STUDY ON MECHANICAL

PROPERTIES OF AL2O3, GRAPHITE

REINFORCED A6063 HYBRID COMPOSITE

A thesis submitted in partial fulfillment of the requirement

for the award of the degree of

BACHELOR OF TECHNOLOGY
in
MECHANICAL ENGINEERING

Submitted by

A. Phani 315175720006
B. Rohit 315175720024
B.M. Arora 315175720027
A. Madhavan 315175720015
A. Saiteja 315175720016
A. Manu Chandan 315175720010

Under the esteemed guidance of

I. Ajit Kumar, M. Tech.,
Assistant Professor

DEPARTMENT OF MECHANICAL ENGINEERING

S.R.K.R. ENGINEERING COLLEGE

(Affiliated to Andhra University, Visakhapatnam)
(Recognized by All India Council for Technical Education, New Delhi)
(Accredited by NAAC ‘A’ Grade with 3.60 CGPA)
(Recognized as Scientific and Industrial Research Organization)
CHINA AMIRAM (P.O): BHIMAVARAM-534 204
2015-2019
 S.R.K.R. ENGINEERING COLLEGE
(Affiliated to Andhra University, Visakhapatnam)
(Recognized by All India Council for Technical Education, New Delhi)
(Accredited by NAAC ‘A’ Grade with 3.60 CGPA)
(Recognized as Scientific and Industrial Research Organization)
CHINA AMIRAM (P.O): BHIMAVARAM-534 204

DEPARTMENT OF MECHANICAL ENGINEERING

Certificate
This is to certify that the project work entitled “Study on mechanical properties of
Al2O3, Graphite Reinforced A6063 Hybrid Composite” is the bonafide work submitted
by Akkireddi Phani (Reg. No. 315175720006) in the partial fulfillment of the
requirement for the award of the degree of BACHELOR OF TECHNOLOGY in
MECHANICAL ENGINEERING during the year 2018-2019.

Guide: HOD:
I. Ajit Kumar, M. Tech., Dr. K. Brahma Raju M.E., Ph. D.
Assistant Professor Professor & Head of the Department
 CERTIFICATE OF EXAMINATION

This is to certify that we had examined the thesis and here by accord our
approval of it as a study carried out and presented in a manner required for its acceptance
in a partial fulfillment for the award of degree of BACHELOR OF TECHNOLOGY
in MECHANICAL ENGINEERING for which it has been submitted.

This approval does not endorse or accept every statement made, opinion
expressed or conclusion drawn as in report. It only signifies acceptance of report for the
purpose for which it is submitted.

Internal Examiner External Examiner

 ACKNOWLEDGEMENT

The satisfaction that accompanies the successful completion of any task would be

incomplete without the mention of the people who made it possible and whose constant

guidance and encouragement crown all the efforts success.

I thank my guide Sri I. Ajit Kumar, Assistant Professor in Department of Mechanical

Engineering for his support in completion of my dissertation. I wish to express my sincere

thanks to Dr. K. Brahma Raju, Head of the Department and all faculty members of

Department of Mechanical Engineering. I also express my sincere gratitude to Our Principal

and Management members of S.R.K.R. Engineering College for providing me the facilities to

complete the dissertation.

We are thankful to Sri K.CH. KISHOR KUMAR Associate Professor and Sri J.

PHANI KUMAR Assistant Professor in mechanical engineering in Gudlavalleru Engineering

College for there insightful support and guidance for successful completion of this project

work.

Last but not least, I express my heartful thanks to all my staff and friends for their

constant support, encouragement and valuable contribution in the completion of this work.

PROJECT ASSOCIATES

A.Phani
B. Rohith
B.M. Arora
A. Madhavan
A. Sai Teja
A. Manu Chandan
 CONTENTS

Title PAGE NO

Chapter 1 1

1. INTRODUCTION 1

1.1. Overview of composites 2

1.2. Types of composites 2

1.2.1. Metal matrix composites 2

1.2.2. Ceramic matrix composites 3

1.2.3. Polymer matrix composites 3

1.3. Processing methods of metal matrix composites 3

1.3.1. Liquid state Fabrication of MMC’s 4

1.3.1.1. Stir-casting or compo casting 4

1.3.2. Solid state Fabrication of MMC’s 5

1.3.3. In-situ Fabrication of Metal Matrix composites 5

1.4. Applications of MMC’s 6

1.5. Mechanical Advantages of Composites 6

1.6. Advantages of composites over Metals 7

1.7. Aim of the Present work 7

Chapter 2 8

2. LITERATURE REVIEW 9

Chapter 3 11

3. EXPERIMENTAL WORK 12

3.1. Raw Materials 12

3.1.1. A6063 Alloy 12

 3.1.2. Al2O3 13

3.1.3. Graphite 14

3.2. Fabrication of composites 15

3.2.1. Stir-casting Equipment 15

3.2.1.1. Muffle Pre-Heater 15

3.2.1.2. Melting Furnace 15

3.2.1.3. Electrical stirrer 16

3.2.1.4. Dies 17

3.2.2. Stir-casting process 17

3.3. Hardness Test 19

3.4. Tensile Test 19

3.5. Compression Test 22

3.6. Wear Test 23

3.7. Density Measurement 23

3.8. Microstructures Analysis 24

Chapter 4 27

4. RESULTS AND DISCUSSIONS 28

4.1. Hardness Test 28

4.2. Tensile Test 29

4.3. Compression Test 30

4.4. Density Measurement 31

4.5. Microstructures Analysis 32

4.6 Wear Test 36

Chapter 5 40

5. CONCLUSIONS 41

REFERENCES 42
 ABSTRACT

Science and technology has developed to such extent that now the demand for advanced
engineering material has increased. This demand can be fulfilled by composite material, one
such material is the metal matrix composites (MMC). In the present investigation, A6063 Alloy
is used as matrix and 2%, 4% and 6wt% Al2O3 with graphite particles of 2wt%. Particulates of
150µm were successfully fabricated by vortex method. The fabrication of these composites
was carried out by stir casting technique. The mechanical properties of the composites
including Hardness, Tensile and Compressive strengths, wear rate and density of the composite
were investigated and also the microstructure is observed. The results showed that the hardness,
tensile and compressive strengths increases with the percentage increases of reinforcement,
density of composite decrease with increasing of reinforcement and from the micrographs it
observed that there was a good interfacial bonding between the Al2O3 and graphite particles
with the matrix phase. It is concluded that the fabricated composites could be used to make
engineering components for automobile application. An attempt has been made successfully to
fabricate the composites and Hence, Alumina and Graphite can be used as reinforcement Metal
Matrix Composites (MMC’s).
 LIST OF FIGURES

Figure No Page No

1.1 Processing methods of MMC’s 3

1.2 Stir casting 5
3.1 Al2O3 powder 13
3.2 Graphite powder 14
3.3 Muffle pre-heater 15
3.4 Stir casting machine 16
3.5 Die for specimen 17
3.6 Melting furnace 18
3.7 Specimen after casting 18
3.8 Brinell’s hardness tester 19
3.9 Tensile Specimen Measurements 20
3.10 Universal testing Machine 20

3.11(a) Tensile specimen before testing 21

3.11(b) Tensile specimen after testing 21

3.12 Testing on specimen 22

3.13 Pin on Disc Setup 23

3.14 Electron Specific gravity balance 24

3.15 Emery polishing papers 25

3.16 Emery polished specimen 25

3.17 Disc polishing Apparatus 25

3.18 Disc polished specimen 26

3.19 Inverted metallurgical microscope 26

4.1 percentage of reinforcement Vs Hardness (BHN) 28

4.2 percentage of reinforcement Vs UTS 29

4.3 percentage of reinforcement Vs UCS 30

4.4 Microstructure of A6063- 2%Al2O3- 2%gr 32

4.5 Microstructure of A6063- 4%Al2O3- 2%gr 33

4.6 Microstructure of A6063- 6%Al2O3- 2%gr 34

4.7 Microstructure of A6063- 2%Al2O3 35

4.8 Graphs of 10 N Normal Load 36

4.9 Graphs of 20 N Normal Load 37

4.10 Graphs of 30 N Normal Load 38

 LIST OF TABLES

Table No Page No

3.1 Chemical Composition of A6063 12

4.1 Hardness test results 28

4.2 Tensile test results 29

4.3 Compression test results 30

4.4 Density measurement results 31

4.5 Wear test results 39

 Chapter-1

INTRODUCTION

1
 INTRODUCTION

1.1 Overview of Composites

Composites are made by combining two or more natural or artificial materials to maximize
their useful properties and minimize their weaknesses one of the oldest and best-known
composites, glass-fibres reinforced plastic (GRP), combinations glass fibres (which are strong
but brittle) with plastic (which is flexible) to make a composite material that is tough but not
brittle. Most composites consist of fibres of one material tightly bound into another material
called a matrix. The matrix binds fibres together somewhat like an adhesive and makes them
more resistant to externally damage, whereas the fibre makes the matrix stronger and stiffer
and help it resist cracks and fractures. Fibres and matrix usually (but not always) made from
different types of materials. The fibres are typically glass, carbon, silicon carbide, or asbestos,
while the matrix is usually the plastic, meatal, or a ceramic material (though material such as
concrete may also be used).

1.2 Types of Composites

Broadly, composite materials can be classified into three groups on basis of matrix material.
They are:

(a)Metal matrix composites (MMCs)

(b)Ceramic matrix composites (CMCs)

(c)Polymer matrix composites (PMCs)

1.2.1 Metal Matrix Composites (MMCs)

Metal matrix composites, as the name implies, have a metal matrix. Examples of matrices in
such composites include aluminium, magnesium and titanium. The typical fibre includes
carbon and silicon carbide. Metals are mainly reinforced to suit the needs of design. For
example, the elastic stiffness and strength of metals can be increased, while large coefficient
of thermal expansion, thermal and electrical conductivities of metals can be reduced by the
addition of fibres such as silicon carbide.

2
1.2.2 Ceramic Matrix Composites (CMCs)

Ceramic matrix composites have ceramic matrix such as alumina, calcium, alumina silicate
reinforced by silicon carbide. The advantages of CMC include high strength, hardness, high
service temperature limits for ceramics, chemical inertness and low density. Naturally resistant
to high temperature, ceramic materials have a tendency to become brittle and to fracture.

1.2.3 Polymer Matrix Composites (PMCs)

The most common advanced composites are polymer matrix composites. These composites
consists of a polymer thermoplastic or thermosetting reinforced by fibre (natural carbon or
boron). These materials can be fashioned into a variety of shapes and sizes. They provide great
strength and stiffness along with resistance to corrosion. The reason for these being most
common is their low cost, high strength and simple manufacturing principles. Due to low
density of the constituents the polymer composites often show excellent specific properties.

1.3 Processing Methods of Metal Matrix Composites

Metal matrix composites have many advantages as compared to monolithic metal so their
applications are increasing day by day in various fields. Various processes are used to
manufacture MMCs and these processes are classified on the basis of temperature of the
metallic matrix during processing accordingly, the processes can be classified into three
categories: (1) Liquid-phase processes, (2) Solid- liquid processes, (3) In situ processes.

Fig 1.1 Processing methods of MMC’s

3
 1.3.1 Liquid State Fabrication of MMC’s

It involves incorporation of dispersed phase into a molten matrix metal, followed by its
solidification. In order to provide high level of mechanical properties of the composites, good
interfacial bonding (wetting) between the dispersed phase and the liquid matrix should be
obtained. Wetting improvement may be achieved by coating the dispersed phase particles
(fibres). Proper coating not only reduces interfacial energy, but also prevents chemical
interaction between the dispersed phase and the matrix.

The methods of liquid state fabrication of metal matrix composites: Stir casting, infiltration
like gas pressure infiltration, squeeze casting infiltration and pressure die infiltration.

1.3.1.1 Stir-Casting or Compo Casting

According to the type of reinforcement, the fabrication techniques can vary considerably. The
above processes are most important of which, Liquid metallurgy technique has been explored
much in these days. This involves incorporation of ceramic particulate into liquid aluminium
melt and allowing the mixture to solidify.

Here, the crucial thing is to create good wetting between the particulate reinforcement
and the liquid aluminium alloy melt. The simplest and most commercially used technique is
known as vortex technique or stir casting technique. The vortex technique involves the
introduction of pre-treated ceramic particles into the vortex of molten alloy created by the
rotating impeller. Ceramic particles and ingot-grade aluminium are mixed and melted. The melt
is stirred slightly above the liquidous temperature (700-800OC).

Liquid state fabrication of metal matrix composites involves incorporation of

dispersed phased into molten matrix metal, followed by its solidification. In order to provide
high level of mechanical properties of the composite, good interfacial bonding (wetting)
between the dispersed phase and the liquid matrix should be obtained. Wetting improvement
may be achieved by coating the dispersed phase particles (fibres). Proper coating not only
reduces interfacial energy, but also prevents chemical interaction between the dispersed phase
and the matrix. The simplest and the most cost-effective method of liquid state fabrication is
stir casting.

4
 Stir casting is a liquid state method of composite materials fabrication, in which a
dispersed phase (ceramic particles, short fibres) is mixed with a molten matrix metal by means
of mechanical stirring. The liquid composite material is then cast by conventional casting
methods and may be processed by conventional metal forming technologic.

Fig 1.2 Stir casting

1.3.2 Solid State Fabrication of MMC’s

Solid state fabrication of metal matrix composites is the process, in which MMC are
formed as a result of bonding of matrix metal and dispersed phase due to mutual diffusion
occurring between them in solid state at elevated temperature and under pressure.

1.3.3 In-situ Fabrication of Metal Matrix Composites

In these techniques the reinforcement phase is formed in situ. The composite material
is produced in one step from an appropriate starting alloy, thus avoiding the difficulties inherent
in combining the separate components.

5
1.4 Applications of MMC’s

The importance of metal matrix composites in various fields has been over the past two decades
a period coinciding with publication of importance MMC applications in the ground
transportation (auto and rail), thermal management, Aerospace, industrial, recreational and
infrastructure industries have been enabled by functional properties that include high structural
efficiency, excellent wear resistance, and attractive thermal and electrical characteristics.

On account of the excellent physical, mechanical and development properties of metal matrix
composite materials, they are applied widely in aircraft technology and electric engineering,
and recently in passenger car technology.

1.5 Mechanical Advantages of Composites

 High resistance to impact damage

 Improved friction and wear properties
 Fibre to fibre redundant load path
 Like metals, thermoplastics have indefinite shelf life
 Close tolerance can be achieved without machining
 High resistance to fatigue and corrosion degradation
 Due to greater reliability, there are fewer inspections and structural repairs
 Manufacture and assembly are simplified because of part integration (joint/fastener
reduction) there by reducing cost
 Excellent heat sink properties of composites, especially carbon-carbon, combined with
their lightweight have extended their use for aircraft brake
 High ‘strength or stiffness to weight’ ratio. As enumerated above, weight savings are
significant ranging from 25-45% of the weight of conventional design
 Composites offer improved torsional stiffness. This implies high whirling speeds,
reduced number of intermediate bearings and supporting structural elements. The
overall part count and manufacturing and assembly costs are reduced
 Composites are dimensionally stable i.e., they have low thermal conductivity and low
coefficient of thermal expansion. Composite materials can be tailored to comply with
a broad range of thermal expansion design requirements and to minimize thermal
stresses.

6
1.6 Advantages of Composites over Metals

 Requirements governing the choice of materials apply to both metals and composites.
It is therefore, imperative to briefly compare main characteristics of the two.
 Composites offer significant weight saving over existing metals
 Composites can provide structures that are 25-45% lighter than the conventional
aluminium structures designed to meet the same functional requirements. This is due to
the lower density of the composites
 Depending on material from, composite densities range from 1260 to 1820 kg/in as
compared to 2800 kg/in for aluminium. Some applications may require thicker
composite sections to meet strength/stiffness requirements, however weight savings
will still result
 Unidirectional fibre composites have specific tensile strength (ratio of material strength
to density) about 4 to 6 times greater than that of steel and aluminium
 Unidirectional composites have specific modulus (ratio of the material stiffness to
density) about 3 to 5 times greater than that of steel and aluminium
 Fibre reinforced composites can be designed with excellent structural damping features.
As such, they are less noisy and provide lower vibration transmission than metals
 High corrosion resistance of fibre composites contributes to reduce to life-cycle cost
which is very low in metals
 Resilience – the ability to deform and spring back to their original shape without major
damage. Shape memory and impact tolerance are two of the biggest advantages of
composites, particularly within the transport industry.

1.7 Aim of the Present Work

The main objective of this work is to prepare a metal matrix composite using Al2O3 and
graphite as reinforcement and Aluminium alloy A6063 as matrix material and to study its
mechanical properties and density. Out of the available manufacturing procedures we have
adopted the stir casting technique to prepare the MMC’s. Different weight % of powder of
Al2O3 and graphite has been reinforced with the matrix material and specimens were casted in
grey cast iron mould and the specimen were tested to determine its mechanical properties and
microstructure.

7
 CHAPTER – 2

LITERATURE REVIEW

8
 LITERATURE REVIEW

Metal matrix composites have raised great attention and interest among scientists and
engineering in recent years due to the considerations of developing applications in automobile
industries. Metal matrix composites have the potential to be use as a replacement for traditional
reinforcement materials for applications which require high strength to weight ratio. Metal
matrix composite such as A6063 and Al2O3 (Alumina) and graphite has high toughness and
greater hardness and increment in ultimate tensile strength (UTS). A lot of work has been done
by researchers on metal matrix composites. A review of relevant literature is given here under,

Pradeep K. Rohatgi [1] focused on the cast aluminium-matrix composites for automotive
applications in the year 1981. According to his synthesis, he stresses that the potential for
extensive application of cast composites is very large in India, especially in the areas of
transportation, energy and electromechanical machinery; the extensive use of composites can
lead to large saving in material and energy, and in several instances, reduce environmental
pollution.

M K Surrappa [2] has done experiment on challenges and opportunities on AMC’s in the year
2003, states that major advantage of AMC’s compared to unreinforced materials such as greater
strength, improved stiffness, improved high temperature properties, controlled thermal
expansion coefficient, thermal/heat management, enhanced and tailored electrical
performance, improved abrasion and wear resistance, control of mass (especially in
reciprocating applications), improved damping capabilities.

H.Ghanashyam shenoy, Soma V. Chetty, Sudheer Prem Kumar [3] were focused on
“Effect of aging conditions on mechanical properties of aluminium based hybrid composite”
and stated that all Aluminium based alloys have increased in tensile strength and hardness with
increasing reinforcement in the year 2012.

Hanumanthe Gowda, P. Rajendra Prasad [4] investigated the mechanical properties such
as hardness and tensile on A6063 alloy reinforced with alumina in 2014. The aim of their work
is to evaluate the tensile strength and hardness on composite. Their work determines the
improvement in properties was been observed with the addition of reinforcement.

G. Nagesh, Sukesha.V, Rajeev Ranjan, K. Sekhar [5] were investigated on the mechanical
and tribological properties of A6063/Al2O3/graphite by stir with squeeze casting method in the
year 2014 and results that improvement of tribological and mechanical properties of

9
composites and the mechanical properties of (1.5% graphite + 1%Al2O3) are superior to those
of the composite reinforced with 0.5%graphite or 1%Al2O3 particles and the wear rate of the
composite decreased dramatically and the tensile strength decreased with weight percent of
graphite, Al alloy composites can exhibit outstanding features such as high melting point, high
hardness and high wear resistance.

Shashi Prakash Dwivedi, Satpal Sharma, Raghavendra Kumar Mishra [6] have studied
on A6063 alloy applications in the year 2014 and determines the A6063 alloys are ever more
accepted in aircraft and automobile due to their high strength to weight ratio and its thixotropic
structure. Its specific tensile strength and rigidity are superior to other aluminium alloys. These
qualities lead to less vehicle and aircraft weight and better fuel economy A6063 alloys have
been developed with significant ductility, strength, elongation, hardness and toughness at room
temperature in as cast state.

Kevin Kurian Paul and Sijo MT [7] stresses on the major challenge when processing MMCs
is achieving a homogenous distribution of reinforcement in matrix and it has a strong impact
on the properties of the material. Regarding his synthesis, he resulted that the Stir casting
technique can achieve uniform distribution of reinforcement in matrix in the year 2015.

A.P.S.V.R. Subramanyam [8] determines that the light weight hybrid composites are most
promised materials of the today’s engineering world in the tear 2015. They have high strength
to weight ratio and they find wide range of application in aviation and automobile sectors

D. Manoj Kumar, G.S. Guru Dattatreya & N. krishnarjun rao [9] states that the usage of
any material matrix composites always depends upon the strong wettability reinforcement
particles in matrix in the year of 2016. For the strong wettability, uniform distribution of
particles and good disposability stir casting method is considered, for the development of the
composites. The physical and mechanical behaviour of the material was determined through
density, hardness, tensile strength, impact energy calculations.

Venkatachalam .G and Kumaravel.A [10] has examined characterisation of A6063- basalt

Ash-fly Ash composites processed by stir casting method, in their survey they tells that the
A6063 alloy has good strength and ductility as well as first rate casting features, high corrosion
resistance, and good fluidity and the machinery, aircraft and defence industries have widely
applied the alloy, and particularly in the automotive industry to replace the Al instead of steel
alloy have been widely applied in the year 2017.

10
 CHAPTER – 3

EXPERIMENTAL WORK

11
 EXPERIMENTAL WORK

This chapter describes in detail about the materials and experimental procedure carried out
during the course of project work.

The steps involved are

 Fabrication of Al2O3 and Graphite reinforced Metal Matrix Composite

 Stir casting method
 Machining of samples of desired dimensions
 Hardness testing of fabricated Metal Matrix Composite
 Tensile testing of fabricated Metal Matrix Composite
 Compression testing of fabricated Metal Matrix Composite
 Wear testing of fabricated of Metal Matrix Composite
 Density measurement of fabricated of Metal Matrix Composite

3.1 Raw Materials

The raw materials used in this experimental work are as follows

 A6063 alloy as matrix material

 Al2O3 and Graphite powders as reinforcement

3.1.1 A6063 Alloy

The chemical composition of A6063 alloy is shown in table 3.1 and it was procured from
venuka engineering private ltd of 7 kg ingots.,

Table 3.1 chemical composition of A6063 alloy, wt. %.

Si Fe Cu Mn Mg Cr Zn Ti Al

0.6 0.35 0.10 0.10 0.9 0.10 0.10 0.10 97.63

A6063 alloys are alloys wherein aluminium (Al) is the major metal. The distinctive alloying
elements are silicon, iron, copper, manganese, magnesium, chromium, zinc and titanium.
A6063 alloys are broadly used in engineering structures and components where light weight or
corrosion resistance is necessary. Alloy collected typically of aluminium have been very
important in aerospace manufacturing as the introduction of metal skinned aircrafts. A6063
alloys with somewhat higher tensile strengths than the usually used kinds of steel. In the present
12
investigation, aluminium based metal matrix composites containing 2, 4, 6wt% Al2O3 with
graphite particles of 2wt% and fourth and fifth composition of only 2wt% of Al2O3 and graphite
respectively were successfully synthesized by vortex method. The matrix materials used in this
study was A6063 Alloy.

3.1.2 Al2O3

Aluminium oxide is a chemical compound of aluminium and oxygen with chemical formula
Al2O3. It is the most commonly occurring of several aluminium oxides and specifically
identified as aluminium oxide. It is commonly called alumina, and may also be called alkoxide,
alkoxide or alundum depending on particular forms or applications. It is in the form of the
precious gemstones ruby and sapphire. Al2O3 is significant in its use to produce aluminium
metal, as an abrasive owing to its hardness, and as a refractory material owing to its high
melting point.

Al2O3 is an electrical insulator but has a relatively high thermal conductivity for a
ceramic material. Aluminium oxide is insoluble in water. In its most commonly occurring
crystalline form, called corundum or α-aluminium oxide, its hardness makes it suitable for use
as an abrasive and as a component in cutting tools.

Metallic aluminium is very reactive with atmospheric oxygen, and a thin passivation
layer of aluminium oxide forms on any exposed aluminium surface. This layer protects the
metal from further oxidation.

Fig 3.1 Al2O3 Powder

13
3.1.3 Graphite

Graphite is a crystalline form of the element carbon. It occurs naturally in this form and is the
most stable form of carbon under standard conditions. Under high pressures and temperatures
it converts to diamond. Graphite occurs in metamorphic rocks as a result of
the reduction of sedimentary carbon compounds during metamorphism. Graphite's high
thermal stability and electrical and thermal conductivity facilitate its widespread use as
electrodes and refractories in high temperature material processing applications. However, in
oxygen-containing atmospheres graphite readily oxidizes to form carbon dioxide at
temperatures of 700oC

Graphite is an electrical conductor, Graphite and graphite powder are valued in

industrial applications for their self-lubricating and dry lubricating properties. The use of
graphite as a refractory material began before 1900 with the graphite crucible used to hold
molten metal. Graphite blocks are also used in parts of blast furnace linings where the high
thermal conductivity of the graphite is critical. Natural and synthetic graphite are used to
construct electrodes in major battery.

Natural graphite has found uses in zinc-carbon batteries, in electric motor brushes, and various
specialized applications. Graphite of various hardness or softness results in different qualities
and tones when used as an artistic medium.

Fig 3.2 Graphite powder

14
3.2 Fabrication of Composites

3.2.1 Stir Casting Equipment

 Muffle Pre-heater
 Muffle Furnace
 Electrical stirrer
 Die

3.2.1.1 Muffle Pre-heater

High temperature muffle pre-heater shown in Figure 3.3 is doubled walled chamber inner
made of 4 nos. sillimanite refractory slabs and outer made of cold rolled mild steel sheets
finished in powder coating. Insulation by ceramic fibre blankets to minimize radiation heat
loss. Doubled walled insulated door mounted on heavy-duty hinges is provided with effective
locking arrangements.

Fig 3.3 Muffle Pre-Heater

3.2.1.2 Melting Furnace

In this melting furnace shown in Fig 3.4, as well, the heating spirals are outside the
furnace chamber and are covered with a resilient ceramic muffle, so aggressive flue gases
cannot even reach them. The furnace is furthermore also protected with exhaust ventilation that
prevents condensation of vapours during firing.

15
3.2.1.3 Electrical Stirrer

The stirrer shown in Fig 3.4 can stir high viscosity medium or thick liquid and stirring
speed can be regulated easily during operation. The stirrer is an ideal device in the field of
biological material, physics and chemistry, reagent, building material, cosmetics and health
products etc. for products developing, for products developing, quality control and material
testing. This electrical stirrer can capable of creating the vortex in crucible which leads to
uniform distribution of reinforcement in matrix material.

Fig 3.4 Stir casting machine

16
3.2.1.4 Die

For the required shape from casting the dies are used. In the stir casting technique, after the
casting the molten composite is poured in dies then we acquire the specimen of composites.
Therefore, in the dies the molten composite is solidified inti the required shape. The die for the
specimen is shown in Fig 3.5,

Fig 3.5 Die for specimen

3.2.2 Stir Casting Process

The synthesis of these composites was carried out by stir casting technique. A6063 alloy were
taken into melting furnace as shown in Fig 3.6, (Bottom pour type stir casting machine) and
melted. After maintain the temperature at 800oC, 1% of magnesium was added in order to
improve the wettability and decrease the porosity. A vortex was created using mechanical
stirrer made of graphite. While stirring was in process, the pre-heated particulates Al2O3 and
graphite at 450oC for one and half an hour, were introduced into the melt. Care has been taken
to ensure to continuous and smooth flow of the particles addition in the vortex.

The molten metal was stirred at 600 rpm under argon gas cover. Hexachloro ethane
used as degasifying agent. The stirring was continued for about 2 minutes after addition of
reinforcement particles for uniform distribution in the melt. Still, the melt with reinforcement
was in stirring condition the same was poured through the bottom pouring unit into the die
directly as shown in Fig 3.5, and the specimen after casting are shown in Fig 3.7,

17
 The stir casting method is repeated by varying the weight percentages of
reinforcement by 2%, 4% and 6% of Al2O3 and keeping the weight percentage of graphite as
constant (2%).

Fig 3.6 Melting Furnace

Fig 3.7 Specimen after casting

18
3.3 Hardness Test

Hardness testing measures a material’s strength by determining resistance to penetration.

There are many methods to determine the hardness of specimens, one of the best method is
Brinells hardness test. The hardness of the alloy and composite was evaluated by using brinell
hardness tester. An average of two readings was taken for each hardness value. Brinells
hardness studies were carried out for the investigated materials using micro hardness tester
with 187.5 kgf load. The indentation time for the hardness measurement was 10 seconds. An
average of two reading was taken for each hardness value in brinells hardness testing machine
as shown in Fig 3.8.

Fig 3.8 Brinells hardness tester

3.4 Tensile Test

Tensile test specimens with 10mm gauge diameter were machined from casted materials
Fig 3.9 shows tensile specimen measurements and Fig 3.10 depicts the experimental setup.

Tensile properties of both alloy and composites were determined by means of

testing machine as per American society for testing and materials E 8- 04 standards. Plotting
has done continuously through a data attainment system with an electronic extensometer.

19
Fig 3.9 Tensile specimen measurements

Fig 3.10 Universal testing machine

20
The tensile specimens before testing and after testing as shown in Fig 3.11(a) and Fig 3.11(b),

Fig 3.11 (a): Tensile specimen before testing

Fig 3.11 (b): Tensile specimen after testing

21
3.5 Compression Test

A compression test is any test in which a material experiences opposing forces that push inward
upon the specimen from opposite sides or is otherwise compressed, “squashed”, crushed, or
flattened. The test sample is generally placed in between two plates that distribute the applied
load across the entire surface area of two opposite faces of the test sample and then the plates
are pushed together by a universal test machine causing the sample to flatten. A compressed
sample is usually shortened in the direction of the applied forces and expands in the direction
perpendicular to the force. A compression test is essentially the opposite of the more common
tension test. The goal of a compression test is to determine the behaviour or response of a
material while it experiences a compressive load by measuring fundamental variables, such as,
strain, stress, and deformation. By testing a material in compression the compressive strength,
yield strength, ultimate strength, elastic limit, and the elastic modulus among other parameters
may all be determined. Fig 3.12 shows the testing on specimen.

Fig 3.12 Testing on specimen

22
3.6 Wear Test

This test method describes a laboratory procedure for determining the wear of materials during
sliding using a pin-on-disc apparatus. For the pin-on-disc wear test, two specimens are required.
One, a pin with a radius tip, is positioned perpendicular to the other, usually a flat circular disc.
A ball, rigidly held, is often used as the pin specimen. The test machine causes either the disc
specimen or the pin specimen to revolve about the disc centre. In either case, the sliding path
is a circle on the disc surface. The pin specimen is pressed against the disk at a specified load
usually by means of an arm or lever and attached weights.

Wear results are reported as volume loss in cubic millimetres for the pin and the disk
separately. When two different materials are tested, the amount of wear is determined by
measuring appropriate linear dimensions of both specimens before and after the test, or by
weighing both specimens before and after the test. If linear measures of wear are used, the
length change or shape change of the pin, and the depth or shape change of the disk wear track
(in millimetres) are determined by any suitable metrological technique, such as electronic
distance gaging or stylus profiling. Fig 3.13 shows the pin on disc setup

Fig 3.13 Pin on Disc setup

3.7 Density Measurement

The physical properties of the composite play an important role in the measured mechanical
properties. The specific gravity or density of a solid is a property that is conveniently measured
to identify a material, to follow physical changes in a sample, to indicate degree of uniformity
among different sampling units or specimens, or to indicate the average density of a large item.
Changes in density of a single material are due to localized differences in crystallinity, loss of

23
plasticizer, absorption of solvent, or to other causes. It is possible that portions of a sample
differ in density because of their differences in crystallinity, thermal history, porosity, and
composition. A test method to determine the density of a material is detailed in ASTM standard
D792-91. This method is used determine the density of the composite and its constituents. Fig
3.14 shows the electron specific gravity balance. The density of a material is determined using
its weight in air and in water. The densities of air (negligible) and water are taken as known
parameters in this test. The volume of the specimen is determined from the difference between
the weight of the material in air and the weight in water and using the known density of water.

Fig 3.14 Electronic specific gravity balance

3.8 Microstructure Analysis

Microstructure of reinforced composites are identified by using inverted metallurgical

microscope and the images are analysed. Microstructure analysis is used among the various
industries to find the structure of the material at various stages of testing. Thus the analysis
explains about the structure of the materials. Generally microstructure analysis is done by using
the optical microscope but now a days there is development done with a digital analysis using
Image progression methods. The influence of the cooling rate on the alloy microstructure was
investigated using computer aided image analysis. Microstructure specimens were sawed by
hack saw and machined by lathe from the cast produced composites. The surface of specimen

24
was prepared with emery polishing papers of grades 100, 200, 300, 400 followed by 1/0, 2/0,
3/0, 4/0 as shown in Fig 3.15. The emery polished specimen is shown in Fig 3.16,

Fig 3.15 Emery polishing papers

Fig 3.16 Emery polished specimen

Now, all the specimens are to be taken for disc polishing in order to obtain smooth reflecting
surface as shown in given Fig 3.17 and Fig 3.18 which were to be tested in inverted
metallurgical microscope as shown in Fig 3.19

Fig 3.17 Disc polishing Apparatus

25
 Fig 3.18 Disc polished specimens

Fig 3.19 Inverted metallurgical microscope

26
 CHAPTER - 4

RESULTS AND DISCUSSION

27
 RESULTS AND DISCUSSIONS

4.1 Hardness Test

The hardness of a material is a physical parameter indicating the ability of resisting local plastic
deformation. The hardness test is conducted on the Al2O3 and graphite particles reinforced
composites under the force of 187.5Kgf with dwell of 10 seconds in brinell’s hardness test
machine. The hardness test results are tabulated below.

Samples Hardness (BHN)

A6063 alloy 50
A6063 – 2%Al2O3 composite 45
A6063 – 2%Al2O3+2%Graphite composite 51
A6063 – 4%Al2O3+2%Graphite composite 62
A6063 – 6%Al2O3+2%Graphite composite 58
Table 4.1 Hardness test results

Table 4.1 shows the comparison of hardness test results of reinforced composites. It is
observed from bar chart that, the hardness of 4% Al2O3 and 2% graphite reinforced A6063
composite is having higher value and 2%Al2O3 and 2% graphite reinforced A6063 composite
is having low value

70
62.41
58.34
60
51.04 50
50
44.66
Hardness (BHN)

40

30

20

10

0
2%Al2O3 2%Al2O3+ 2%Gr 4%Al2O3+2%Gr 6%Al2O3+2%Gr A6063
% of reinforcement
Fig 4.1: Percentage of reinforcement vs Hardness (BHN)

28
4.2 Tensile Test

Ultimate tensile strength (UTS) is the maximum stress that a material can withstand while
stretched or pulled. The tensile test is conduct on the A6063 and Al2O3 and graphite reinforced
composite in universal testing machine. The results are tabulated below.

Samples UTS(MPa)
A6063 alloy 145
A6063 – 2%Al2O3 143
composite
A6063 – 2%Al2O3+2%Graphite composite 87

A6063 – 4%Al2O3+2%Graphite composite 156

A6063 – 6%Al2O3+2%Graphite composite 93

Table 4.2 Tensile test results

Table 4.2 shows the comparison of tensile test results of reinforcement composites. It is
observed from the bar chart that, the ultimate tensile strength (UTS) of 4% Al 2O3 reinforced
A6063 composite is high and that of 2% Al2O3 reinforced A6063 composite is low.

180
156
160
143 145
140

120
UTS (MPa)

100 93
87
80

60

40

20

0
2%Al2O3 2%Al2O3+2%gr 4%Al2O3+2%gr 6%Al2O3+2%gr A6063
% of reinforcement

Fig 4.2: Percentage of reinforcement vs UTS (MPa)

29
4.3 Compression Test

Compressive strength or compression strength is the capacity of a material or structure to

withstand loads tending to reduce size, as opposed to tensile strength, the compression test is
conducted on the A6063 and Al2O3 and graphite reinforced composite in universal testing
machine. The results are tabulated below.

Samples UCS(MPa)
A6063 alloy 90
A6063 – 2%Al2O3 composite 204

A6063 – 2%Al2O3+2%Graphite composite 67

A6063 – 4%Al2O3+2%Graphite composite 95

A6063 – 6%Al2O3+2%Graphite composite 57

Table 4.3: Compression test results

Table 4.3 shows the comparison of compression test results of reinforcement composites. It is
observed from the bar chart that, the Ultimate compression strength of 4% Al2O3 reinforced
A6063 composite is high and that of 6% Al2O3 reinforced A6063 composite is low.

30
A6063composite.
250

204
200

150
UCS (MPa)

95 90
100
67
57
50

0
2%Al2o3 2%Al2o3+2%gr 4%Al2o3+2%gr 6%Al2o3+2%gr A6063
% of reinforcement

Fig 4.3 Percentage of reinforcement vs UCS (MPa)

4.4 Density Measurement

Density is a fundamental concept in physics and engineering. It is defined as the mass of the
material per unit its volume. Since, density and mass are so closely related, you can calculate
the mass. The density test on the reinforced composite using the principle of Archimedes.

Samples Density(g/cc)

A6063 alloy 2.69

31
 A6063 – 2%Al2O3 composite 2.45

A6063 – 2%Al2O3+2%Graphite composite 2.60

A6063 – 4%Al2O3+2%Graphite composite 2.40

A6063 – 6%Al2O3+2%Graphite composite 1.98

Table 4.4: Density measurements results

Table 4.4 shows the comparison of density test results of reinforced composites. As the weight
% of alumina increases there is considerable decrease in density.

32
 4.5 Microstructure Analysis

Microstructure analysis is done under inverted metallurgical microscope and the following
images are obtained.

Fig 4.4: Microstructure of A6063+2%Aluminium oxide+2%graphite

33
Fig 4.5: Microstructure of A6063+ 4% Aluminium oxide+2%Graphite

34
Fig 4.6: Microstructure of A6063+ 6%Aluminium oxide+ 2%Graphite

35
 Fig 4.7: Microstructure of A6063+ 2%Aluminium

The images obtained from optical microscope are shown in Fig 4.4, Fig 4.5, Fig 4.6, Fig 4.7,
and from the above Figures we can conclude that there is uniform distribution of reinforcement
in the matrix phase.

36
4.6 Wear Test

The wear test was conducted for a period of 8 min and the track velocity was 1.0 m/sec. In all
the results it was evident that the resistances to wear increases with increasing Al2O3 and
Graphite particulate content. With increasing percentage of reinforcement, the amount of
particle present strengthens the matrix and hence more wear resistance was observed. The
MMCs with lower weight fractions of Al2O3 and Graphite particulate underwent large wears,
and the wear increased almost linearly with time. The sliding wear behavior of 4%Al2O3 and
2% graphite composite for various normal loads of 10N,20N and 30N was shown in Figures
respectively.

. Fig 4.8 Graphs of 10 N Normal load

37
Fig 4.9 Graphs of 20 N Normal load

38
Fig 4.10 Graphs of 30 N Normal Load

39
% composition Load (N) Wear (Microns) Coefficient of friction

10 40 0.69

A6063 – 2%Al2O3 + 20 7 0.46

2%Gr Composite
30 42 0.50

10 5 0.56

A6063 – 4%Al2O3 + 20 3 0.45

2%Gr Composite
30 15 0.49

10 19 0.58

A6063 – 6%Al2O3 + 20 23 0.47

2%Gr Composite
30 45 0.47

Table 4.5 Wear test results

Table 4.5 shows the Wear test results of reinforcement composites. It is observed that, the wear
for 4% Al2O3 and 2% graphite reinforced A6063 composite is having lower value. The
coefficient of friction is lowest for 4% Al2O3 and 2% graphite among all the fabricated
composites.

40
 Chapter -5

CONCLUSIONS

In the present work detailed investigation was carried out on the A6063 reinforced with
Al2O3 and graphite composites. The investigation includes manufacturing of composites
through stir casting technique and evaluation of mechanical properties like hardness, tensile,
compression, wear, density and microstructure according to the experimental plan. The
following conclusions can be drawn from the present investigation.

 A6063 reinforced with Al2O3 and graphite composites were produced by stir casting
route successfully.
 The hardness of composites increases with increasing in the amount of Al2O3 in 2%
and 4%and then decreases in 6%Al2O3 and graphite reinforcements.
 The tensile strength of the composites increases with increasing in the amount of Al2O3
in 2% and 4%and then decreases in 6%Al2O3 and graphite reinforcements.
 The compressive strength of the composites increases with increasing in the amount of
Al2O3 in 2% and 4%and then decreases in 6%Al2O3 and graphite reinforcements.
 The density of the composites decreases with increasing the percentages of Al2O3 and
graphite particulates with a minimum value of (1.98g/cc).
 From the microstructure, we can conclude that there was a good interfacial bonding
between the Al2O3 and graphite particles and matrix phase.
 The wear of composites and coefficient of friction decreases upto 4% of Alumina and
then increases.

41
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