study of mechanical and corrosive behaviour of …...reinforcement and it can be continuous or...
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4th International Conference on Multidisciplinary Research & Practice (4ICMRP-2017) P a g e | 43
www.rsisinternational.org ISBN: 978-93-5288-448-3
Study of Mechanical and Corrosive Behaviour of
Metal Alloy Composites-Ingrained with Micro and
Hybrid Reinforcement
Pratibha Arya1*
, Swati Gangwar2, Vimal Kumar Pathak³
1Department of Mechanical Engineering, Madan Mohan Malaviya University of Technology,
Gorakhpur, Uttar Pradesh 273010, India 2Assistant Professor, Madan Mohan Malaviya University of Technology, Gorakhpur, Uttar Pradesh, 273010, India
³Assistant Professor, Manipal University Jaipur, Rajasthan, 303007, India
Abstract – Today composites have brought to diversity of changes
towards development in the field of marine, aerospace and
automobile industries in virtue of their appealing properties like
high mechanical strength, better corrosion and temperature
resistance, etc. The Metal alloy hybrid composites (MAHCs) are
more auspicious and are capable of full-filling the needs of
modernistic evolutions in various fields. The actual selection of
materials depends on the type of usage which will make a
composite free from error. The current paper scrutinizes various
classes of metal matrix composites (MMCs) ingrained with micro
and hybrid reinforcements that alters the mechanical and
corrosion properties of a composite that makes them reasonable
for their use in marine, ship hull, automotive parts and other
heavy duty applications.
Key Words: Metal alloy hybrid composites, Micro and Hybrid
Reinforcement, Mechanical properties, Corrosion behaviour.
I.BACKGROUND INFORMATION
or the past few decades, the selection of materials had
switched to more prominence developments in the field of
aerospace, automobiles and other heavy duty applications in
order to achieve reduced weight, eco-friendly, better quality
and performance of material at low cost. In the early 1980s,
the prototype of developed materials began to change
drastically.
Metal matrix composites filled with monofilaments like Boron
Carbide (B₄C), Silicon Carbide (SiC), Zirconia (Zr) are very
permissible since early 1960s because of their high
mechanical strength. The major section of research was made
for defence and automotive applications such as missiles,
space crafts, vehicles etc. [1].
Comparable to the current usage, metal alloy composites
(MACs) has drew attention towards growing activities in
automobile parts, space shuttle, aircraft industries etc. because
of their enhanced properties due to addition of secondary
phase material called reinforcement.
II. INTRODUCTION
Metal matrix composites (MMCs)are constructive fusion of
two or more than two materials with dominant material as
metal whereas the other material may or may not be metallic
and possess the properties of the dominant material. The
dominant material used is called matrix and is generally
continuous in nature and the other material used is called
reinforcement and it can be continuous or discontinuous in
nature. The function of matrix is to cover the reinforcement
and bind them adhesively. The reinforcements ingrained can
be in the form of fibers, macro / micro / nano particle,
whiskers, flakes, laminates etc. The main purpose of
reinforcement is to enhance the properties of the composite
material such as mechanical, physical and tribological
properties [2].
The modern composites are different from the traditional
monolithic composites due to metal alloys used as matrix and
hybrid reinforcements which enhance the overall properties of
a composite.When the reinforcements ingrained are two or
more than two, then the composite is called hybrid composite
or hybrid reinforced composite [3].
2.1 Fabrication methodology
There is various fabrication techniques used in the processing
of MMCs. The appropriate method for the fabrication of
MMCs depends on various factors such as different types of
matrix used, different classes of reinforcements and their
particle size and also area of application. Fabrication
techniques required in composites targets in achieving
composites with better microstructural, mechanical, corrosion,
and other properties.
The fabrication techniques can be broadly divided into two
different categories:-
Liquid state technique
Solid state technique
a) Liquid state fabrication technique
F
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In the liquid state technique the particles are regularly
dispersed well within the molten metal before being casted
and then solidified. The methods involved in liquid state
techniques are generally cost effective and are more efficient
and feasible [4].
Stir Casting
Stir casting have been the most suitable method of fabricating
metal based composites up to 30% wt. fractions of
reinforcements. The reinforcement is stirred with the help of a
stirrer into the molten metal at appropriate temperature. It
involves the use of a proper stirring system in order to obtain
desirable fusion of reinforcement in to the molten metal.
Dissemination of ingrained particle into the molten metal
depends on the temperature of the molten metal, particle size,
and geometry of the stirrer and also on the physical and
chemical properties of the molten metal. Molten metal after
stirring is then cast by traditional casting method. If the
distribution of the ingrained (reinforcements) is not proper
then there are chances of reinforcements to get accumulated in
some specific regions and form clusters. To overcome this
situation the reinforcements are injected along with inert gases
into the molten metal which enables proper diffusion of
reinforcements. The figure below shows stir casting method
having inert gas injected with the reinforcement [4].
Fig 1: Stir casting machine equipped with inert gas source [4]
Compo Casting
Wettability and dispersion of micro / nano size ingrained
reinforcements are very challenging in case of stir casting
because when reinforcement having very fine particles then
they acquire more surface energy as well as surface area
which results in accumulation of particles. In order to attain
regular dispersion, negligible accumulation and effective
adhesive bonding between the matrix and ingrained
reinforcement particle we prefer compo casting. In compo
casting the reinforced particles are mechanically entangled
into the semi-solid slurry at semi solid temperature and thus
protect the composite from gravity segregation. As the size of
the reinforced particle is decreased the ductility of the
composites increases in case when composites are compo
casted. Since semi molten metal is operated at low
temperature in compo casting, longer tool life is attained.
Squeeze Casting
The idea of squeeze casting was introduced by Chernov in
1878 by using high steam pressure over molten metal during
solidification. The above fig. shows that within the closed die
halves high pressure is produced and movable mould parts are
used for employing pressure over the molten metal andthus
the molten metal is pressed forcefully to move into the
preformed cavity in the lower mould and then after
solidification upper half die is removed. Squeeze casted
components have better weldability, surface finish as well as
dimensional accuracy.
4th International Conference on Multidisciplinary Research & Practice (4ICMRP-2017) P a g e | 45
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Fig 2: Schematic diagram of compo casting of a piston [4]
Fig 3: Schematic diagram for Squeeze Casting process
Spray forming process
Fig 4: Schematic diagram of spray forming process [4]
46 | P a g e Study of Mechanical and Corrosive Behaviour of Metal Alloy Composites-Ingrained
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Spray forming fabrication technique employ melting of alloy
or metal and then molten metal is forced to pass through the
small cavity, passing a steam of inert gas under pressure and
injecting reinforced particles through jet on the molten metal.
In this method the dispersion of reinforcements is
inappropriate in the molten metal and thus the properties of
overall composite are affected. The composites fabricated by
this method are inexpensive.
b). Solid State Fabrication Technique
In solid state fabrication technique, both the matrix and the
reinforcement are used in powder (micro / nano) form i.e. no
melting is required and thus there are no chances of
developing any chemical reaction. In this method distribution
of reinforced particles are generally uniform. This method is
not very economical and also complicated and thus liquid
state fabrication technique is generally preferred.
Powder Metallurgy
Manufacturing of metal matrix composites by powder
metallurgy involves mingling of reinforced particles with the
metal (or metal alloy) in powder form and then degassing the
obtained product under vacuum to make it free from unwanted
or excess gases, sintering is done under high temperature and
pressure. One of the main disadvantages of this process is that
it squeezes the nano particles and exploits the grain boundary
strengthening potential. This technique is very economical for
making complex parts with accurate dimensional tolerances
and minimum remnants but is inappropriate in large scale
production.
Fig 5: Schematic Diagram of powder metallurgy fabrication technique [4]
TABLE 1:
COMPARISON OF DIFFERENT FABRICATION TECHNIQUES AND
THEIR APPLICATIONS
S.
No
.
Fabricatio
n Method
Economic
Condition
Application Note
1 Stir
Casting
Least expensive Commerciall
y most
appropriate
technique for
large scale
production,
especially
used for
fabricating
aluminium
based
composites.
Rely on the
properties of
the materials
and most
appropriate
for grainy
type of
reinforcement
s employed in
MMCs or
MAHCs.
2 Compo
casting
Low Extensively
used in
aerospace
industries and
manufacturin
g of
automobile
parts.
Best for
fabrication of
composites
especially in
case of
discontinuous
fibres or
flake,
whiskers,
particulate
reinforcement
s.
3 Squeeze
casting
Medium Extensively
used in
automobile
industries for
making parts
of
automobiles.
Relevant for
fabricating
MMCs with
all types of
reinforcement
and can be
utilized for
large scale
production.
4 Spray
casting
Medium Employed to
yield
frictional
materials,
electrical
brushes, and
electrical
contacts as
well as
grinding tool.
Materials
with high
density can
be produced
and
reinforcement
s in
particulate
are used.
5 Powder
metallurgy
Medium For
generating
small and
cylindrical
objects like
pistons bolts,
valves,
improved
strength and
materials
resistant to
heat.
Matrix and
reinforcement
s both are
used in the
form of
powder,
melting of
materials are
not required
4th International Conference on Multidisciplinary Research & Practice (4ICMRP-2017) P a g e | 47
www.rsisinternational.org ISBN: 978-93-5288-448-3
The fig. above shows that, Manoj Singla et. al. in his work,
fabricated composite by two methods i.e. first without stirring
and second with manual stirring and found that during
fabrication of silicon carbide filled composite without stirring
accumulation of SiC particle takes places i.e. there was no
proper dispersion of reinforcement which leads to weak
microstructural strengthening
Now on manual stirring of SiC particle in the molten metal,
SiC particle were mixed but on stopping the stirrer, the
particles approached the surface again and some of the
particles got tucked with each other to form cluster. This
problem was encountered due to poor wettability between the
SiC particles and molten metal [5].
III. LITERATURE REVIEW
The aim of this literature survey is to study regarding recent
developments in the fields of composites basically metal
matrix composite (MMCs) as well as metal alloy hybrid
composites (MAHCs) and investigating the behavior of
different types of ingrained particles (reinforcements) on
different classes of metal based composites.
Under this literature survey generally following investigations
are made:-
Role of ingrained particles on the mechanical
properties of metal matrix composites (MMCs) and
metal alloy hybrid composites(MAHCs).
Role of ingrained particles on the corrosive nature of
metal matrix composites (MMCs) and MAHCs.
Role of hybrid ingrained particles on the mechanical
as well as corrosive behavior of hybrid metal matrix
composites (MMCs) and metal alloy hybrid
composites (MAHCs).
(a) Role of the ingrained particles on the mechanical
properties of the MMCs and MAHCs
TABLE 2:
ANALYSIS OF REINFORCEMENTS AND EFFECT ON MECHANICAL BEHAVIOUR OF MMCS AND MAHCS.
S.
No.
Matrix/
Alloy
Reinfor-
cement
Wt.% Fabrication
Technique
Testings’ Results Application Ref
No.
1 Al SiC
&TiB₂
10 0.5 Stir Casting Hardness & wear
test
Increase in TiB₂ increases the
wear resistance
Aerospace &
Automotive
6
2 Al 7075 SiC +
Al₂O₃
0+0 5+5
10+1015+
15
Stir casting Hardness & wear
test
Increased mechanical
properties, HVN=112 at 15%
Structural
aerospace Marine
7
3 Al 6061
SiC &SiC
+
Grhybrid
5-15 Stir casting Tensile test &
SEM analysis
UTS for hybrid 144.73-
192.45 MPa & SiC 132.32
150.95MPa
Piston,
connecting rod,
brake disk
8
4 AZX915
Mg alloy
TiC 12 Stir casting Dry sliding
test,Micro
hardness test
Coefficient of friction =
0.068 ± 0.03HVN = 88.74 ±
5.93
Automotive and
aerospace
11
5 Al6061 SiC
(500grit
25 Stir casting Mechanical
testing &
Yield strength increased from
(88.66 – 294.7) Mpa
Design of
Actuator cylinder
12
Fig 6:Micrograph of sample without stirring [5]
Fig 7: Micrograph of sample with manual stirring [5]
48 | P a g e Study of Mechanical and Corrosive Behaviour of Metal Alloy Composites-Ingrained
www.rsisinternational.org ISBN: 978-93-5288-448-3
size) microstructure
studies
6 Al (pure)
SiC 402530 Stir casting Tensile,hardness
test and
Temperature
analysis using
ANSYS
Al+SiC has less tensile
strength than C70, hardness
nearer to C70, it withstand
more temp. than C70
Connectingrod 13
7 MgAZ91
D
B₄C+Gr
0+01.5+0
1.5+1.5
Stir Casting
Wear, hardness,
tensile
Wear resistance, BHN &
UTS is max. at 1.5%
B₄C+0% Gr
Automobile
marine and
aerospace
14
8 Al SiC 3,6,9,12,1
5
Stir casting Hardness &
MechanicalTestin
g
Compressed 30%, at 15%
SiC : BHN=53 MPa
Automobile 15
(b) Role of ingrained particles on the corrosive nature of
the MMCS and MAHCs
Corrosion is the deterioration of a material due to chemical
reactions with its surrounding. Corrosion is broadly classified
into different classes according to the type of environment,
material and morphology of the corrosion damage.
Reinforcements are added generally to reduce corrosion rate
as much as possible. Corrosions results in the massive
degradation or erosion of the metals which results in the
failure of the material. Thus in order to avoid this loss various
method are adopted and therefore the reinforcements that are
highly resistant to corrosive environments are reinforced with
the matrix material so as to obtain composite that offers good
resistant to corrosion.
TABLE 3:
ANALYSIS OF REINFORCEMENTS AND THEIR ROLE ON CORROSIVE NATURE OF MMCS AND MAHCS.
S. No. Matrix/
Alloy
Reinforce
ment
Wt.% Fabrication
Technique
Testing Result Application Ref
No.
1 Al 6061 B₄C &
Gr
5+5
10+10
15+15
Stir casting Corrosion study with
4, 8, 12 wt.% NaCl
solution at room
temperature
Excellent corrosion
resistance
Automotive industries
especially in brake
pads and brake rotors
16
2 Al 6061 ZrO₂-n 0 2.5
5 7.5
Stir casting Corrosion test and
micro-structural
analysis
Corrosion resistance
increases and good
interfacial bond
Aerospace, sub-
marines
17
3 Al SiC 25 Stir casting Corrosion hardness
and impact test
Corrosion rate= 4.9
mm/month BHN=44.8
Marines and
automobiles
18
4 LM 13
Al alloy
SiC 10 Stir casting Corrosion test in NaCl
solution, hardness test
Corrosion rate =
0.0063 mmpy in 5%
NaCl solution,
hardness increased
Marine bodies,
aerospace
19
5 Zn pure Gr 1 3
5
Powder
metallurgy
Corrosion test in HCl
solution
Best corrosion
resistance with 1% Gr
Aircraft and
aerospace vehicles
20
6 Al MoO₃ 10 Stir casting Corrosion test Improved corrosion
resistance
Transportation and
aerospace
21
7 Al SiC (11,6,
3 µm)
15 Powder
metallurgy
Corrosion test in 3.5%
NaCl solution and
microstructural
analysis
With smaller particle
size of SiC corrosion
rate decreases
Structural material 22
8 Al 7075 SiC 2 4
6
Liquid melt
metallurgy
technique using
vortex method
Weight loss corrosion
test, open circuit
potential test in 0.035,
0.35, 3.5% solution of
NaCl
Corrosion rate
decreases with
increase in
reinforcement content
Automobile aircraft
and marine
industries
23
4th International Conference on Multidisciplinary Research & Practice (4ICMRP-2017) P a g e | 49
www.rsisinternational.org ISBN: 978-93-5288-448-3
9 Al 7075 SiC
TiC
2.5+2.5
5+5
7.5+7.5
Stir casting Corrosion testing in
3.5% NaCl and
mechanical testing
Highest corrosion
resistance with 15% of
hybrid MMCs, better
mechanical properties
Ship body 24
10 Al 6063 Al₂O₃ 6, 9, 15,
18
Stir casting Corrosion test in NaCl,
NaOH, H₂SO₄ media
Better corrosion
resistance in H₂SO₄
Marine industries 25
11 Al 6061 SiC 10, 20 Stir casting Electro-chemical test
in 3.5% NaCl solution
Corrosion resistance
decreases with
increasing SiC
Brake drum, shaft 26
(c) Role of the ingrained particles on the mechanical as
well as corrosive nature of the MMCs and MAHCs
The study of mechanical properties and corrosive nature of the
MMCs are significant on adding reinforcement. On enhancing
mechanical properties, corrosion rate may tend to decrease or
increase depending on the type of reinforcement added and
vice-versa. On adding reinforcement mechanical as well as
corrosion behaviour of the composite is altered.
TABLE 4:
ANALYSIS OF REINFORCEMENT AND THEIR EFFECT ON THE MECHANICAL AS WELL AS CORROSIVE BEHAVIOUR OF MMCS AND MAHCS.
S.
No.
Matrix /
alloy
Reinforcement Wt.% Fabrication
technique
Tests Results Application Ref.
no.
1 Al 6061 SiC 0.5 1 1.5
2 2.5
Stir casting Corrosion, flexural
strength (EI) and
hardness
Flexural strength &
hardness is increasing
continuously
Marine 27
2 Ti Alloy B₄C 0510 Powder
metallurgy
Corrosion and
mechanical testing
Hardness and corrosion
resistance increases with
increase in B₄C, wear rate
decreases
Aerospace
and
automobile
28
3 Cu Steel chips and
Al₂O₃
5 7.5
10 10
Stir casting Hardness, wear,
tensile, corrosion
test and optical
microscopy
Improved mechanical
properties and wear
resistance, better
corrosion resistant in
3.5% NaCl solution
Electrical
appliances
29
4 Al 2011 TiB₂ 5,
10
Stir casting Corrosion,
mechanical,
microstructural
study
Improved tensile,
hardness, better corrosion
resistant
Sports,
marines &
automobile
30
IV. CONCLUSION
This paper draws attention towards some extraordinary metal
and metal alloy composites reinforced with micro/nano hybrid
reinforcements and their fabrication techniques that have
intensifying properties and can withstand major applications
such as biomedical, marines, automobiles, and aerospace etc.
Stir casting is the most acceptable method of fabricating metal
alloy hybrid composite because of its satisfactory cost and
convenience. Aluminium alloy based composites are the most
advisable matrix material because of its favorable properties
in different areas due to high strength to weight ratio. The
hardness of the aluminium can be increased from 50 HVN to
112 HVN and corrosion rate can be decreased from 4.9
mm/month to 0.0063 mm/ month on adding silicon carbide
(SiC) and zirconium dioxide (ZrO₂) and hardness and
corrosion can further be enhanced on decreasing the particle
size. Corrosion test can be performed in NaCl, NaOH and
H₂SO₄ media. Corrosion property of the material is adversely
affected on adding graphite (Gr) as reinforcement and also
corrosion rate is increased on on increasing the wt.% of the
graphite.
Such properties in the materials and further enhancement in
their overall properties make them unique and most
acceptable material for their used in the various developing
field
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