2017 First International Conference on Recent Advances in Aerospace Engineering (ICRAAE)

MECHANICAL PROPERTIES OF ALUMINIUM

ALLOY AA2219 REINFORCED WITH
GRAPHITE
G.Yuvaraj1, V.Bhuvaneswari2, G. Vignesh3, L. Vairamuthu4
1
Assistant Professor, 2Assistant Professor, 3UG Scholar, 4UG Scholar,
KPR institute of Engineering & Technology
Coimbatore, India
1
yuvarajg75@gmail.com, 2bhuvaneswari.v@kpriet.ac.in, 3 harry.vignesh97@gmail.com, 4vairamuthulva@gmail.com

Abstract— Aluminium alloy-based metal matrix composites
(AMMCs) normally used in wear resistant and light weight
applications. In this work, mechanical properties like Hardness
test and SEM analysis of Aluminium Alloy AA2219 is reinforced
with graphite powder in the ratio of 1.5%, 3%, 4.5% (in terms of
weight) was done. Fabrication of AA2219 with graphite was done
by using stir casting method, maintained at the temperature of
1023 K and running speed at 500 rpm. The proposal work is
aimed at obtaining a composite material with good surface finish
and less casting effects. By testing, we obtained the increase in
graphite percentage, hardness values is decreased between 37.14
to 32.65 BHN. From the X-Ray diffraction analysis, Peak value of
alumina is attained in the range of 44°-45°, but by adding
graphite reinforcement, the peak value is obtained in the range of
38°-39°, which results in phase change.
Keywords—Aluminum alloy ; Graphite ; Mechanical Properties ;
Stir Casting Method
I. INTRODUCTION
Today’s most important demand of an automobile
industry is to reduce energy consumption and pollution in an
automobile. This could be done in one way by increasing the
efficiency. For the properties like strength, good corrosion
resistance and high machinability must be improved. This
challenge could be accomplished by Metal Matrix
Composites. Metal Matrix Composites (MMCs) having the
properties of light weight, high specific strength, good wear
resistance and low thermal expansion coefficient.
A. P. Divecha et al. [1] done the experimental studies on
silicon carbide reinforced with rice and aluminium, made by
conventional metal working techniques. Metin Kok [2]
investigated the mechanical properties of the composites such
as hardness and tensile strength of Al2O3 particle content in
three different sizes. Ashish Srivastava et.al. [3] did the review
of the fabrication and characterization of hybrid metal matrix
with summarizing the recent developments covering
Aluminium used in manufacturing process. S A Mohan
Krishna et.al. [4] studied the effect of aluminium alloy
reinforced with Silicon Carbide and Graphite particles have
been prepared by stir casting technique. Dinesh M. Pargunde
[5] done the modest attempt would be made to develop
Aluminum based Silicon Carbide (AlSiC) with an objective to
develop a conventional low cost method of producing Metal
Matrix Composites (MMCs). M. Sambathkumar et.al.[6]
investigated the micro scale deformation behavior of the
Aluminum 7075 hybrid metal matrix composite by their two
dimensional microstructure with the aid of finite element
method. Bhaskar Chandra Kandpal et.al. [7] the recent
progress in production technologies of metal matrix
composites is reviewed. Vengatesh.D et.al. [8] discussed about
recent composite technology and performance behaviour of
the material mixed with nonmetal and analyzed the
mechanical properties and fabrication technique. D. Sujan
et.al. [9] studied the reinforcement of aluminium metal matrix
composites with silicon carbide (SiC) and Aluminium oxide
(Al2O3) to evaluate their physical and mechanical properties.
Saurobh Poddar et.al. [10] studied the density, electrical
conductivity, hardness and microstructural behaviour of an
Aluminium alloy T6 discontinuously reinforced with varying
amounts of natural graphite particles. Kamaal Haider et.al.
[11] studied the Reinforcement of silicon carbide and Al2O3
by stir casting technique, result indicated that the developed
method is quite successful and there is an increase in the value
of tensile strength, hardness value. Livia Serio et.al.[12]
evaluated the influence of the process parameters on the
mechanical properties of aluminum plates (AA 5754-H111)
with a thickness of 6 mm, welded by means of Friction Stir
Welding, analysis involved the process parameters such as the
welding tool rotation speed and the welding tool travel speed.
S. H. J. Lo [13] investigated the mechanical properties of a
Zn-Al alloy reinforced with alumina fibres were evaluated.
Tensile, compression and impact properties were determined
at 25, 100 and 150°C. V.Ramakoteswara Rao et.al. [14]
investigated the AA7075 Alloy as the matrix metal and
Titanium carbide (TiC) particles (2-10%) with an average
particulate size of 2μmas reinforced material were processed
by stir casting route and inferred the results are good in tensile
properties. Eras Atas et.al. [15] analysed the wear using
Computerized pin on disc wear tester with counter surface as
EN32steel disc (58-60 HRC) and cylindrical pin as the
composite specimens and proved the hardness strength is
good. D M Nuruzzaman et.al. [16] three different types Al-
SiC composite specimens having 10%, 20% and 30% volume

978-1-5090-4983-7/17/$31.00 © 2016 IEEE

 2017 First International Conference on Recent Advances in Aerospace Engineering (ICRAAE)
fractions of silicon carbide were fabricated, the results mixing process. In this process, the matrix material (adding
obtained results show that density and hardness of the graphite with aluminium) is heated to above its liquids
composites are greatly influenced by volume fraction of temperature. Hence the metal is totally melted. The melt is
silicon carbide particulates. Vijaya Ramnath et.al. [17] done then cooled down to a temperature between the liquids and
the mechanical investigation of aluminium alloy, alumina solidus points and kept in a semi-solid state.
(Al2O3) and boron carbide metal matrix composites. K.
Shirvanimoghaddam et.al.[18] studied the influence of
processing temperature and inclusion of micron-sized
B4C,TiB2 and ZrSiO4 on the mechanical performance of
aluminium matrix composites was fabricated through stir
casting. From the literature survey, we traced out very rarely
used the combination of graphite along with aluminium alloy.
In the present work, the reinforcement of graphite in different
percentage with Aluminium AA2219 was studied, and the
results obtained good in surface roughness and porosity
strength.

II. MATERIALS USED

Aluminium alloys (AA2219) have very good corriosion

resistance properties, it bought it from ladhan pvt ltd.
Wherever, Graphite powder is added inorder to improve the
toughness of aluminium alloys and it bought it from lobaine,
Coimbatore. It is mixed in different percentage and obtain the
good machinability property. General properties of aluminum
alloy and graphite powder is seen in table 1 & table 2.

TABLE 1. MECHANICAL PROPERTIES OF GRAPHITE POWDER Fig.1. STIR CASTING SETUP

S.no. Properties of Graphite Values

B. Composition of specimens prepared
1
Bulk density(g/cm3) 1.6-2.3
2 Total weight is 750grams required to fabricate the composite
Porosity(%) 0.6-46 bar (100%).
3 1. Aluminium – 738.75gm with 1.5% of WC- 11.25gm.
Modulus of Elasticity (Gpa) 7-19
4 2. Aluminium – 727.5gm with 3% of WC- 22.5gm.
Compressive strength (Mpa) 20-210 3. Aluminium – 716.25gm with 4.5% of WC-33.75gm.
5
Thermal Conductivity (W/m.k) 240
IV. TESTS CONDUCTED
TABLE II: MECHANICAL PROPERTIES OF ALUMINUM ALLOY A. Brinell Hardness Test
S.no. Properties of Aluminum Values
1 Density(g/cc) 2.84
III. METHOD OF MAKING THE COMPOSITE
2 Hardness(BHN) 49.5
A. Stir casting
3 Modulus of elasticity(Gpa) 73.1
Stir casting is a liquid state method of composite materials 4 Shear strength(Gpa) 285
fabrication, (is shown in fig 1) in which a dispersed phase
(ceramic particles, short fibers) is mixed with a molten matrix 5 Thermal conductivity(W/m-K) 120
means of mechanical stirring. The liquid composite material is 6 Melting point (◦c) 643-750
then cast by conventional casting methods and may also be
processed by conventional metal forming technologies.
The hardness is expressed in Brinell Hardness Number
(BHN) computed by dividing the load in kilograms by the area
In a stir casting process, the reinforcing phases are of indentation made by the ball measured in square
distributed into molten matrix by mechanical stirring. An millimeters. American Society for Testing And Material’s
interesting recent development in stir casting is two-step standard BH test is ASTM E-10. For measurement up to BHN
 2017 First International Conference on Recent Advances in Aerospace Engineering (ICRAAE)
500, brinell hardness is equal to 0.96 times the Vickers
hardness. Method of measuring the hardness of a material by
pressing a chromium-steel or tungsten-carbide ball (commonly
one centimetre or 0.4 inch in diameter) against the smooth
material surface under standard test conditions and the
specimenis shown in fig 4.

B. Scanning Electron Microscopy

Scanning Electron Microscopy (SEM), also known as SEM

analysis or SEM microscopy, is used very effectively in
microanalysis and failure analysis of solid inorganic materials.
SEM is performed at high magnification, generates high
resolution images and precisely measures very small features
Fig 3. X-Ray Diffraction setup
and objects.SEM provides detailed high resolution images of
the sample by rastering a focussed electron beam across the
surface and detecting secondary or backscattered electron V. RESULTS AND DISCUSSIONS
signal is shown in fig 2.
A. Hardness test results

The hardness test results is done in three different diameter of

the indent ball with three different composition of graphite
along with AA2219 alloy. Hence it proves increasing in
percentage of graphite, improves the hardness of the specimen
either by using pure aluminum alloy AA2219. Table III, IV
shows the trials of three different percentage of graphite.

TABLE III. HARDNESS TEST RESULTS IN DIFFERENT GRAPHITE

PERCENTAGE

Force Intender
Graphite Trial I Trial II Trial III
applied dia
(%) mm mm mm
(N) (mm)

1.5 250 5.0 2.8 2.8 2.8

Fig 2. SCANNING ELECTRON MICROSCOPE

C. X-Ray Diffraction Method

3 250 5.0 2.9 2.8 2.9
XRD-analysis is an analytical designed to provide more in
depth information about crystalline compounds, including
identification and quantification of crystalline phases. This 4.5 250 5.0 3.1 2.9 2.9
is a useful tool when trying to positively identify a
contaminant or corrosion product, and for identification of
foreign phases for purity analyses of crystalline powders. It
is shown in fig 3.Avoid combining SI and CGS units, such
as current in amperes and magnetic field in oersteds. This TABLE III. HARDNESS TEST RESULTS IN DIFFERENT GRAPHITE
often leads to confusion because equations do not balance PERCENTAGE
dimensionally. If you must use mixed units, clearly state
the units for each quantity that you use in an equation. Brinell
Force Intender Average Number
Graphite
applied dia
(%)
(N) (mm) dia(mm) (BHN)

1.5 250 5.0 2.8 37.14

3 250 5.0 2.845 34.8

 2017 First International Conference on Recent Advances in Aerospace Engineering (ICRAAE)

Brinell

Hardness number
Force Intender Average Number
Graphite
applied dia
(%)
(N) (mm) dia(mm) (BHN) 35
34
4.5 250 5.0 2.965 32.65 33
32
31

1.5 3 4.5
% of Graphite
 
Fig 5. Hardness graph

B. Scanning Electron Microscopy Results

SEM provides images with magnification up to ~X50,000

allowing submicron- scale feature to be seen Rapid, high
resolution imaging with identification of elements present.
Characterization of particulates and defects. SEM provides
detailed high resolution images of the sample by rastering a
focussed electron beam across the surface and detecting
secondary or backscattered electron signal. The SEM is also
 capable of performing analyses of selected point location on
the sample.
Some of the microstructural images, that we seen before and
after conducting porosity test of given workpiece in the fig 6
and fig 7,8 of composite. As the graphite percentage is
increases the porosity is also increased which results in less
casting defects.



Fig 4. Specimen and Hardness tested specimen


FIG 6. MICRO STRUCTURE OF 1.5% OF GRAPHITE WITH MAGNIFICATION OF 500


 2017 First International Conference on Recent Advances in Aerospace Engineering (ICRAAE)
Fig 7. Micro Structure of 3% of Graphite with Magnification of 500
Fig 8. Micro Structure of 4.5% of Graphite with Magnification of 500
C. XRD-analysis
It is an analytical designed to provide more in depth
information about crystalline compounds, including
identification and quantification of crystalline phases. This is a
useful tool when trying to positively identify a contaminant or
corrosion product, and for identification of foreign phases for
purity analyses of crystalline powders. XRD analysis is the
unique method in determination of crystllinity of a
compound.
Peak value of alumina is attained in the range of 44°-45°in the
fig 9. In reinforcement with graphite the peak value is
obtained in the range of 38°-39° which results in phase change
occurred before the actual phase change of aluminium.
VI. CONCLUSION
The following conclusions were drawn from the AA2219
metal matrix composite after conducting the experiments and
analyzing the results:
Based on hardness test results, the sample A (Al 98.5% &
Graphite 1.5%) is having maximum hardness of 37.14 BHN.
Based on the X-ray diffraction results, Peak value of
alumina is attained in the range of 44°-45°. In reinforcement
with graphite the peak value is obtained in the range of 38°-
39° which results in phase change.
Based on the Scanning Electron Microscopy results, the
sample A (Al 98.5% & graphite 1.5%) is having less pore
when compared to other composition.
Fig 9. XRD result graph
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