mm F. Flow chart showing experimental procedure Weigh Al Alloy 2024 and preheat at 450 0C for 3-4 hours. Weigh SiCp and preheat at 800-900 0C for 2 hours before melting Start melting Al 2024 in an electric resistance furnace and maintain melt at 800 0C Degas the melt by solid degasser C2Cl6 to remove gasses. Set the melt at 700 0C to achieve semi solid state Add preheated SiCp and 1 wt% Mg in the melt. Mechanical stirring at 300 rpm for 15 min for primary dispersion of SiCp. Set the melt at 760 0C. Again mechanical stirring at 400 rpm for 10 min at 750 0C Pour at 750 0C the molten melt into preheated mold die. Solidification of cast samples. Machine cast samples for microstructure analysis, tensile strength, hardness, impact test and density measurement. Heat treatment of machined test samples.

Experimental Procedure for Testing of samples Discussion on test Results and Conclusions G. Characterization At the end, the samples so obtained would be characterized using relevant characterization tools / physical facilities.


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3. Experimental Setups Used by Various Researchers 1. DC Motor 2. Kaowool Insulator 3. Heater Band 4. Nitrogen Gas 5. Graphite Crucible 6. Mould Figure: Schematic of the experimental set-up to produce cast MMC [1] 1. Stirrer 2. Stopper 3. Thermocouple 4. Powder 5. Argon Gas 6. Valve 7. Coated injector 8. Graphite Crucible 9. Resistance Furnace 10. Mold Figure: Schematic of the Experimental Setup to produce cast MMC [5]


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Figure : Schemetic View of Set-up for fabrication of Composite [11] 1. Transformer-dimmer 2. Injection Hopper 3. Four Blade Stirrer 4. Graphite Crucible 5. Molten Aluminum 6. Coal Fired Furnace Figure: Schemetic of Stir Casting Process [13]


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Figure: Schemetic diagram for Stir Casting Technique [15] Figure: (a), (b) Induction resistance furnaces with temperature regulator cum indicator and (c) Melt-Stirring setup utilized for casting of composites [17]


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Figure: Experimental Setup used to produce MMC [20] Figure: Stir Casting Setup [21]


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1. Ultrasonic Transducer 2. Ultrasonic Power Supply 3. Control System 4. Heat Jacket and Crucible 5. Temperature Sensor 6. Heat Jacket Power Switch 7. Argon Gas 8. To wall outlet Figure: Schemetic of Experimental Setup [23]


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Figure: Metal Matrix Composites by Stir Casting Method [25]


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Figure: Stir Cast Apparatus [33]


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Figure: Schemetic Illustration of the Mixing Equipment used for (a) the distributive mixing Process and (b) the Rheo-Process [36]


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Figure: Experimental Setup and with Stirring Speed Controller [37]


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Figure: Stir Casting Setup [38]


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Figure: Experimental Setup used for Stir Casting [40] Figure: Stir Casting Experimental Setup [42]


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Figure: Fabrication of MMC using Stir Casting Method [43] Figure: Schematic diagram of Stir Casting Technique [44]


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Figure: Ultrasonic Cavitations Based Dispersion Experimental Setup [45] Figure: Schematic Sketch of Ultrasonic Stir Casting [48]


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Figure: stir Casting Furnace [49]


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Figure: Stirring of Molten Metal in the Furnace, Slag Produce during Casting Process, Preheating of Die and Casting of Al 6061+Fe2 O2 [50]


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Fig 1 Stir Casting Experimental Rig Fig 2 Power Control Panel Fig 3 Mechanical Stirrer Assembly Fig 4 Electric Resistance Furnace Fig 5 Crucible Lid Fig 6 Sample Mold Die Figure 1: Stir Casting Experimental Rig Figure 2: Power Control Panel [Top Loaded Electric Resistance Furnace with Mechanical Stirrer Assembly] Figure 5: Crucible Lid

Figure 3: Mechanical Stirrer Figure 4: Electric Resistance Figure 6: Sample Assembly with lifting / lowering Furnace with Stainless Steel Mold Die Mechanism with Variable Speed Crucible and Stainless Steel Electric Motor [1 HP] Stirrer Rod Figure: Stir Casting Experimental Rig with Sub Assemblies [61]


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4. Comparison of Process Parameters of Stir Casting Techniques Ref.# Researcher Year

Development of Al Metal Matrix Composites Character- ization Technique Matrix / Preheat Melting Temp 0C / Time Inert gas Reinforcement, Preheat Temp 0C / Time Speed rpm, Time Techniques 1 J. Hashim 2001 Stir Casting A359 750 N @ 3 cc/ min SiCp + Mg 100 TS, HV OM 2 S.Naher 2004 Stir Casting A356 630 130 min N SiCp 900 0C for 4 hrs 200-500 2 min - OM 3 S.B.Prabu 2006 Stir Casting A384 Super- heated - SiCp (60 um) 800 0C for 2 hrs 600 – 700 10-15 min BHN OM, SEM 4 S. D. N. Nageswara 2010 Ultrasonic Stir Casting A356 700 2 min Argon SiCnp (34 nm) 0.1-0.5 wt% 750, 3 min TS, BHN, HV OM, SEM 5 S. A. Amirkhan 2011 Stir Casting A356 700 2 min Argon SiCp (8,80,40 um) Mg 1 wt% 500 TS OM, SEM 6 M. H. Zamani 2011 Stir Casting A356 850 - 1% Al2O3 (80 nm) 10% ZrO2 (0.5,1,1.5,2.0 wt%) 420, 14 min TS, BHN SEM 7 E. S. Y. El-Kady 2011 Stir Casting A356 680 Argon Al2O3 (200,60nm) 15 vol. %, 400 0C for 2 hrs 1000 - OM, XRD, SEM 8 A. R. I. Kheder 2011 Stir Casting Al 700-900 - SiC, Al2O3, MgO (50,60,50 um) 5-20 wt% 400-500 15-20 min TS, BHN, Impact OM, SEM 9 G.G. Sozhamannan 2012 Stir Casting Al-11 Si- Mg 700,750,8 00, 850, 900 Argon SiC (40 um) 10 vol % 1000 0C 450 - TS, BHN, TS, BHN, IMPACT 10 B. S. Kumar 2012 Stir Casting A357 740 N SiCnp (50,18nm) Mg 1 wt% (10000C) (0, 0.5, 1.5, 2.5, 3.5, 4.5 wt%) - TS, BHN OM, SEM, TEM, EDS 11 J. J. Rino 2012 Stir Casting Al-4.5 wt% Cu - - SiC & Zircon Sand - TS, H, Charpy


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12 A. D. Sable 2012 Stir Casting Al (4500C) 3-4 hrs 760 - SiCp (320 grit) (900 0C) (5, 10, 15, 20, 25, 30 %) 400, 10 min TS, BHN, Charpy OM 13 A. D. Sable 2012 Stir Casting Al (4500C) 3-4 hrs 760 - SiCp (320 grit) (900 0C) (5, 10, 15, 20, 25, 30 %) 400, 10 min TS, BHN, Charpy OM 14 A. Mazahery 2012 Stir Casting Al 356 (16um) 750 N SiC (50 nm) (0,0.5, 1.5, 2.5, 3.5, 4.5wt%) Mg 1wt% - TS, BHN OM, EDS 15 S. Chatterjee 2013 Stir Casting Al 900 - TiO2 (20 nm) Mg 2 wt% - TS OM, SEM, EDS 16 A. Jailani 2013 Stir Casting Al - - SiC (10%) 100, 15-20 min TS, HV, Charpy OM, SEM 17 B. M. Viswa 2013 Stir Casting A356 - C2Cl6 - SiC (25 um-0,3,6,9 wt%) +grp (44 um -3 wt%)+Mg 1wt% 500-600, 10 min TS, HV OM, SEM 18 K. L. Meena 2013 Stir Casting Al6063 750 - SiCp (400 mesh- 5,10,15,20 wt%) 1100 0C for 1.5 hrs 200, 20 min TS, HRB, Izod, OM 19 D. Singla 2013 Stir Casting Al 7075 1000 C2C16 Flyash 6000C + Mg, TS, BHN, Charpy XRD 20 V. Kumar 2013 Stir Casting AA 2218 850 - Al2O3 - TS, HV, Charpy OM 21 Gopi K. R. 2013 Stir Casting Al 6061 756 C2Cl6 ZrO2 (2,4,6,8,10 wt%) + Grp 200 0C 400, 1 min BHN OM 22 P. Phutane 2013 Stir Casting Al-HE-30 800 - SiC (25 um) 500, 10 min TS, BHN OM 23 D. K. Koli 2013 Stir Casting A356 750 - Al2O3 (50nm) - 24 Dr. G. Nandipati 2013 Stir Casting Al 2024 638 Argon B4C (50nm) (0.1, 0.2, 0.3, 0.4, 0.5, 1.0, 1.5, 2.0, wt%) - TS, HV OM, SEM


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25 L. Rasidhar 2013 Stir Casting Al (99.7%) 730-750 Argon FeTiO3 (57nm) (1-5 wt%) 650-700 10-15 min TS, HV OM, XRD, SEM, EDS 26 J. Shree 2013 Stir Casting Al 6061 750-760 C2Cl6 SiCp 600-800 0C for 2 hrs 400, 10 min 27 N. S. Abtan 2013 Stir Casting Al 750-900 - SiCp (63 um) (5,10,15,20 wt%) 700 0C TS, BHN, Charpy OM 28 A. Kumar 2013 Stir Casting A359 730-750 - Al2O3 (30 um) (2,4,6,8 wt%) 800 0C 300 TS, HRC OM 29 R. S. Rana 2013 Ultrasonic Stir Casting A 5083 760 N SiCnp (40nm) (1,2,3,4 wt%) Sip (35 um) (3,5,8,10 wt%) TS, BHN SEM, TEM 30 A. R. N. Abed 2013 Stir Casting A 7075 650 - Al2O3np (1,2.5wt%) 300, 20min TS, HV OM, XRD, SEM, AFM 31 B. P. Samal 2013 Stir Casting Al 800 - SiCp (10 wt%) 500 TS, OM, XRD 32 S. Mathur 2013 Stir Casting Al-4Cu 450,3hr 700-725 - SiCp (400 grit) 5 wt% 1100 0C for 2 hr 600, 3min TS, BHN IZOD 33 A. Mittal 2013 Stir Casting Al 6061 750, 1100 RHA (8,16,24 wt%) 200 0C for 1 hr +Cu (3wt%) 1100 0C + Mg (3wt%) 850 0C for 1hr 600 HV XRD, SEM, EDS 34 R. G. Bhandare 2013 Stir Casting Al 6061 500-900 N Al2O3 (320 mesh) (5000C for 30 min) SiC/Grp Mg 1wt % 300-600 2min 35 T. Rajmohan 2013 Stir Casting Al 356 750 - SiC (25 um) Mica (45 um) 620 0C, Mg 500 5-7 min TS, BHN / HRB SEM, EDS 36 K. K. Alaneme 2013 Stir Casting Al-Mg-Si alloy 750-800 - SiC (30 um) 10 wt% BLA (50um) 250 0C, Mg 0.1 wt% 400 10 min TS, H OM, SEM


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37 B.V. Ramnath 2014 Stir Casting Al-Si 700 Al2O3 900, 5min 38 Raghavendra N. 2014 Stir Casting Al 7075 700-720 - Al2O3 (149,105,74 um) (100, 140, 200 mesh)(3,6,9,12 wt%) 350 0C 5min TS, BHN / HV OM 39 P. O. Babalola 2014 Stir Casting Al 6061 670 Argon SiCp (10 vol .%) 500 40 S. Haque 2014 Stir CastingAl 6061- Cu 450,40 min 800 - SiCp 1100,2hrs 200-600, 10min SEM 41 Vinoth M. A. 2014 Stir Casting Al-Si 750-800 C2Cl6 SiCp (3 wt%) / Cenosphere (5, 10, 15, wt%) 450,3-4hrs 10-30 gm/min (feed rate) 350-890 8-10 min TS, BHN 42 Tony Thomas 2014 Stir Casting Al LM6 800 - SiC 600 10 min TS, BHN 43 `G. Sutradhar 2014 Stir Casting LM6 alloy 750 - SiCp (5-12.5 wt%) Mg 3wt% 850-900 0C 400-500 TS, HV, Impact OM, XRD 44 B. V. Ramanath 2014 Stir Casting Al alloy (95 %) 830 550, 3-4 hrs - Al2 O3 B4C 400 0C 550 10 min TS, BHN, Charpy OM 45 Mr. Praveen. G 2014 Stir Casting Al alloy 850 - MgO (80 nm) 0.5,1, 1.5, 2.0 wt% 100 15-30 min BHN XRD , SEM 46 L. Poovazhagan 2014 Stir Casting(Ultrasonic ) AA 6061 680-800 Argon SiC (45-65 nm) (0.3, 0.5, 0.8, 1.0, 1.25, 1.5 vol%) 2 kW 20 kHz TS, BHN OM, SEM, EDS 47 M. T. Alam 2014 Stir Casting Al alloy 680 - SiC (10, 20, 30, 40, 50 wt%) 300 30 seconds HRA SEM, EDX 48 H. R. Ezatpour 2014 Stir CastingAl 6061 (50 um) 750 - Al203 (40 nm) (0.5, 1, 1.5,wt%) 450 15 min - OM, SEM


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49 T. Q. Hashimi 2014 Stir Casting Al alloy 700-800 - SiC 600-700 10 min 50 K. Kumar 2015Stir Casting (Ultrasonic) Pure Al alloy 700 - Al 2O3 np (0.5, 1 wt%) 20-30 kHz TS, HV SEM 51 B. P. Pavithran 2015 Stir Casting Al 6061 700 C2 Cl6 SiC (50 um) Graphite (60 um) 500 0C for 1 hr 300 17 min TS, BHN 52 Phaniphushana 2015 Stir Casting Al 6061 750 C2 Cl6 Fe2 O3 (2,4,6,8 wt%) 300-350 5-10 min TS, BHN OM 53 P. Melali 2015 Stir Casting Al 2024 750 - SiC (50 nm) Al & Cu (60 um) 1 wt% each 512 6 min - OM 54 S. Thanesekaran 2015 Stir Casting A 356 800 - SiC (5-20 um) 20 vol % Al203 (15-20 um) 10 vol % Mg 1% 250 30 min 200 10 min TS, HV, OM 55 S. K. Thandalam 2015 Stir Casting LM 13 (Al-4.5 % Cu) - - ZrSiO4-90 & 135um15 & 65um 30 wt% & 20 wt% - TS, BHN OM, SEM 56 M. Vykuntarao 2015 Stir Casting Al 2024 750 15 min - Al203 nanparticles Sonication 5 min 57 K. K. Paul 2015 Stir CastingAl LM6 450 0C for 3 to 4 hours 620-900 - SiC (20um) 20 vol% 900 0C 600 TS, BHN OM 58 Jamaluddin Hindi 2015 Stir Casting Al6063 - - SiC (200-300 mesh)2,4,6 wt % - TS, HV, Charpy OM 59 S.B. Rayjadhav 2016 Stir Casting Al 6061 820 - SiC (60-90 um) 0,5,10 wt% 800 0C for 1 hr - 20- 40 sec BHN OM 60 V.R. Raju 2016 Stir Casting Al-4Cu 700 Argon Al powder 75 um Al203 13 nm C NT 9 nm 300 2 hrs TS, BHN OM, XRD, SEM, TEM 61 Muhammad Arshad Chaudhry et al. 2017 Stir Casting Al 2024 750-760 C2 Cl6 SiC (45-55 nm) (0.3, 0.6, 0.9, 1.2, 1.5, 1.8 wt%) 400 , 10 min TS, BHN, Charpy OM, XRD, SEM, EDX


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5. Scope of Future Work Metal matrix composites with micron size reinforcements have been used with great success in the automotive, aerospace, defense, sports and industrial applications. � In case of MMNCs, incorporation of as little as one volume percentage of nano size ceramic particles has led to a much greater increase in the strength of aluminum. � Such potential improvements have great implication for the automotive, aerospace and in particular, defense industries due to the drastic weight savings and superior properties that can be achieved. 6. Challenges � Research on structure-property correlations in nano composites, new challenges in the development of suitable fabrication techniques for nano composites, their characterization and mechanics, in order to understand interactions at much smaller sizes. � Problems with non-compatibility and agglomeration can be overcome through surface modification of reinforcements for homogeneous dispersion without agglomeration. � To control the grain size of matrix and agglomeration of nano particles during processing and retaining improved microstructure. � Research is expected to produce high class and low cost reinforcements as there is a great need to categorize different grades of AMMNCs based on property profile and manufacturing cost. 7. Conclusions Upon carrying out extensive review of the already published research so far, following inferences may be drawn: � A comparison of process parameters of stir casting techniques has been made to select an AMMNC material for required industrial applications. � Mechanical stirring process is in appropriate to distribute and disperse. nano scale particles uniformly in metal melts due to their large surface to volume ratio and low wettability which can be enhanced by heat treating of SiC nano particles.

� To ensure uniform distribution of nano particles, restirring process can help to disperse the SiC nano particles. � A full incorporation of SiC nano particles into the Al alloy matrix can be obtained in the semi solid state without any addition of a wetting agent. � Strength and hardness of the AMMNCs is governed by the degree of grain refinement. � By increasing the stirring speed and stirring time, homogeneous distribution of SiC nano particles in the Al matrix is expected. � The addition of Si to Al matrix improves the wettability among SiC nano particles and Al. � There are exciting opportunities for producing extraordinary strong, light weight, wear resistant AMMNCs with adequate ductility by stir casting to be easily adoptable by the automotive engineering industry locally and globally. 8. References: [1] J. Hashim, The Production of cast metal matrixcomposites by a modified stir casting method, Jurnal Teknologi, 35 (A) (2001) 9-20. [2] S. Naher,D. Brabazon, L. Looney, Development and assessment of a new quick quench Stir casterdesign for the production of metal matrix composites, Journal of Materials Processing Technology 166 (2004) 430-439. [3] S. B. Prabu, L. Karunamoorthy, S. Kathiresan, B. Mohan, Influence of Stirring speed and Stirring Time on Distribution of Particles in Cast Metal Matrix Compopsite, Journal of Materials Processing Technology 171 (2006) 268-273. [4] S. Donthamsetty, N. Rao. D, Investigation on Mechanical Properties of A356 Assisted Cavitation, Journal of Mechanical Engineering, ME 41, 2 (2010). [5] S. Amirkhanlou, B. Niroumand, Development of Al356 / SiCp cast composites by injection of SiCp containing composite powders, Materials and Design 32 (2011) 1895-1902.


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[61] Muhammad Arshad Chaudhry, Prof. Dr. Liaqat Ali, Prof. Dr. K. M. Ghauri (2017) having reviewed “Development and Characterization of Nano Particle Metal Matrix Composites” (Stir Casting) and having adopted the standard operating procedure. The information contained in the present article is being shared with the academic elites and technical personnel in the relevant disciplines.

development and characterization of nanoparticle metal

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