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1
STUDY AND EVALUATION OF MECHANICAL
PROPERTIES OF AL7075/CENOSPHERE/E-
GLASS METAL MATRIX COMPOSITES.
Sunil kumar K A1 & D.P. Girish2
1Department of Mechanical Engineering, JSSATE, Bangalore 2Department of Mechanical Engineering, Government engineering college, Ramanagar
Abstract— In this present investigation efforts are made to study the mechanical properties of
Cenosphere and e-galass fibers reinforced Al7075. Among various reinforced materials used,
Cenosphere, is one of the cheapest & low density reinforcement which is available as waste
product after the coal has been burnt in thermal power plants. Hence Al 7075 metal matrix with
cenosphere as reinforcement can easily overcome the cost barrier & can serve as best supplement
having different physical and mechanical properties for serving a wide range of applications
offering wide use in the today’s world . Specimens were prepared by varying E-glass and
cenosphere. The test specimens were made as per requirement of ASTM standard for conducting
tensile test. The Metal matrix composites (MMCs) results in improvised properties like increased
specific strength, specific modulus, damping capacity and good wear resistance in comparisons
to regular alloys. Among the available MMC’s aluminium composites are main in use due to
their high strength to weight ratio.
Key words: E-glass, cenosphere, Short E-glass fibers, Al7075 alloy composite, MMCs
1 INTRODUCTION
Composite materials or composites are engineering materials made from two or more constituents’ materials that
remain separate and distinct on macroscopic level while forming a single component. A composite material is
defined as a structural materials created synthetically or artificially by combining two or more materials having
dissimilar characteristic. One constituent is called matrix phase and other is called reinforcing phase. Reinforcing
phase is embedded in the matrix to give desired characteristic.
Particulate aluminium reinforced composite materials are widely used due to its properties like low density,
isotropic nature and the cost of production is low and the secondary processing such as fabrication and use of these
material is easier than any conventionally used. The present research is to study the effect of reinforcement’s like the
cenosphere and e-glass on mechanical properties of Al-7075. Different compositions of Al-7075 hybrid composites
were made by stir-casting method by varying the weight percentage of cenosphere, e-glass and Al-7075 alloy, then
it is followed by machining of casts to standard test specimen size was done. Later tensile test are performed on the
test specimens.
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2. OBJECTIVES OF PRESENT WORK
Objective of this work is to fabricate the Al 7075- Cenosphere-E-glass composite by using stir-
casting technique. This approach involves mechanical mixing of the reinforcement particulate
into a molten metal bath and transferring the mixture directly into a shaped mould prior to
complete solidification. In this technique aluminium alloy 7075 ingot pieces are to be heated in
the furnace to its molten state. When the temperature is maintained between 800-850oC, a vortex
will be created using a mechanical stirrer. Cenosphere particles are to be preheated in the
furnace. The temperature of the furnace is maintained between 825-850oC. Preheated cenosphere
particles and e-glass are to be added to the melt when the stirring is in progress. Stirring is
continued for about 15 min after addition of cenosphere particles and E-Glass fibers for uniform
mixing in the melt.
Castings are prepared by pouring the melt into preheated moulds of cylindrical shapes. Then
these specimens are to be tested for mechanical and to be compared with pure Al 7075.
3. EXPERIMENTAL DETAILS
Following steps are carried out in our experimental work:
1. Material selection
2. Composite preparation
3. Testing
3.1 Material selection
The Al 7075 alloy (matrix material), cenosphere (reinforcement) and E-glass short fibers
(reinforcement) were used for fabrication of MMCs. The chemical composition of Al7075 is
given in the Table 1.
Table 1: Chemical Composition of Al 7075
Composition Zn Fe Mg Mn Cu Si Cr Ti
% Composition 5.6 0.5 2.5 0.3 1.6 0.4 0.23 0.2
3.2 Composite preparation
The cenosphere and short E-Glass fibers were used as the reinforcement and the cenosphere
content in the composites was varied from 2 to 6% in steps of 2% by weight and E-glass short
fibers are varied from 1 to 5% in steps of 2% by weight. Liquid metallurgy technique was used
to prepare the composite materials in which the cenosphere particles were introduced into the
molten metal pool through a vortex created in the melt by the use of an alumina-coated stainless
steel stirrer. The coating of alumina on the stirrer is essential to prevent the migration of ferrous
ions from the stirrer material into the molten metal. The stirrer was rotated at 550 rpm and the
depth of immersion of the stirrer was about two-thirds the depth of the molten metal. The pre-
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heated (773 K) cenosphere particles and short E- Glass fibers were added into the vortex of the
liquid melt which was degassed using pure nitrogen for about 3 to 4 min. The resulting mixture
was tilt poured into preheated permanent moulds.
Figure 3.1 Furnace Figure 3.2 Die
Figure 3.3 pouring Figure 3.4 specimen after casting
3.3 Machining
The specimens that are casted are further machined into desired shape with the help of Lathe in
Machine shop because the casted specimen will not have required dimension. For the testing of
the specimen on the machine the centre portion diameter should be according to the standard.
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Figure 3.5 Lathe machine figure 3.6 Hardness specimens
Figure 3.7 tensile specimens
3.4 Hardness test
Brinell hardness is determined by forcing a hard steel or carbide sphere of a specified diameter
under a specified load into the surface of a material and measuring the diameter of the
indentation left after the test. The Brinell hardness number, or simply the Brinell number, is
obtained by dividing the load used, in kilograms, by the actual surface area of the indentation, in
square millimeters. The result is a pressure measurement, but the units are rarely stated.
The BHN is calculated according to the following formula:
Where
BHN = the Brinell hardness number
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F = the imposed load in kg
D = the diameter of the spherical indenter in mm
Di = diameter of the resulting indenter impression in mm
Figure 3.9 computerized brinell hardness testing machine
3.5 Tensile test
Tensile tests were conducted at room temperature using universal testing machine (UTM) in
accordance with ASTM E8-82. The tensile specimens of diameter 8.9 mm and gauge length 76
mm were machined from the cast composites with the gauge length of the specimen parallel to
the longitudinal axis of the castings. Fracture surface was studied using Scanning Electron
Microscope
4. RESULTS AND DISCUSSION
4.1 Hardness test
Hardness of aluminum based metal matrix composites are mainly influenced by type of
reinforcement is largely influenced by type of reinforcement dispersion, size shape. The
influence of E-glass fiber and cenosphere content on hardness of Al7075 matrix alloy is shown
in Fig.4.1 and 4.2 shows variation of hardness of Al7075+E-glass fiber+ cenosphere hybrid
composite with increase in cenosphere at constant percentage of E-glass fiber. It is observed that,
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for a given percentage of E-glass fibers, there is a continuous increase in the hardness of the
hybrid metal matrix composites with increase in cenosphere. In the absence of E-glass fiber a
maximum BHN is noticed for 6wt% cenosphere particles (Al7075+6% cenosphere +0%E-glass
fiber). In the presence of E-glass fiber, the maximum hardness recorded with increase in the
percentage of cenosphere alone from 0 to 6wt%, a maximum improvement of 38 % is observed,
whereas with addition of E-glass fibers from 0% to 5% with corresponding cenosphere content a
maximum hardness was recorded Al7075+4% cenosphere +3%E-glass fiber hybrid composite.
With further increase in cenosphere there is decrease in hardness. This marginal decrease is
observed at higher percentage of reinforcement may be attributed to uneven dispersion and poor
wettability of reinforced phase. Among all the combinations of hybrid composites studied, the
highest hardness was recorded for Al7075+4% cenosphere +3% E-glass fiber hybrid metal
matrix composites. This combination has exhibited a maximum improvement of 84.5 BHN,
which is 33% higher than the unreinforced alloy. The fundamental reason behind the
improvement in the hardness of hybrid composites was the presence of hard reinforcing phase
underneath the indenter during brinel hardness test [48-49]. Presence of hard secondary phase in
soft and ductile aluminum matrix generally contributes to significant improvement in the
hardness of hybrid composites. The remarkable improvements in the hardness of the hybrid
composites with addition of reinforcing phase are generally attributed to following reasons [50].
Figure 4.1variation of hardness with respect to cenosphere and E-glass for as cast
composite specimens
80
82
84
86
88
90
92
94
96
98
100
1% 3% 5%
Hard
ness(B
HN
)
E GLASS
2% cenosphere
4% cenosphere
6% cenosohere
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Figure 4.2 variation of hardness with respect to E-glass and cenosphere for as cast
composite specimens
4.2 Tensile test
4.2.1 Effect of e glass, cenosphere and heat treatment duration on ultimate
tensile strength of al 7075 alloy
Figure 4.3 shows variation of ultimate tensile strength with respect to cenosphere and E glass
for as cast specimens
80
82
84
86
88
90
92
94
96
98
100
2% 4% 6%
Hard
ness(B
HN
)
Cenosphere
1% E-Glass
3% E-Glass
5% E-Glass
0
50
100
150
200
250
300
350
1% 3% 5%
UT
S,
Mp
a
E GLASS
2% cenosphere
4% cenosphere
6% cenosphere
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Figure 4.4 shows variation of ultimate tensile strength with respect to E glass and cenosphere for
as cast specimens
The ultimate tensile strength values for AA7075 alloy and its hybrid composites with varying
cenosphere and glass fibre content are shown in Fig. 4.3. It can be observed that with the
increase in cenosphere and Glass fibre content the ultimate tensile strength is increased
Compared to AA7075 alloy, the composite with highest cenosphere and Glass fibre content has
highest tensile strength which is almost 55% increment. The reinforcements, cenosphere and
Glass fibre are contributing to ultimate tensile strength of AA7075 matrix. The strengthening of
AA7075 is mainly due to the even dispersion and good bonding of reinforcements with the
matrix material. The uniform dispersion of reinforcements as seen in Fig. 5.4 is reflected in the
increment in ultimate strength values. It is important to be mentioned here that with increase in
the percentage of cenosphere particles there is a tremendous enhancement in the tensile strength
continuously for a given percentage of glass fibre.
4.3 YIELD STRENTH
In the present work, it can be seen from Fig. 4.5 and fig 4.6 that, with the increase in Cenoshere
and Glass fibre content, the yield strength is increasing. The AA7075 alloy had yield strength of
162 MPa while that of hybrid composite with Al7075+6% cenosphere +5% E-glass fiber had
about ~220 MPa. The maximum increment in yield strength of about 58% was displayed by
Al7075+6% cenosphere +5% E-glass fiber hybrid composite when compared with that of
AA7075 alloy. As mentioned, the yield strength of composites mainly depends on the
reinforcements and work hardening. In present the two reinforcements helped in improving the
yield strength of the composites. Further the yield strength doesn’t simply increase with the
0
50
100
150
200
250
300
350
2% 4% 6%
UT
S,
Mp
a
Cenosphere
1% E Glass
3% E Glass
5% E Glass
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addition of reinforcement but their dispersion and bonding with the AA7075 matrix grains do
play very important role. As shown in micrographs in the earlier sections, the uniformly
dispersed reinforcement with good interfacial bonding contributes to yield strength. As reported
by a researcher that with the addition of SiC and rice husk ash, the yield strength of aluminium
hybrid composites was improved [51]. Further, with the increase in reinforcement content from 2
to 8 wt%, the yield strength had an increasing trend.
Figure 4.5 Shows variation of Yield strength with respect to Cenoshere and E-glass for as cast
specimens
0
50
100
150
200
250
1% 3% 5%
YIE
LD
ST
RE
NG
H
E GLASS
2% cenosphere
4% cenosphere
6% cenosphere
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Figure 4.6 Shows variation of Yield strength with respect to E-glass and cenoshere for as cast
specimens
4.4 PERCENTAGE ELONGATION
Fig. 4.7 and fig 4.8 shows the ductility of AA7075 alloy and its composites with varying Glass
fibre and cenoshere content. It can be observed that the ductility is decreasing ith the increase in
the Cenosphere and Glass fibre content. The highest ductility was observed in case of AA7075
alloy while least was observed in case of Al7075+6% cenoshere +5% E-glass fiber hybrid
composite. The maximum drop in ductility of about ~62% was observed in case of Al7075+6%
cenoshere +5% E-glass fiber hybrid composite when compared to other hybrid omposites with
varied cenoshere and E glass fibre content. The drop in the ductility was mainly attributed to
presence of irregularly shaped reinforcement especially cenoshere and glass fibre whose sharp
edges acts as nucleation sites for crack. The presence of hard ceramics leads to embrittlement
due to local stress concentration at the interface of matrix and reinforcement. Further, particle
cracking could be the other reason which can contribute to low ductility values. These results are
well supported by many other works on composites where the researchers have found that the
introduction of hard ceramic phase in the soft ductile matrix can reduce the ductility of base
metal or alloy [53, 54].
0
50
100
150
200
250
2% 4% 6%
YIE
LD
ST
RE
NG
H
Cenoshere
1% E-Glass
3% E-Glass
5% E-Glass
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Figure 4.7 shows variation of percentage elongation with respect to cenoshere and E glass for as
cast specimens
Figure 4.8 shows variation of percentage elongation with respect to E glass and cenoshere for as
cast specimens
0
2
4
6
8
10
12
14
16
1% 3% 5%
perc
en
tag
e e
lon
gati
on
E GLASS
2% cenosphere
4% cenosphere
6% cenosphere
0
2
4
6
8
10
12
14
16
2% 4% 6%
perc
en
tag
e e
lon
gati
on
Cenosphere
1% E galass 3% E galass
5% E galass
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Conclusion
1. Aluminum 7075 based hybrid metal matrix Composites reinforced with E-glass fibre and
cenoshere with various weight fraction were successfully synthesized by stir casting technique.
2. A remarkable improvement in microhardness is noticed with increase in glass fibre and
cenoshere twofold increase in hardness of Al7075-GF- cenoshere composite when compared
with unreinforced alloy.
3. Ductility of the composites diminishes with addition of secondary particles in the aluminum
alloy. However, Al7075 alloy have higher ductility when evaluated with the hybrid composites
under all the compositions studied.
4. Ultimate Tensile strength of Al7075 alloy and Al7075-GF- cenoshere composites increases
with increase in percentage of dual reinforcement.
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