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International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056

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Experimental Analysis of Mechanical Properties of Aluminum Alloy
LM-4 by Variation of Copper Content
Abhishek Yadav1, Jitender Panchal2
1M.Tech Scholar, Department of Mechanical Engineering, MIET, Mohri Shahbad, Kurukshetra, India
2Department of Mechanical Engineering, MIET, Mohri Shahbad, Kurukshetra, India
*Corresponding Author: khilari.abhishek@gmail.com

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Abstract - Copper is the only material that is having room temperature fatigue behavior of the peak-aged A354
greatest impact of all alloying elements on the strength and and C355 alloys, while its effect on the overaged alloys at
hardness of aluminum cast alloys. Cu improves the high temperature was negligible; (ii) fatigue cracks
machinability of aluminum alloys by increasing the hardness, nucleated mostly from large inter metallic compounds; (iii)
making it easier to generate small cutting chips and fine at room temperature, C355 alloy was characterized by
machined finishes. On the other side, copper generally reduces higher fatigue strength in comparison to A354 alloy [3]. The
the corrosion resistance of aluminum. Copper is generally used Silicon is present as a uniformly distributed fine particle in
to increase the tensile strength and hardness through heat the structure. However, when the primary silicon appears as
treatment. It also reduces the resistance to corrosion and hot coarse polyhedral particles, the strength properties decrease
cracking, or hot tearing. with increasing silicon content, but the hardness goes on
In this work, emphasis is given on the influences of copper in increasing because of the increase in the number of silicon
aluminum alloy LM-4. A total five alloy were made with particles [4]. A linear single variable model for precipitation
variation of copper in the composition of 5%, 7%, 9%, and heat treated Al-Zn-Mg-Cu aluminum alloy hardness and yield
11% using die casting process and their mechanical properties strength described. Based on the major alloying elements
were calculated and analyzed. Tensile test bar was tested at and the strengthening precipitate compositions, a concept
room temperature. The ultimate tensile strength was model was developed. A Refined composition model was
increased with increase in copper content. The maximum subsequently developed to account for the effect of minor
ultimate tensile strength was obtained in LM-4 at 11% of alloying (Mn) and impurity elements (Fe, Si). The model was
copper. also valid refined composition for predicting yield strengths
of Al-Zn-Mg-Cu-Zr aluminum alloys [5].Activation energy for
Key Words: Aluminium Alloy, Copper, Tensile Strength, recrystallization on homogenized samples which were rolled
Hardness, Impact Strength up to the maximum possible reduction in area (~75% by iso
conversion methods using differential scanning calorimetry
1. NTRODUCTION data, whereas, stored strain energy was determined by X-ray
diffraction analysis. It was analyzed that for the same sample
The effect of Mg/Si ratio and Cu content on the stretch the activation energy for recrystallization interrelated well
formability of aluminum alloys of the series 6xxx by using with the stored energy by optical and transmission electron
scanning electron microscopy (SEM), hardness tests, forming microscopy, Micro structural evolution was also analyzed.
limit diagram measurements and tensile tests. It was found The cry rolled annealed sample showed an improved yield
that the formability of Al–Mg–Si alloys decreases due to a strength with a reasonable ductility. The YS found to be 10
decrease in the work hardening and strain-rate hardening times higher than that of the cast homogenized sample. This
capability, with the increase of Mg/Si ratio. It also have been is attributed to the recovery of low angle grain boundaries,
investigated that with the addition of Cu improved the work increasing grain boundary spacing, formation of nano twins
hardening capacity, but slightly decreases the strain-rate and decrease in the dislocation density without any
hardening potential [1].The Aluminum alloys with silicon as recrystallization [6].Al-Si alloys find wide application in the
a major alloying element are a class of alloys, which are the marine, electrical, and automobile and aircraft industries
basis of many manufactured castings. This is mainly due to because of high fluidity, low shrinkage in casting, high
the outstanding effect of silicon in the improvement of corrosion resistance, good weld-ability, easy brazing and low
casting characteristics, combined with other physical coefficient of thermal expansion [7]. This Al-Cu phase
properties, such as mechanical properties and corrosion diagram shown only goes up to ca 60%, by weight, of Copper
resistance [2]. The relationship between room temperature and is “split” at around 54wt%Cu by a particular phase. This
(RT) and high temperature fatigue behavior of A354 and "split" means that the two parts of the diagram must be
C355 alloys and their micro structural features, in particular, considered separately. The diagram up to the 54% point is
secondary dendrite arm spacing (SDAS) and intermetallic very similar to the "standard" phase diagram. The eutectic
compounds. The micro structural analyses and rotating composition is at 33%Cu/67%Al, and the Te is ca. 550 K. A
bending fatigue tests emphasized that (i) SDAS influenced 25%Cu/75%Al composition is known as a hypoeutectic alloy

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A 36%Cu/64%Al composition is correspondingly called controlling these parameters, showing a reduction in time
hypereutectic [8]. consumption during the thermal treatment. A relationship
has been established between UTS, hardness, and
time/temperature for ageing and retrogression regimes by
multiple linear regression method. For optimized ageing
temperature and retrogression time- temperature, in order
to obtain both specific UTS and hardness, this correlation
can be used [11]. Aluminum and aluminum alloy are gaining
huge industrial significance because of their outstanding
combination of mechanical, physical and tribological
properties over the base alloys. These properties include
high specific strength, high wear and seizure resistance, high
stiffness, better high temperature strength, controlled
thermal expansion coefficient and improved damping
capacity [12]. Several methods for estimating fatigue
properties of wrought aluminum alloys from simple tensile
data or hardness was discussed. Among them, Park-Song
modified Mitchell’s method provided the best estimation
results in low fatigue life regime [13]. The presence of
Figure 1: phase diagram of Aluminum-Copper [8] additional elements in the Al-Si alloys allows many complex
intermetallic phases to form. Copper is a potent
The influence of the Si content of the aluminum alloys on precipitation-strengthening agent in aluminum. Cu additions
their wear resistance has been well documented and eutectic up to about 5% lead to alloys with high strength and good
alloys are reported to have better wear resistance than those toughness when subject to natural or artificial aging. The
of hypoeutectic and hypereutectic composition. Manganese addition of Cu increases considerably the strength of Al–Si
is also able to change the morphology of the iron-rich phases alloys, due to precipitation of dispersed Al2Cu (θ) phase
from platelets to a more cubic form or to globules. These during aging. The strengthening contribution from
morphologies improve tensile strength, elongation, and precipitation is typically a function of both precipitate size
ductility [9]. The effect of five different heat treatment distribution and volume fraction [14].
methods as peak aging (T6), over aging (T74), high The scanning electron microscope (SEM) microstructures of
temperature and subsequently low temperature aging the five samples of 6351 aluminum alloy with different
(HLA), retrogression and raging (RRA) and double contents of copper with 400x magnification as shown in Fig.
retrogression and raging (DRRA) on strength, fracture 2. Porosity in aluminum alloys is classified into two kinds: (i)
toughness and microstructure of 7N01 aluminum alloys by macro porosity (~1–10 mm), which is mainly comprised of
by optical microscopy (OM), transmission electron massive shrinkage cavities, and occurs in long-freezing range
microscopy (TEM), and scanning electron microscopy (SEM). alloys, caused by failure to compensate for solidification
The strength and fracture toughness of the five samples are shrinkage, and (ii) micro porosity (~1–500 μm), distributed
tested. The results showed that 7N01 Al-alloy treated at T6 more or less homogeneously, due to the failure to feed inter
condition has high strength but low fracture toughness. dendritic regions, and the precipitation of dissolved gases
Compared with T6 treatment, T74 and HLA treatments (i.e., gas porosity). In all aluminum alloys samples
increase the fracture toughness by 67% and 90% investigated was observed the two types of porosity like
respectively, while the strength decrease by 9% and 17%. marked in yellow arrows in Fig. 2 [15].
RRA process which improves the fracture toughness without The mechanical properties of aluminum, nylon, GFRP,
sacrificing strength, was a proper treatment method for aluminum-GFRP composite & aluminum-nylon composite
7N01. The fracture toughness of DRRA treated alloy was were found by using experimental method, The deflection of
much lower than that of RRA. Quantitative analysis through aluminum composite beams is less than that of pure material
TEM images showed that the heat treatment affects the beams, the natural frequencies of pure materials (GFRP &
mechanical properties of 7N01 Al-alloy highly through Nylon) are larger than those of composite beams made by
changing the precipitates in grains and on grain boundaries them if nylon is taken as synthetic fiber with Al, but if GFRP
[10]. The relation between ageing and retrogression is taken then its deflection is found to be increased when
temperatures on Al 6061 alloy on hardness and ultimate compared to pure GFRP. So, nylon suits good to make
tensile strength (UTS) was studied. It was found that higher composite beam with Al as compared to other synthetic
UTS and hardness were obtained at elevated ageing, fibers like GFRP [16, 17].
retrogression temperatures, and lowest retrogression time.
Alloy ultimate tensile strength has been improved by

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Figure 2: Microstructures of the 6351 aluminum alloy samples with different copper content; porosity (yellow
marked); Al(MnCuFe)Si constituent (black marked) [15]

The addition of copper as main alloying element (mostly wt. % copper the strength of the alloy can increase through
range 3–6 wt. %, but can be much higher), with or without precipitation hardening, with or without the presence of Mg;
magnesium as alloying constituent (range 0–2 %), allows Hardening is achieved through the precipitation of Al2Cu or
material strengthening by precipitation hardening, resulting Al2CuMg intermetallic phases during ageing which leads to
in very strong alloys. Also the fatigue properties are very strengths second only to the highest strength 7xxx series
good for this series. Copper tends to precipitate at grain alloys [19]. The influence of Ni on the overall properties of
boundaries, making the metal very susceptible to pitting, thin film, composition of Al–Cu–Ni which was deposited by
intergranular corrosion and stress corrosion [18]. Up to 12 thermal evaporation. The chemical composition was

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detected by energy dispersive X-ray spectroscopy and combination of high toughness with stable microstructure
showed a compositional spread of approximately 20 at. % Ni. amongst the differently aged samples [25].
Decreasing the Ni content in the Al–Cu–Ni thin films resulted
in an increased grain size and characteristic surface 2. EXPERIMENTAL PROCEDURE
microstructure evolution. Chemical dissolution experiments
have shown that Ni is enhancing the chemical stability of Cu, 2.1 Casting
excepting inside the compositional region between 7 and 13 For casting process different metals such as alumimium,
at% Ni [20]. The ultimate tensile strength of the alloy copper, magnesium, silicon, iron, manganese, nickel, zinc
improved as compared to LM 12, the solidifications lead, tin, titanium was melted one by one according to there
temperature for Al- Alloy reduces and this is an important melting points i.e metal with highter melting point was
factor to consider which temperature the heat treatment not melted first and so on. A specimen (casted product) was
should exceed. When increase the silicon content then the obtained by the combination of all these metals.
melting point of aluminum alloy is decreases whereas The amount of heat that must be removed from a casting to
fluidity was increases [21, 22]. The hardness measurements cause it to solidify is directly proportional to the amount of
to characterize the early stages of precipitation in three Al– superheat and the amount of metal in the casting, or the
Mg–Si alloys with different Cu contents (Al–0.51 at.% Mg– casting volume. Conversely, the ability to remove heat from a
0.94 at %Si, with 0.01 at.%, 0.06 at.%, or 0.34 at.% Cu) at a casting is directly related to the amount of exposed surface
range of single and multi- stage heat treatments to evaluate area through which the heat can be extracted and the
the changes in precipitation processes. Three ageing insulating value of the mould. These observations are
temperatures were investigated, 298 K (natural ageing), 353 reflected in Chvorinov's Rule, which states that tf, the total
K (pre-ageing) and 453 K (automotive paint-bake solidification time, can be computed by
conditions). The Cu content had significant effects on the
microstructural evolution within the alloy. Formation of ?? = C
clusters which can act as precursors of elongated Where V is the volume of the casting, A is the surface area, C
precipitates during paint-baking was found to be enhanced is the mould constant, n is a constant, which varies from 1.5
with increasing Cu content. This improved the paint-bake to 2.0 (2 in Chvorinov’s work).
hardening response and mitigated the deleterious effects of The total solidification time is the time from pouring to the
natural ageing [23]. The effect of Mg level on the completion of solidification and mould constant C depends
microstructure and mechanical properties for die-cast Al – Si on the characteristics of the metal being cast (its density,
– Cu alloys under the as cast, the solutionised, and the heat capacity, and heat of fusion), the mould material (its
solution and aged conditions was investigated. It was found density, thermal conductivity, and heat capacity), the mould
that the Mg additions resulted in an effective strengthening thickness, and the amount of superheat. Chvorinov’s rule is
to the alloy under both the as-cast condition and the solution one of the most useful guide to the students of foundry
and aged condition showed by SEM and TEM analysis. In the engineering. It provides a powerful general method of
die-cast Al–Si–Cu alloys, the lamellar and blocky Al2Cu (Si) tackling the feeding of castings to ensure their soundness
were formed overall the experimental alloys, but the and producing castings with improved structure and
irregular Al-Cu-Mg-Si intermetallic were emerged when Mg properties. Since a feeder and a casting are both within the
content was higher than 0.32wt%. The addition of Mg same mould and fill with the same metal under the same
offered extra strengthening after the solution and ageing. Mg conditions, Chvorinov's rule can be used to ensure that the
content can be controlled at a level up to 0.73wt% for casting will solidify before the feeder by designing a feeder
increasing the strength with acceptable ductility under as- with a higher modulus than the casting. Different cooling
cast and heat treatment conditions [24]. The deformation rates and solidification times can produce substantial
behavior of an aluminum–lithium alloy heat treated to variation in the resulting structure and properties. For
different tempering conditions at high strain rate in instance, die casting, which uses metal moulds, has faster
compression using a direct impact Hopkinson Pressure bar cooling and produces higher-strength castings than sand
was investigated. Detailed microstructural investigation was casting, which uses a more insulating mould material.
carried out using electron back scatter diffraction and bulk Derivation of Chvorinov’s Rule has analyzed the heat
crystallographic texture was determined using X-ray transfer within a theoretically infinite mould filled with
diffraction. The naturally aged sample showed less liquid metal and suggested that the distance travelled by the
propensity to adiabatic shear band formation and therefore, solidification front, x [26]
highest toughness, compared to artificially aged samples. ?=?
This can be attributed to higher resistance to instability by Where? is a constant (cm s-1/2) and t is the solidification time
prolonged strain hardening from dislocation– precipitate (s). Schwartz also suggested that, for one dimensional heat
interaction in the underage sample compared to peak and flow, the temperature at the mould/metal interface, Ti , is
over aged samples under dynamic loading conditions. The assumed to be constant and can be calculated as
single stage peak-aged sample provides the best

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Ti =

Where Tm is the melting temperature (°C) (assuming no
solidification interval), bm and bs are the heat diffusivity of
mould and solidifying metal (cal cm-2 s -1 C -1), and s is
thermal diffusivity of solidifying metal (cm2 s -1 ). The
diffusivity is often measured as the product of KC, where K
is thermal conductivity (Cal cm-1 s-1C -1).and C is the specific
heat (Cal g-1 C -1).
The heat diffusivity ratio is small for sand moulds, and hence
Ti is lower than Tm by only about 2%. Therefore, the amount
of heat lost from the solidified layer would be negligible, and (a)
the surface temperature of metal in sand castings will not
depend on the actual shape of the casting. Chvorinov
proceeded to show that the solidification time of castings
poured with no superheat can be expressed as [26]
t=

In this work the tensile test at room temperature was
conducted on a standard universal testing machine using
ASTM code D638-02 a (Type-I) [27] as shown in Fig.3

(b)

Figure 3: Drawing of Test Specimen [27]

Table 1: Dimensions of Test Specimen [27]

Specimen Dimension in (mm) (c)
Thickness 7 mm or Over 7 to 14 Figure 4 (a) Unfinished tensile specimen, (b)
Dimension (See Less mm Machining of the specimen, (c) Final tensile specimen
Drawing)
Type-I Type-II Type-III
W- Width of 13 6 19 3. RESULT AND DISCUSSION
Narrow section
L-Length of 57 57 57 3.1 Tensile Strength
narrow section
The engineering stress-strain curve for pure Aluminum
WO-Width over 19 19 29
all specimens with an enlarged scale, shows the strains from
LO Length over 165 183 246 zero to specimen fracture. Here it appears that the rate of
all strain hardening diminishes up to UTS (Ultimate Tensile
G-Gage length 50 50 50 Strength).Beyond UTS, the material appears to strain soften,
so that each increment of additional strain requires a smaller
D-Distance 115 135 115 stress. [17]. Fig. 6 shows the stress strain curve for
between grips aluminum alloy LM-4 with variation of copper content from

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5-11%. The tensile strength values lie in the range of 158.41
MPa to 234.31 MPa at room temperature.

(b)

Figure 5: Ultimate tensile strength of aluminum alloy
with variation of copper content

It was observed that increase in tensile strength attributed
to the dissolution of the Cu rich intermetallic phase particles,
mainly the Al2Cu phase during solution treatment. It also
resulted in solid solution hardening (the process mainly
responsible for the observed increase in strength). The value
of ultimate tensile strength of cast aluminum alloy are higher
than the base aluminum alloy LM-4

(c)

.

(a)

(d)

Figure 6: Comparison of LM-4 with (a) LM-4 with Cu-
5%, (b) LM-4 with Cu-7%, (c) LM-4 with Cu-9%,
(d) LM-4 with Cu-11%

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(b)
Figure 7: Combined Comparison of aluminum alloy
LM-4 Figure 8: (a), (b) Hardness of aluminum alloy with
variation of copper content
The improvement of tensile strength of cast aluminum alloy Fig. 8 (a & b) elucidate the variation of copper content on the
LM-4 with variation of Cu (5-11%) in comparison to base hardness of cast aluminum alloy. It may be observed that
alloy is shown in Fig. 7. The aluminum copper alloy was hardness of cast aluminum alloy was increased with
successfully synthesized by the die casting method. Mixing of increased in copper percentage, the highest hardness value
copper and aluminum particles lead to the cluster formation was obtained in cast Al-Cu-11% is 91.32 BHN whereas the
and hence resulted in the formation of improved alloy. minimum hardness was obtained in base aluminum alloy
LM-4 .
3.2 Hardness Test
3.3 Impact Test
Some alloys may improve their strength and hardness by the Toughness is the ability of a material to absorb energy and
formation of uniformly small dispersed particles within the plastically deform without fracturing. Impact test is a
original matrix when the solidified alloy is subjected to heat method for evaluating the toughness of engineering
treatment. These particles are called second phase particles materials. The notched test specimen is broken by the
and the strengthening achieved through the precipitation of impact of a heavy pendulum or hammer, falling at a
these particles is known as age hardening. These predetermined velocity through a fixed distance.
precipitated particles strengthen the heat treated alloys by
blocking the movement of dislocation. Al-Cu alloys are Table 2: Impact testing result
suitable for casting, as these alloys can be heat treated and Dimension Energy in
Material
can be age hardened [28, 29]. (mm) (Jules)
LM-4 2
LM-4 (5% Cu) 2.5
LM-4 (7% Cu) 55x10x10 3
LM-4 (9% Cu) 4
LM-4 (11% Cu) 4.5

The Charpy test is performed by preparing the specimen as
per IS: 1757 standard. The impact results are shown in table-
2 and Fig. 10. It was found that the LM-4 with Cu 11%
absorbed more energy than the other cast aluminum alloy
because it contains less amount of aluminum.

(a)

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 It was found that the LM-4 with Cu 11% absorbed
more energy than the other cast aluminum alloy
because it contains less amount of aluminum.

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