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Study of Mechanical and Tribological Characteristics of Aluminium Alloy

Reinforced with Sugarcane Bagasse Ash

Conference Paper · December 2018

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National Institute of Technology Sikkim
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 An International Conference on Tribology,
TRIBOINDIA-2018
th th
13 -15 December 2018, VJTI, Mumbai, India

Study of Mechanical and Tribological Characteristics of Aluminium

Alloy Reinforced with Sugarcane Bagasse Ash

Anwesh k. Virkunwar a, Shouvik Ghosh b, Ranjan Basak c

a, c
Mechanical Engg. Department, National Institute of Technology, Sikkim, India.
b
Mechanical Engg. Department, Jadavpur University, Kolkata, India.

ABSTRACT

Metal matrix composites are the materials in which reinforcement materials are added to improve their properties. The main problem associated
with the Metal Matrix Composites is the high cost of reinforcement material. To overcome this obstacle, a need arises to look for low cost
reinforcements like Sugarcane Bagasse Ash (SCBA), Rice Husk Ash (RHA), Fly Ash etc. In the present paper, the Mechanical and tribological
Properties (i.e. wear and friction) of Al6061 reinforced with SCBA and fabricated by stir casting technique are studied. The volume fraction
of SCBA reinforcement is varied in the range of 4-12% by volume. The reinforcement of SCBA particles increases the tensile strength of the
Aluminium alloy. From the micro-hardness test conducted on Vickers micro-hardness tester, it is observed that micro-hardness of the alloy
slightly decreases with increase in volume fraction of the reinforcement. The amount of wear depth decreases with increase in volume fraction
of SCBA indicating higher wear resistance for the composite. From the Tribological tests it was also concluded that with higher volume
fraction of the co-efficient of friction is higher. From the studies conducted it can be concluded that addition of RHA reinforcement improved
the mechanical and Tribological properties of aluminium Al6061 alloy.

Keywords: Sugarcane Bagasse Ash, Tensile Strength, Hardness, Friction, Wear.

1. Introduction

From last few years there has been a rapid increase in utilization of aluminum alloy in Industries due to its unique property of light weight &
low cost. Different types of reinforcing materials are added to aluminium alloys to improve the properties. The reinforcing Materials are
broadly classified as Ceramic Synthetic particulates, Industrial wastes and Agro wastes derivatives. Most of the engineering applications
require materials that are stronger, lighter and less expensive. A good example, is the current research, that have good strength to weight ratio
suitable for automobile applications where fuel economy with improved engine performance are becoming more critical [1]. The aluminum
matrix composites (AMCs) represent a class of MMCs possessing properties like low density, high stiffness and strength, superior wear
resistance, controlled co-efficient of thermal expansion, higher fatigue resistance and better stability at elevated temperature. Due to this, these
composites are used for the design of a wide range of components for various applications [2]. It has been found that the use of AMCs in
engine applications can reduce the overall weight, fuel consumption and pollution in the automobiles and aircrafts [3,4]. AMCs reinforced
with either silicon carbide or alumina particles are attractive materials for such applications [3–5]. The use of inexpensive reinforcements and
natural materials will reduce the cost of AMCs and increases its application [4]. Therefore now-a-days most of the research going on Agro-
Waste, as they are easily available, low cost, low density, reduced environmental pollution. These agrowaste ashes often contain a high
percentage of silica (SiO2) with a distribution of other refractory oxides such as Al2O3 and hematite (Fe2O3) [6,7]. For Development of
Aluminium metal matrix composites, stir casting is one of the liquid methods which is being extensively used [8]. In the present work, an
attempt is made to produce aluminum alloy Al6061 reinforced with SCBA particles by Stir Casting method and study the mechanical and
Tribological properties of Al6061-SCBA AMCs. Many researchers studied that Agro waste derivatives like bamboo leaf ash (BLA), rice husk
ash (RHA), bagasse ash (BA), palm kernel shell ash (PKSA), maize stalk ash (MSA), corn cob ash (CCA), bean shell waste ash (BSWA) can
be used as reinforcing material improving the Mechanical & Tribological Properties of AMCs [9,10,11,12,13]. Praveen et al. [14] Studied the
microstructure & Mechanical properties, concluded that the hardness and tensile strength were increased up to 4% of BLA in the AMCs, with
further increase in BLA content the hardness and tensile strength decreased. Himanshu et al. [15] concluded that the Organic material
reinforcement additions to aluminium matrix have shown increase in the mechanical properties of resulting composites. Usman et al. [16]
developed the AMCs by varying the % volume of SCBA in the range of (5-30), it was observed that the Ultimate tensile strength and Hardness
value increases with increase in % reinforcement up to a certain value. Aigbodion et al. [17] studied the effect of Bagasse ash (BA) particles
as reinforcing material on the wear behavior of Al-Cu-Mg alloy. The results showed that the wear rates of the Al-Cu-Mg/BA composites are
lower than that of the matrix alloy and further decrease with increasing Bagasse ash content. Wear rate increases as the sliding speed and
applied load increases. Concluded that the wear properties can be improved by the addition of BA ash particles as reinforcing material.
Lakshmi et al. [18] studied the mechanical properties and wear behavior of sugarcane ash reinforced in aluminum alloy. It is observed that
mechanical properties and wear rate increased with increase in reinforcement content. Bodunrin et al. [19] Agrowaste derivatives are very
promising materials for the development of AMCs on a commercial scale and more agro wastes should be investigated.

2. Experimental Procedure

2.1. Specimen Preparation

Stir casting is a liquid state method of fabricating composite materials. For the present study the composite Al6061-SCBA metal
matrix composites with three different volume fractions were fabricated using stir casting process. Aluminium alloy (AL6061), is used as base
metal that has been reinforced with 4, 8, 12 wt. % of SCBA particles. Initially a small chunk of AL6061 was inserted in graphite crucible and
melted at 800oC in a furnace. Simultaneously, SCBA particles also preheated in another furnace up to 600 0C to remove the moisture and
Organic constituents. Then measured quantity of preheated SCBA particles were add into the molten aluminium alloy. Then with the help of
a mechanical stirrer which is driven by electric motor, stirring was carried out with speed of 700-800 rpm. Stirring was continued for 5-8 mins
so that all the SCBA particles should mix uniformly into the molten aluminium alloy. The pouring temperature was kept slightly above the
casting temperature to enhance fluidity. The casting composition done for different samples are shown in table 1 and a pictorial representation
of the samples prepared for tensile testing is also shown in fig. 1.

Table 1- Composition of samples prepared.

Sample No. Composition

1 Al + 4% SCBA

2 Al + 8% SCBA

3 Al + 12% SCBA

Fig. 1 – Samples

3. Results and Discussion

3.1. Microstructure
Microstructure plays an important role in the performance of a composite material and mainly the physical properties of material depend on
the microstructure, reinforcement particle size, shape and reinforcement distribution in the alloys, prepared samples were examined using a
Metallurgical Microscope to study the SCBA reinforcement material distribution pattern in the Aluminium alloy. Micrographs shown in Fig.
2. (a, b, c) with respect to % volume fraction of SCBA reinforcement.

Fig. 2 - (a) Al 6061 with 4% Wt. of SCBA (b) Al 6061 with 8% Wt. of SCBA (c) Al 6061 with 12% Wt. of SCBA

A uniform distribution of sugarcane bagasse ash particles in matrix without voids and discontinuities can be observed from the above
micrographs. It is found that there was good bonding between matrix material and sugarcane bagasse ash particles however, no gap is observed
between the particle and matrix.

3.2. Tensile Strength

The casted samples were machined to required ASTM E8M04 standard dimensions. The tensile tests were conducted on these
samples according to ASTM E8M04 standard at room temperature, using a universal testing machine. Fig. 3. represents the variation of tensile
strength for the composites with varying volume fraction of SCBA particle in the AMC.
From the study It is observed that the Tensile Strength value increases
with increase in volume fraction of SCBA reinforcement and for 8%
vol SCBA it is maximum and thereafter the tensile strength decreases
with increase in reinforcement. The results are clear indication that
SCBA particle increases the tensile strength of AMCs. Similar findings
were reported by Usman et al. [16]. But with increase in SCBA volume
fraction above 8% vol the tensile strength decreases, this phenomenon
occurs because increased ash reinforcements in the matrix produces
more sites for crack initiation and hence lowers the load bearing
capacity of the composites thus reducing the ultimate tensile strength
[20]. This slight reduction in the strengthening capacity expected from
load transfer from the matrix to the particulates. It is noted that when
hard particulates are used as reinforcement in metal matrix composites
(MMCs) there is improvement in the strength due to the synergy of
direct and indirect strengthening mechanisms [21]. Further, study
reveals that tensile strength decreases beyond 12 % vol. of SCBA Fig. 3 - Effect of SCBA content on tensile strength
reinforcement with the matrix metal. of AL6061/SCBA AMCs

3.3. Microhardness

The micro-hardness tests of the composites are carried out using Vickers micro-hardness testing machine. Before the test, the samples were
cleaned to remove dirt, scratches etc.
The Study suggests that the hardness value slightly decreases with
increase in % volume SCBA reinforcement up to 8% vol. thereafter
with increase in percent of reinforcing material the hardness value
increases. The results of micro-hardness testing for different samples
are shown graphically in fig. 4. Whereas the Hardening behaviour of
the composite materials is concerned, due to particles addition in the
matrix, the strain energy also increases in the periphery of the particles
in the matrix and this tendency may be due to the formation of the
dislocation at the boundary of the ceramic particles by the difference in
the thermo-expansion coefficient between the matrix and ceramic
particles [22].
Fig. 4 - Effect of SCBA content on microhardness
of AL6061/SCBA AMCs

3.4. Tribological properties of AA6061/ SCBA Composites

The tribological test was carried out on Pin on disk Multi tribotester (Ducom-20, India) setup. To study the tribological characteristics of Al-
% SCBA under dry conditions and at ambient temperature (280C).

Fig. 5 - Effect of SCBA content on Wear Depth of Fig. 6 - Effect of SCBA content on Co-efficient of
Al6061/SCBA AMCs Friction of Al6061/SCBA AMCs

The Al-SCBA samples (size 12mm x 12mm x 6mm) were pressed against a rotating steel Disk made from material EN8 steel with hardness
55 HRc. The tribological tests were performed by applying the Load 19.62 N and sliding speed 3m/s was maintained for duration 6 minutes.
During the tests co-efficient of friction and wear depth were measured by the machine as system responses (friction and wear study) and digital
data was collected for further analysis. Fig. 5. and Fig.6. are graphical representations of Wear depth and co-efficient of friction values with
respect to volume fraction of reinforcement. In case of wear study, it is observed that wear depth decreases with increase in volume fraction
of SCBA reinforcement. Similar findings were also reported by Aigbodion et al. [22]. At the initial stage, aluminium alloy, being the softer
constituent, wears out at a faster rate than the reinforcing ceramic particles [23]. Thereafter sliding for some time, the harder ceramic particles
stand in relief at a higher level on the surface. Thus, from wear resistance point of view (Fig. 5.) higher volume fraction of SCBA reinforcement
is desirable.
It is observed that the Coefficient of friction increases with increase in volume fraction up to certain value again as the % vol. of reinforcing
material increases COF decreases. Thus, the study reveals that from friction perspective (Fig.6.) lower or higher amount of reinforcement is
desirable as it provides lower coefficient of friction.

3.5. Scanning electron Microscopy (SEM)

The microstructure study of composite samples is carried out after the wear testing is completed. The wear tracks are analysed by scanning
electron microscopy to study the wear mechanism. Fig. 7 (a ,b, c) shows a SEM image of wear track surface of Al-SCBA composites.

Fig. 7 (a) - SEM photomicrograph of wear surface of Fig. 7 (b) - SEM photomicrograph of wear surface of
Al6061-4% wt. of SCBA Al606- 8% wt. of SCBA

The SEM image exhibits longitudinal grooves and partial irregular

pits that indicate adhesive wear. Some traces of micro-cutting and
micro-ploughing effect are also noticed that suggest abrasive wear
mechanism. Thus, it can be concluded that both abrasive and adhesive
wear mechanisms are observed with abrasive wear being predominant
in nature.

Fig. 7 (c) - SEM photomicrograph of wear surface of

Al6061- 8% wt. of SCBA

4. Conclusion

From the present study the following conclusions can be made

❖ The Tensile Strength of the composite increases with increase in volume fraction of SCBA reinforcement, for composites with more
than 8% weight fraction of Sugarcane Bagasse ash particles, the tensile strength was seen to be decreasing.
❖ Hardness slightly decreases with increase in volume fraction of SCBA reinforcement up to 8% weight fraction of Sugarcane Bagasse
ash particles, for composites with more than 8% weight fraction of Sugarcane Bagasse ash particles, the hardness was seen to be
increasing.
❖ Wear depth decreases as the amount of SCBA particles reinforcement increases in the alloy.
❖ Co-efficient of friction increases as the amount of SCBA particles reinforcement increased up to 8% volume, thereafter on further adding
of reinforcing material the Co-efficient of friction decreases.
❖ Thus, SCBA particles can be used as reinforcement material to improve the Mechanical and tribological properties of the aluminium
alloy.
 ❖ SEM photographs show presence of both adhesive and abrasive wear phenomenon.

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