Experimental investigation of mechanical properties of AA6063/ZrO2 metal matrix composites

S. Rajaram a*, P. Karthikeyan a, T. Jaya Surya a, K. Kaniskar a, V. Pazhanivel a

a
Department of Mechanical Engineering, K.Ramakrishnan College of Engineering, Samayapuram,Tiruchirappalli-
621 112, Tamilnadu, India

Abstract

The experimental investigation of AA6063/ZrO 2 metal matrix composites was made by a stir casting method by
differing the weight fraction of zirconium dioxide such as 0 wt. %, 2 wt. %, and 4 wt. % and the mechanical
properties are studied successfully through various test methods such as microhardness, tensile, and wear. The
AA6063/ ZrO2 metal matrix composites of hardness, UTS, and wear test specimens were prepared as per the ASTM
standard. From the hardness and UTS test results, the maximum hardness of 71.0 HV, and the maximum ultimate
strength of 168.384Mpa were obtained in the sample of AA6063 with 4 wt. % ZrO 2 composites. A Pin-on-Disc wear
test result revealed the lower wear rate of 2.5*10 -6 mg/m identified in the test sample of AA6063 with 4 wt. % ZrO 2
composites. The morphology of AA6063/ ZrO2 composites was studied with help of an SEM test and from its
microstructure, uniformly distributed ZrO2 particulates are identified.

Keywords: Aluminum alloy (AA6063), Zirconium dioxide (ZrO2), hardness, tensile, wear, SEM

1. Introduction

Today's competitive world MMCs are developed due to its natural properties like corrosion resistance,
lightweight, and density, aluminum reinforced MMCs are developing widely. Metal matrix composites (MMCs) are
composed of base metal and ceramic, and metal or natural reinforcement. [1]. As compared to unreinforced alloys,
MMCs possess improved properties. The MMCs composites have high thermal conductivity, high strength, low
density, and low reinforcement costs [2]. In recent years, materials used for engineering applications have
undergone drastic changes. composites have been resourceful in enabling the reduction of weight in the aerospace,
automotive, military, and electronics industry Aluminum is widely used in structural applications due to its non-
ferrous metallic systems [3]. In aluminum alloys are alloys in which Al is the principal ingot and silicon, manganese,
copper, zinc, and magnesium are the alloying components [4]. The glazing bars, windscreens, automobiles,
irrigation pipes, assembling window sections, and furniture by AA6063 composites [5].The microstructure of the
reinforcement, including size, shape, and distribution, orientation, and volume percentage are strongly affected the
elastic properties of MMCs [6]. Due to the uniqueness and improved properties of composite materials, it is majorly
found in defense, aviation and numerous automobile industries which is then compared to rigid materials [7].
Aluminum is a preferred material for metal matrix composites because of its engineering properties, low density,
and ease of fabrication [8]. MMCs composites strength depends on which type of reinforcement is added to a base
metal [9]. Generally, Due to its good mechanical, and thermal properties and comprise low density Aluminum alloys
are used as materials in automobile and aircraft industries [10].

* Corresponding author.

Email address: ram69@krce.ac.in (S.Rajaram)

2. Materials and casting process

Aluminum alloy 6063 (AA6063), Zirconium dioxide (ZrO2) reinforcement, stir casting setup and AA6063 with 0 wt.
% ZrO2, 2 wt. % ZrO2, and 4 wt. % ZrO2 metal matrix composites are shown in Fig 1.

2.1 Aluminum alloy 6063(AA6063)

AA6063 is medium strength and is used in architectural applications such as window frames, doors, and dental
industries. It has improved surface finish, good formability, weldability, corrosion resistance, and fair machining. In
this Aluminum alloy extensively used for complicated extrusions and available in various tempers. The weight
percentage chemical composition of the AA6063 and ZrO2 reinforcement are shown in Table 1.

Table 1. Wt. % chemical composition of AA6063 and ZrO2 reinforcement

Chemical elements AA6063 Wt. % Chemical elements ZrO2 Wt. %

of AA6063 of ZrO2

Mg 0.9000 SiO2 0.25

Si 0.7000

Mn 0.0860 TiO2 0.16

Fe 0.2220

Cu 0.1850 Fe2O3 0.07

Zn 0.0110

Ti 0.0110 Y2O3 3-5

Cr 0.1490

Al 97.6630 Zr bal

2.2 Zirconium dioxide (ZrO2)

Zirconium dioxide is also called as zirconia and it is naturally white crystalline of zirconium. Its maximum present
kind, with a shape of monoclinic crystalline structure. ZrO 2 is described by its high grating and thermal resistivity
properties, and mechanical resistance, the maximum use of zirconium dioxide is inside the production of ceramics,
like in medicine, refractory cloth, insulation, abrasives, and enamels.

2.3 Casting process of AA6063/ZrO2 composites

A stir casting setup consists of a furnace, mechanical stirrer, and feeder. AA6063 alloy was charged into the
crucible at about 700 °C. Once it reaches the liquid state the reinforcement of ZrO 2 is added to the crucible inside
the furnace and the stirrer is introduced to mix the reinforcement with the help of a variable speed motor vertically
with the range of 70 to 850 rpm. The molten metal is taken outside and poured into the die and then cooled at
atmospheric temperature and the composite was removed from the die. A similar process is repeated for all the
three samples such as AA6063 with 0 wt. %, 2 wt. %, and 4 wt. % of ZrO 2 metal matrix composites. The number of
attempts to develop AA6063-ZrO2 reinforced composites to study the mechanical properties of AA6063- ZrO2
composites.

[Fig.1. - to be included here]

3. Results and discussions

Test results of hardness, tensile, and wear of AA6063/ZrO 2 composites are shown in Table 2. The test samples and
test graphs of hardness, tensile, wear, and SEM test images are shown in Fig 2.

3.1 Vicker’s microhardness test

The Vicker’s microhardness test was carried out as per the ASTM E384 standard. The results revealed that the
maximum hardness of 71.0 HV is attained at 4 wt. % of ZrO 2 with AA6063 composites and which has compared to
the unreinforced AA6063 composite. From the results can be inferred that there is a significant increase in hardness
of material with an increase in weight percentage of ZrO2.

3.2 Tensile test

To determine the tensile strength of the material the tensile test was carried out as per the ASTM E8 standard by
using a UTM. The UTS of the tensile samples of AA6063 reinforced with 0 wt. %, 2 wt. %, and 4 wt. % of ZrO 2 and
the AA6063 with 4 wt. % of ZrO2 composites has a higher tensile strength of 168.384Mpa is compared to the
unreinforced AA6063 composite.

3.4 Wear test

A Pin- on- Disc wear test specimen was prepared as per the ASTM G99 standard. From the test results, a lower wear
rate of 2.5*10-6 mg/m was obtained in the composite of AA6063 with the 4 wt. % of ZrO2 reinforcement which is
compared to the base metal matrix AA6063 composite. Hence, it’s confirmed the reduction of wear loss by an
increase in the weight percentage of ZrO2.

3.5 SEM test (Scanning electron microscopic test)

The microstructure of AA6063/ZrO2 composites was carried out using an SEM test with a magnification of 500 X
From the SEM image, the agglomeration is identified in the 0 wt. % of ZrO 2 AA6063 composite and the presence of
ZrO2 identified in the metal matrix composites of AA6063 with 2 wt. % and 4 wt. % was confirmed it’s uniform
distribution.

[Fig.2. – to be included here]

Table 2. Test results of microhardness, ultimate tensile strength, and wear rate

Material Vicker’s microhardness Ultimate tensile strength Wear rate in (mg/m)

value in HV value in Mpa

AA6063 59.8 123.571 5.4* 10- 6

AA6063+2 wt. %ZrO2 67.5 165.298 3.9*10- 6

AA6063+4 wt. %ZrO2 71.0 168.384 2.5*10- 6

Conclusions

The AA6063 reinforced with ZrO2 metal matrix composites of various weight fractions such as 0 wt. %, 2 wt. %, 4
wt. % made by a stir casting technique and the mechanical properties of AA6063/ZrO 2 composites were studied
successfully through various testing methods such as microhardness, tensile and wear. The following conclusions
were made by observed test results of AA6063/ZrO2 composites.
 From Vicker’s microhardness test, AA6063 with 4 wt. % of ZrO 2 composites revealed a higher hardness of 71.0
HV, in which around 12% of the hardness was improved than unreinforced AA6063 composite.
 The maximum ultimate tensile strength of 168.384Mpa was obtained in AA6063 with 4 wt. % ZrO 2 which is
compared to higher value than base metal matrix AA6063 composite. The test was made by a universal testing
machine.
 A Pin-on-Disc wear test result revealed the lower wear rate of 2.5*10 -6 mg/m identified in the test sample of
AA6063 with 4 wt. % ZrO 2 composites which has compared with the other samples of 0 wt. % ZrO 2 and 2 wt.
% ZrO2 AA6063 composites.
 The SEM micrographic test confirmed that the ZrO 2 particulates are distributed uniformly in the test samples of
2 wt. % and 4 wt. % AA6063 composites. The agglomeration is identified in the base AA6063 composite.
 The above test results revealed that the hardness and UTS of AA6063/ZrO 2 increased considerably with increase
in weight percentage of ZrO2 which is then compared with a base metal matrix of AA6063 composite. Also, it is
inferred there is considerable reduction in wear rate with an increase in weight percentage of ZrO 2 which is then
compared with a base metal matrix of AA6063/ZrO2 composites.

Acknowledgement

The authors listed in this work have made significant contribution towards completion of this entire work described
in this report through continuous research, testing and evaluation of experiment.

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