Characterization of Economical

Aluminium MMC Reinforced with Weld

Slag Particles

P. Paranthaman, P. M. Gopal and N. Sathiesh Kumar

Abstract Rapid advancement in technology forces the researchers to search for

advanced materials with higher performance like composites. The composites are
known for their better mechanical properties and less weight, but the cost is the major
factor that hinders the wider application of these materials. In this study, welding
slag is reused as reinforcement to produce economical metal matrix composites,
because slag is produced in enormous amount during welding of materials which
causes pollution. The aluminium alloy (Al 6063) is used as base material. Weld
slag of different weight proportions (0, 5 10 and 15 wt%) is mixed with Al 6063
through stir casting process, and samples are taken for investigation. The mechan-
ical properties of the composites like tensile strength, compression strength and its
wear behaviour are analysed. And also, the microstructure of the MMC is analyzed
through optical microscope (OM) to determine the weld slag distribution in alu-
minium matrix material. The observed result indicates that the addition of weld slag
particles with aluminium increases the mechanical properties. The composite having
15% of welding slag exhibits the best tensile and wear resistance.

Keywords Composite · Weld slag · Stir casting · Tensile strength · Compressive

strength

1 Introduction

Metal matrix composites (MMCs) gain significant importance worldwide due to

their superior mechanical properties, because materials with better strength and less
weight are well suitable and necessary for engineering applications [1]. Further, the
development of sustainable and reusable materials from existing things has observed

P. Paranthaman (B) · P. M. Gopal · N. Sathiesh Kumar

Department of Mechanical Engineering, Karpagam Academy of Higher Education,
Coimbatore 641021, India
e-mail: paranth.ponnusamy@gmail.com

© Springer Nature Singapore Pte Ltd. 2019 9

S. S. Hiremath et al. (eds.), Advances in Manufacturing Technology,
Lecture Notes in Mechanical Engineering,
https://doi.org/10.1007/978-981-13-6374-0_2
10 P. Paranthaman et al.

an ideal global attention and importance from engineers as well as the wide-ranging
community and government [2, 3].
Aluminium and its alloys have superior mechanical properties while adding rein-
forcements during metal matrix composite (MMC) development. The wide spectrum
of unique properties can be attained with Al MMCs at comparatively low process-
ing expenditure. The Al-based MMCs have superior specific stiffness and strength,
enhanced elevated temperature properties (concerning its monolithic alloy) and ther-
mal conductivity. The multi-functional characteristic of Al-based composites has
seen its exploitation in aerospace technology, electronic heat sinks, antenna reflec-
tors, automobile drive shafts fins and engine machineries, along with others [4].
Properties of these Al-based matrix composites majorly subject to (1) composition
of the base alloy, (2) the character of material reinforced and (3) the techniques opted
for MMC processing.
Thus, a large amount of research works reported in the literature have attempted
to address how these facets influence the properties and behaviour of aluminium
matrix composites. The majority of research works reported on the literature on Al
composites has been committed frequently only on some of the aluminium alloys,
such as A357, A359, 2618, 2254, 6061 and 7075. However, not much study has
been reported on the exploitation of Al 6063 as matrix material for the Al MMC
fabrication. Al 6063 alloy is the most readily obtainable aluminium alloy in the global
metal markets. It is processed in soaring quantities at small price by the majority of
aluminium processing industries for applications such as the production of glazing
bars and window sections, wind screen and sliding roof sections for the automobile
industry, pipes and tubing and for furniture also. The perspective for developing
aluminium-based MMC with superior performance by using Al 6063 alloy as base
material has created the thrust of this research exertion.
In recent past, an enormous amount of research works are carried on waste particle-
reinforced MMCs. Currently, fly ash cenosphere [5], rock dust [6, 7] and CRT glass
[7, 8] like waste particles are tried as reinforcement, and good results were obtained.
Similar to these wastes, welding slag is noteworthy and is produced while joining
metals which cause the pollution and leftover of resources. But, an effective recycling
technique for this industrial waste is not yet discussed widely.
Hence, the current research intents to reuse welding slag as reinforcement to pro-
duce the composite materials. Further, among various MMC development method-
ologies, stir casting furnishes superior matrix particle attachment as a result of stirring
action of particles into the metals. The studies in the literature described that the uni-
form mixing and wetting be able to obtain by choosing suitable parameters while
MMC processing [9].
The present research investigation explores the mechanical and wear behaviour
of welding slag-reinforced Al 6063 MMCs. The effect of reinforcement percentage
on mechanical and wear behaviour of MMC has been investigated experimentally.
Characterization of Economical Aluminium MMC … 11

2 Materials and Methods

Al 6063 is selected as base material due to its availability, low cost and its wider
applications. Aluminium 6063 is the most commonly available metal which is in
pre-tempered grades. It is mostly used in aircraft structures and all complicated
extrusions. It has a good surface finish, high resistance to corrosion, suitable for
welding and can be anodized effortlessly. The typical elements of the aluminium
alloys are copper, manganese, silicon, magnesium and zinc, wherein silicon and
magnesium play key role.
The reinforcement material used in this study is welding slag which is a residue
after welding. The slag is collected for the nearby industries and ball milled to obtain
uniform size of 50 µm. The ball milled welding slag is shown in Fig. 1, and the
chemical composition is given in Table 1.
The MMC is developed through stir casting method by reinforcing welding slag
at three weight percentages (5, 10 and 15). Along with MMCs, one base metal
sample also is developed for reference. A calculated amount of welding slag is kept
in a furnace and heated up to 600 °C (preheating). Then, these preheated particles
were put into Al 6063 molten metal. Then, the mixture is heated to around 720 °C.
Degassing agent (hexachloroethane) was used to reduce gas porosities. The melt is
consequently stirred at 900 r/min with the aid of a mechanical stirrer that is fastened
with adjustable speed motor. Then, the temperature in the furnace was maintained
constant for 10 min at 720 °C; subsequently, the composite mixture is poured into

Fig. 1 Welding slag

Table 1 Chemical composition of welding slag

Constitution CaO SiO2 FeO MnO MgO Al2 O3 Others
Composition (%) 43.21 17.15 21.43 5.22 7.18 3.43 Remaining
12 P. Paranthaman et al.

Fig. 2 a Tensile testing and b compression testing

the mould cavity of 200 mm × 40 mm × 30 mm, and the required composite is

obtained. The die was released after 5 h, and the cast specimens were taken out.
Brinell hardness method is followed for measuring hardness of the developed
MMC as per the ASTM standards. Hardness is measured at the five distinct places
of the polished MMC surface, and average value is taken into consideration. Tensile
and compression test are also performed on the specimens prepared based on ASTM
standard. Three specimens were prepared from each MMC samples for both tensile
and compression test. Then, the average values are taken for the analysis. Figure 2
shows the tensile and compression testing procedures for the developed specimens.
Wear analysis for the developed MMC is performed under dry conditions through
pin-on-disc apparatus. The counter disc material used is hardened EN31 steel.

3 Result and Discussion

3.1 Microstructure

The Al composites produced were examined for its microstructure using an optical
microscope (OM). A series of emery papers of grit sizes ranging from 1000 µm
is utilized for polishing the specimens of optical microscopy inspection. Polycrys-
talline diamond suspension of particle size varying from 10 to 0.5 µm with ethanol
solvent is utilized for fine polishing. The samples were etched with 0.5% HF solution
by swabbing for 3–6 min (subsequently rinsing in water and drying) prior to OM
inspection. An optical microscopic image obtained from the analysis is shown in
Fig. 3.
The optical microscopic images clearly show the presence of welding slag rein-
forcement particles in the aluminium matrix. The existence of reinforcement particles
at the grain boundaries can be clearly identified from Fig. 3a. These reinforcement
Characterization of Economical Aluminium MMC … 13

Fig. 3 a Microstructure of 5% welding slag-reinforced MMC. b Microstructure of 10% welding

slag-reinforced MMC. c Microstructure of 15% welding slag-reinforced MMC

particles help to hinder the dislocation motion during plastic deformation which will
increase the properties of the aluminium.

3.2 Hardness

Hardness of the aluminium is increased when the welding slag is added, and it
increases with every rise in welding slag percentage. Hardness of the aluminium
base material is 35 BHN, and it increases to 55 BHN when 15 wt% of welding slag
is introduced to the aluminium matrix which is found to be 57% increase. As stated
earlier, the presence of reinforcement particles at the grain boundaries hinders the
motion of dislocation during plastic deformation (indentation during hardness test).
14 P. Paranthaman et al.

Hardness

Hardness (BHN)
60

40

20

0
Aluminium Al+5% WS Al+10% WS Al+15% WS
Composite

Fig. 4 Hardness of the base material and MMC

Table 2 Tensile test results

Description and units Observed values/results
Base material Al + 5% WS Al + 10% WS Al + 15% WS
Tensile stress (N/mm2 ) 80.12 90.05 107.05 112.27
% of elongation 7.1 5.4 4.2 3.4

Hence, higher energy is required to move the dislocation; i.e., hardness of the material
is increased. Enhancement in Al hardness with respect to reinforcement percentage
is shown in Fig. 4.

3.3 Tensile Strength

The variation in mean tensile strength with respect to slag percentage is represented
in Table 2. Tensile strength of the aluminium increases greatly up to 10% welding slag
addition, and further increase in reinforcement did not give significant effect; i.e., the
tensile strength only increases to 112.27 from 107.05 N/mm2 . Addition of welding
slag reinforcement into the aluminium base material results in elongation loss. The
elongation of aluminium decreases with increase in welding slag percentage. This
loss of ductility may be due to rise in aluminium hardness as a result of reinforcement
addition.

3.4 Compression Strength

Compression test is also carried out on UTM in accordance with ASTM standard.
Compression test results of the developed MMC are publicized in Fig. 5. It clearly
depicts that the compressive strength of the aluminium increases up to 10% welding
slag addition, whereas further addition of reinforcement results in a slight decre-
ment in compressive strength. The effect of welding slag reinforcement over the
compression strength of the aluminium is not high as that of tensile strength.
Characterization of Economical Aluminium MMC … 15

Fig. 5 Compressive strength Compression Strength

Compression Strength
of the base material and 630
MMC 625

(N/mm2)
620
615
610
605
Base Material Al + 5 % WS Al + 10 % WS Al + 15 % WS
Composite

Fig. 6 Wear behaviour of Wear rate

the base material and MMC (10¯3 mm3·m−1) 0.65
wear rate

0.6

0.55

0.5
Base Material Al + 5 % WS Al + 10 % WS Al + 15 % WS
Composite

3.5 Wear Behaviour

Wear rate of the specimens tested under same experimental conditions, i.e. same
load, sliding speed and distance, is shown in Fig. 6. The wear analysis parameters
are 10 N load, 1 m/s sliding velocity and 1000 m sliding distance. Resistance to wear
capability of the aluminium is found to be greater than before with the addition of
welding slag reinforcements. MMC hardness increment with respect to weld slag
weight percentage results in increased wear resistance. It is a well-known fact that
the harder material always gives the better wear resistance [10].

4 Conclusion

Composite technologies offer a way of lightweight and high-strength components. In

the view of economy, the developed composite material gives extreme output. From
the investigation and results, it can be able to conclude that
• The tensile stress was increased due to presence of welding slag compare to other
metals.
• The compression property of Al 6063 with welding slag (10%) is found to be good
due to presence of welding slag compare to other metals.
• The microstructure result confirms that the particulate distribution is better in
developed Al 6063 composite and also shows the signs of healthier interfacial
bonding.
16 P. Paranthaman et al.

• Compression and tensile strength of Al 6063/welding slag MMC are getting

improved with an increase in weight per cent of the reinforcing phase at the cost
of ductility decrement.
• Wear rate of the aluminium decreases with respect to the welding slag percentage.

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