study of mechanical and corrosive behaviour of …...reinforcement and it can be continuous or...

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

44 | P a g e Study of Mechanical and Corrosive Behaviour of Metal Alloy Composites-Ingrained


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.



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]



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



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]



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



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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study of mechanical and corrosive behaviour of …...reinforcement and it can be continuous or...

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