FABRICATION AND EXPERIMENTAL TESTING OF

ALUMINIUM7075 WITH GRAPHITE METAL

MATRIX COMPOSITE MADE

OF STIR CASTING

A PROJECT REPORT

Submitted by

K.S. AJHAY KRISHNA 513116114002

S. ARUN KUMAR 513116114006
S. ASHWIN VINO 513116114009
S. HARANYA 513116114028
In partial fulfillment for the award of the degree of

BACHELOR OF ENGINEERING
IN

MECHANICAL ENGINEERING

THANTHAI PERIYAR GOVERNMENT INSTITUTE OF TECHNOLOGY

VELLORE-632002.

ANNA UNIVERSITY: CHENNAI 600025

MARCH 2020

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 ANNA UNIVERSITY: CHENNAI 600 025
BONAFIDE CERTIFICATE
Certified that this project report “FABRICBTION AND EXPERIMENTAL
TESTING OF ALUMINIUM7075 WITH GRAPHITE METAL MATRIX
COMPOSITE MADE OF STIR CASTING” is the Bonafide work of

K.S. AJHAY KRISHNA 513116114002

S. ARUN KUMAR 513116114006

S. ASHWIN VINO 523116114009

S. HARANYA 513116114028

who carried out the project under my supervision

SIGNATURE SIGNATURE

Dr . PRAVEEN RAJ, M.E., Ph.D., Prof. T. SUJA, M. TECH., Ph.D.,

HEAD OF THE DEPARTMENT, PROJECT GUIDE, ASST.PROFESSOR

Department of Mechanical Engineering, Department of Mechanical Engineering,

Thanthai Periyar Government Institute Thanthai Periyar Government Institute

Of Technology, Vellore- 632002. Of Technology, Vellore- 632002.

Project Viva Voce Examination held on …………………

INTERNAL EXAMINER EXTERNAL EXAMINER

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 ACKNOWLEDGE
We wish to express our sincere thanks to our Principal
Dr. V. KUMAR, M.E., Ph.D, for encouraging us to do our project and
offering adequate duration in completing our project.

We would like to express our sincere thanks to our Head

of the Department Dr. P. Praveenraj, M.E., Ph.D, who has inspired
profoundly and Prof. P.T.SUJA, M.TECH., Ph.D, who guided us
technically in accomplishing this project & for providing all the necessary
facilities to complete our project work successfully.

We would also thank our faculty advisor, Prof. K.

Anbukarasi, M.E., Ph.D., for giving constant support in doing this project.

We extend our thanks to all professors, Dr. G.

Padmanaban M.E., Ph.D., Prof. E. Elavenil M.E., Prof. P.
Vijayalakshmi M.E., Prof. T. Suja M.TECH., Prof. K. Anbukarasi M.E.,
Ph.D., Prof. K. Bharathi M.E., and Prof. M. KanthaShoba M.E., who
have helped us throughout our project work.

In conclusion, we express our sincere thanks to our

project coordinators, faculty members and friends who have helped us
throughout the project work and our parents who helped us thoroughly for
shaping our things well in order.

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S.NO Content PAGE NO.

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 ABSTRACT

Composite materials are now utilized for many industrial applications

for its properties. The objective of this project is preparation of Aluminium- grahite
composite by stir casting technique with 20% of Graphite with 99.5% of aluminium.
The fabricated mateal matrix composite material is undergone the following testings
Wear (abrasive and corrosive), tensile, hardness, chemical test and hardness.
Composite could mean almost anything if taken at face value since all materials is
composed of dissimilar subunits. This module introduces basic concepts of stiffness
and strength underlying the mechanics of advanced composite material. Metal Matrix
Composite (MMCs) are one of the important innovations in the development of
advanced materials. Among various matrix materials available, aluminium and its alloy
are widely used in the fabrication of MMCs. AL based MMCs with various castings like
SiC, AL203, Zircon, Graphite and mica Because of the likely possibilities of these
combinations in forming highly desirable of these combinations in formation highly
desirable composite.

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 INTRODUCTION

Aluminum and its alloys are widely used in a large number of

industrial applications due to their excellent combination of properties, e.g. good
corrosion resistance, excellent thermal conductivity, high strength to weight ratio,
easy to deform, and high ductility. Aluminum alloys have been generally used in
manufacturing automobile and aircraft components because of high strength to
weight ratio in order to make the moving vehicle lighter, which results in saving in
fuel consumption, household appliances, containers, and electronic devices. For
these reasons, a number of investigations into its electrochemical behavior and
corrosion resistance have been carried out in a wide variety of media.

In recent years the aerospace, military and automotive industries

have been promoting the technological development of composite materials to
achieve good mechanical strength/density and stiffness/density ratios. Composite
materials usually refer to a combination of several materials that provide unique
combination of properties which cannot be obtained by the individual constituents
acting alone. The corrosion behaviour of the composites in the various environments
that the material is likely to encounter is one important consideration when choosing
a suitable material for a particular purpose. It has been established by various
research studies that the corrosion behaviour of a metal-matrix composite is decided
by numerous factors such as the composition of the alloy, the matrix microstructure,
the dispersoid used, its size and distribution in the matrix, the nature of the interface
between the dispersoid and the matrix, and even the technique adopted for
preparing the composite. Even a very small change in any one of these factors can
seriously affect the corrosion characteristics of the material. One of the main
obstacles to the use of metal-matrix composites (MMCs) is the influence of
reinforcement on corrosion resistance. This is particularly important in aluminium
alloy based composites, where a protective oxide film imparts corrosion resistance.
The addition of a reinforcing phase could lead to further discontinuities in the film,
increasing the number of sites where corrosion can be initiated and rendering the
composite liable to severe attack.

Graphite is well known as a solid lubricant and its presence in

aluminium alloy matrices makes the alloy, self-lubricating. Aluminium alloys
reinforced with graphite fibers are emerging as potential structural materials for
aerospace needs and their outstanding mechanical properties have drawn
considerable scientific attention to the exploration of their possible applicability to
high-technology naval applications. Aluminium alloys dispersed with graphite
particles are known as potential materials for tribiological applications such as
bearings, bushings, pistons, etc. The reason for the excellent tribiological properties

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of graphitic aluminium is that aluminium alloy matrix yields at low stresses and
deforms extensively, which enhances the deformation and fragmentation of the
surface and sub-surface graphite particles even after short running-in period. This
provides a continuous film of graphite on the mating surfaces which, essentially,
prevents metal to metal contact and hence prevents seizure.

The objective of this work was to study the effect of different

percentages of graphite, namely 1, 2, and 3 %, on the corrosion behaviour of pure
aluminium after their immersion for 40 min and 72 h in freely aerated 3.5% NaCl
solutions. A particular attention was paid to the effect of graphite on the pitting
corrosion of aluminum. To achieve this objective, the study was carried out using
different electrochemical techniques such as cyclic potentiodynamic polarization,
chronoamperometric currenttime variations, and electrochemical impedance
spectroscopy, along with optical microscopy, SEM, and EDX examinations.

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 LITERATURE SURVEY

This review presents mechanical and tribological properties

of AMMCs containing single or multiple reinforcements. Fabrication was done by
using stir casting method. Addition of Al2O3 (alumina) as reinforcement to aluminium
alloy gives an improvement in its mechanical and tribological properties. Graphite
reinforcement improves the machinability of aluminium and acts as self-lubricating
property. SiC particles show higher hardness of aluminium. Organic agricultural
wastes utilized for reinforcement are fly ash, bagasse ash and coconut ash helps to
improve the tensile strength, yield strength, etc.

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METHODOLOGY

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