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ABSTRACT
Aluminium and its alloy based cast metal matrix composites have gained lot of popularity in all the emerging fields of
engineering and technology because of their superior mechanical properties compared to monolithic materials. The desired
properties of the metal matrix composites have influenced by the weight percentage of reinforcements in the cast metal matrix
composites, which imposed to study the mechanical behaviour of the cast metal matrix at different weight fraction of
reinforcement particles. The present paper aims to investigate the mechanical behaviour of aluminium alloy (LM6)- Al2O3p
composites at different weight fraction of reinforcement particles, which were produced by using stir cast technique.
Experiments were carried out over range of particle weight percentage of 2.5 -7.5 wt% in steps of 2.5wt%. The experimental
results show that the mechanical properties of cast MMCs are different at different weight percentage of Al2O3p. The
morphology of cast MMCs indicates that the distribution of Al2O3p is not uniform throughout the casting.
Key words: LM6, Al2O3, Metal matrix composites (MMCs), hardness, strength.
1. INTRODUCTION
There have been much pioneering efforts over the last 40 years in the development of MMCs as new engineering
materials; those have improved properties, and lightweight characteristics and competitive costs compared to
traditional materials. Recently, metal-matrix composites (MMCs) are emerged as potential alternatives to conventional
alloys in high-strength and stiffness applications [1]. But, the cost is the key factor for their wider application in
automotive and aerospace industries, although potential benefits in weight saving, increased component life, and
improved recyclability should be taken into account [2]. Today, even in those terms, MMCs are still significantly more
expensive than their competitors. Only simpler fabrication methods, higher production volumes, and use of cheaper
reinforcements [1] can reduce the cost of MMCs. There are several methods are used to manufacture aluminium alloy
based metal matrix composites such as powder metallurgy (PM), where metal and ceramic powders are blended and
hot-pressed [3], and liquid-state processes such as melt infiltration [4-8], compo casting, blending of ceramic powder
and molten aluminium, and casting, melt stirring [9-15], pressurized infiltration and squeeze casting [16-30]. Out of
which melt-stir casting technique is one of the cost effective and quite popular methods due to its unique advantages. In
this technique, the reinforcement particles are introduced directly into the liquid melt and stirred the melt at a suitable
stirring speed thoroughly to ensure their proper mixing in the matrix alloy.
The objective of the present investigation is to study the effect of varying weight percentage of Al2O3 on the mechanical
behaviour and the metallographic properties of the aluminium-silicon alloy (LM6) matrix composites. The results are
compared with the solidification behaviour of aluminium alloy i.e.LM6.
2. METHODOLOGY
The aluminiumsilicon alloy i.e.LM6, which is a well known alloy of aluminium, is used as the base/matrix metal in
the experiments for the fabrication of the composites that has been reinforced with 2 wt%, 4 wt% and 6 wt. % of Al2O3
of average 400 mesh size. The chemical composition of the matrix material (LM6) and the thermo physical properties
of aluminium alloy, Al2O3 & sand have given in the table-1 & table-2. The composites are fabricated by the liquid
metal stir casting technique. The aluminium alloy is melted in clay graphite crucible using an electric resistance
furnace and 3wt.% Mg has been added with the liquid metal, in order to achieve a strong bonding by decreasing the
surface energy (wetting angle) between the matrix alloy and the reinforcement particles. The addition of pure
magnesium has also enhanced the fluidity of the molten metal. The melt has mechanically stirred by using an impeller
after addition of the pre-heated Al2O3 particle (about 850-9000C). The processing of the composite has carried out at a
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temperature of 7500C with a stirring speed of 400-500 rpm. The melt has poured at a temperature of 745 0C into a
silica sand mould. The geometry of mould cavity has shown in Fig.1. The figure of composite casting has shown below
in Fig.2. Experiments carried out for a wide range of particle weight percentage varying from 2 to 6% in steps of 2%.
The micro structural characteristics of the alloys and composites of the castings have also evaluated.
Elements
Si
Percentage (%)
10-13.0
0.1
0.6
0.5
0.1
0.1
Sb
Ti
Al
Remaining
TABLE-2 Thermo physical properties of the matrix, reinforcement particle and sand
Properties
LM6
SiC particulates
Sand
Density(gm/cm3)
2.66
3.2
1.6
Average particle size ( mesh)
------400
----Thermal conductivity(W/m-K)
155
100
0.52
Specific heat (J/Kg-K)
960
1300
1170
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4. CONCLUSIONS
The experimental study on the microstructural behaviour and mechanical behaviour of the LM6 reinforced with Al2O3
composites at different weight fraction of Al2O3 concluded, the following points: The microstructural analysis of MMC castings at different weight fraction of Al2O3p shows that the distributions of
Al2O3 particles are not uniform throughout the casting and segregation of particles are more at the middle of the
castings.
The mechanical behaviour of the as cast Al alloy/Al2O3 metal matrix composites such as hardness and tensile
strength of the casting are enhanced on increasing the weight percentage of Al 2O3 in the matrix metal.
REFERENCES
[1]
[2]
[3]
[4]
[5]
[6]
[7]
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