Global Academy of Technology

PROJECT PHASE 2 PRESENTATION

Course Code: 15ME85

Mr. Poorna Chandra

Assistant Professor

Department of Mechanical Engineering

 Fabrication and Microstructural Evaluation of
Al-Red mud and Al-SiC Composites
NAME USN
PRASAD J SHETTY 1GA16ME066
PRASAD GOWDA K N 1GA16ME067
SURYA V S 1GA16ME102
VARUN KUMAR R 1GA17ME421

Guide:
Mr. Poorna Chandra, 2019-20

Assistant Professor, 8TH SEMESTER Place of work:

B.E IN MECHANICAL ENGINEERING Global Academy of Technology
GAT, Bengaluru.

Fabrication , Microstructural Evaluation and Comparative Study of

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Al-Redmud and Al-SiC Composites
 AIM OF THE PROJECT

 To fabricate aluminium based Red mud MMCs and

aluminium based Silicon carbide particulate MMCs using
stir casting technique, followed by microstructural study
and comparative study of the composites.

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 ABSTRACT
 The project work mainly involves, an attempt to investigate the
mechanical properties, microstructural analysis and comparative
analysis of composites.
 Fabrication of red mud and silicon carbide with Aluminium will be
carried using liquid metallurgy.
 Further microstructural analysis and mechanical properties like
hardness, density and surface roughness will be investigated.
 Comparative analysis will be made between the two fabricated
composites.

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 INTRODUCTION
• Aluminium alloys are preferred engineering material for automobile,
aerospace and mineral processing industries for various high performing
components that are being used for varieties of applications
• Al6061 alloy are highly corrosion resistant, exhibits moderate strength and
finds much applications
• Stir casting is one of the most convenient method where process
parameters are regulated with most effective way.
• Composites-A composite material can be defined as a combination of two
or more materials that results in better properties than those of the
individual components used alone

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 INTRODUCTION
• CLASSIFICATION OF COMPOSITES

COMPOSITES

Based on Material Matrix Based on Reinforcement Material

1. Metal Matrix composite 1. Fibre Reinforced Composite

2. Polymer Matrix Composite 2. Laminar Composite
3. Ceramic Matrix Composite 3. Particulate Reinforced Composite

Classifications of Composites

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 INTRODUCTION
PARTICULATE METAL MATRIX COMPOSITES

• Particulate reinforced composites are inexpensive. Cost is an important and

essential item for large volume usage.

• Processing by casting or powder metallurgy, followed by conventional secondary

processing by rolling, forging, and extrusion can be used.

• Higher temperatures are possible than with the unreinforced metal.

• Enhanced modulus and strength

• Increased thermal stability

• Better wear resistance

• Relative isotropic properties compared to those of the fibre reinforced composites.

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 TYPES OF REINFORCEMENT
• Types of reinforcement
• Aspect ratio

SILICON CARBIDE:
• Silicon carbide, the key particulate reinforcements, are obtained from the commercial
abrasives industry.
• Silicon carbide particulates are produced as a by-product of the process, used to make
whiskers of this material.
Composition (%)

Density 3.21 gm/cc

Coating Temp 12000C

Melting Temp 27300C

Flexural Strength 450-560 Mpa

Young’s Modulus 430 Gpa

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 TYPES OF REINFORCEMENT
RED MUD
• Red mud is the major waste material obtained during the production of aluminum
from bauxite, by the Bayer’s process.
• Storing and disposal of red mud has been biggest problem.
• Required for aerospace and automobile applications. Composition (%)

Al2O3 17-20

Fe2O3 44-47

SiO2 7-9

TiO2 8-11

Na2O 3-5

CaO 1-3

LOI 11-15

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 TYPES OF MATRIX MATERIAL
ALUMINIUM 6061:
• The Al alloys are quite attractive due to their low density, their capability to be
strengthened by precipitation, their good corrosion resistance, high thermal and
electrical conductivity, and their high damping capacity.
• The most popular type of MMCs is Aluminum alloys reinforced with ceramic
particles

• Chemical Composition of Aluminum 6061

Material Fe Si Mn Zn Cu Ti Cr Mg Al
Weight% 0.25 0.60 0.03 0.1 0.22 0.1 0.24 0.82 Bal

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 APPLICATIONS OF COMPOSITES

• In Aerospace industries
• In Automotive
• In Medical
• In Electrical field
• In Sports
• In Chemical Industry
• Other

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 LITERATURE SURVEY
Author Title abstract
M.A.Hassan Development of M.A.Hassan et al. carried out research work on,
Aluminium ‘‘Development of Aluminium Metal Matrix Composite
Metal Matrix Using Stir Casting Method ‘’ using AL6063 as matrix
Composite Using material and varying % by weight of silicon carbide
Stir Casting particulate as reinforcement and found that increase in the
Method percentage weight of silicon carbide improves the
mechanical properties.

Lokesh K. S Effect of Red Lokesh K. S et al. carried out research work on ‘’ Effect of
Mud Particles on Red Mud Particles on Scratch Resistance of Aluminum
Scratch Based Metal Matrix Composites’’ and found that Red mud
Resistance of particles gets uniformly distributed with aluminum matrix
Aluminum Based using stir casting technique. It was concluded that sample
Metal Matrix filled with 2% of red mud particles exhibited 41% increase
Composites in hardness number as compared to the sample filled with
8% of red mud particles.

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 LITERATURE SURVEY
author Title Abstract
S. A. Development of S. A. Suryakumai et.al carried out research on , “ Development
Suryakumai aluminium metal Of Aluminium Metal Matrix Composites” and found that on
matrix composite addition of Sic particles improved the hardness and wear
properties. It was concluded that Micro hardness and tensile
strength improved by 34% and & 7%

M.D.Antony Microstructural M.D.Antony et.al carried out research on,” Microstructural

Analysis of Analysis of Aluminum Hybrid Metal Matrix Composites
Aluminum Hybrid Developed Using Stir Casting Process” .
MMC Developed It was concluded that Characterization study made by SEM and
Using Stir Casting optical microscopic analysis result predict that the dispersion of
Process the SiC particles are equal in all over the specimens.
Anthony.M An Investigation Anthony.M.Xaviorb et.al carried out research on “The
.Xaviorb on the Mechanical Mechanical Properties of Hybrid Metal Matrix Composites”
Properties of It was concluded that the density of the SiC reinforced particulate
Hybrid MMC Aluminum composites with different weight fractions, was
studied and the density increases with SiC .

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 SUMMARY OF LITERATURE SURVEY
 On thorough study of the published work on the fabrication,
characterization, and microstructure analysis of MMCs, the following
observation is made.
 Stir casting fabrication method has the advantages of simplicity, flexibility,
applicability to large quantity production and also it minimizes the final
cost of the product. Hence every study in literature adopts stir casting
method to fabricate the composite.
 Currently our project work also carried out using stir casting method for
fabrication of the composite and further microstructural analysis is carried
out to compare the Al-Red mud and Al-SiC metal matrix composite.

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 METHODOLOGY

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 OBJECTIVES
The main objectives of the project are:

1. Compare the effect of Red mud (3%) and Silicon Carbide (3%) reinforcement of Al6061-Redmud and Al6061-

SiC composites.

2. To fabricate red mud reinforced Aluminum 6061 alloy metal matrix composites and Silicon Carbide reinforced

Aluminum 6061 alloy metal matrix composites using stir casting method.

3. To investigate the addition of red mud and SiC on its mechanical properties such as, hardness, density of the red

mud and SiC reinforced Aluminum metal matrix composites.

4. To perform microstructural analysis using scanning electron microscope (SEM) to analyze the distribution of the

reinforcement in the composites.

5. To investigate the surface roughness of the machined composites.

6. Comparative studies of the composites develop with respect to hardness, density, microstructural analysis and

surface roughness.

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 EXPERIMENT DETAILS
Fabrication of Metal Matrix Composites
Two operations:
• production of the composites materials itself, and fabrication of this composite
into useful product forms.
• Both operations can affect the properties and interfacial characteristics of the
final product.
The methods which are commonly employed to manufacture DMMC:

1) Liquid phase processes

2) Solid state processes

• Stir casting and vortex method

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 PREPARATION OF MOULD

Cylindrical Mould Cavity with Vent

Molding box
Holes

Preheating of Mould Mould ready for pouring molten metal

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 STIR CASTING
• Two step fabrication method – furnace and stirring assembly.

Factors

• The difficulty in achieving a uniform distribution of the reinforcement material

• Wettability between the two main substances

• Porosity in the cast metal matrix composites

• Chemical reactions between the reinforcement material and the matrix alloy.

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 CASTING PROCESS
1. Redmud particles and Silicon Carbide particles of required microns are preheated
in the Electric Oven.

2. Aluminum alloy (Al6061) pieces are placed in electric induction furnace (850 0C)
and then preheated Redmud particles is added into the crucible containing molten
aluminium alloy

3. In order to achieve proper wettability little magnesium is added and degassing is

carried out.

4. The molten metal is then poured to a prepared cylindrical mould cavity of

100mm length and 50mm diameter at about the same melting temperature.

5. Similarly, the casting of Aluminium alloy reinforced with Silicon Carbide (3%) is
carried out to prepare Aluminium – Silicon carbide composite

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 CASTING PROCESS

Pouring Molten metal Cooling in still air into mould cavity

Casted Aluminium-Redmud Casted Aluminium-Silicon carbide

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 MACHINING PROCESS
• The High Speed Steel (HSS) cutting tool is been used to machining the fabricated
composites at different speeds.
• The components are machined in a HMT Lathe

Machined Aluminium with 3% Machined Aluminium with 3%

Redmud Composite Silicon Carbide Composite

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 RESULTS AND DISCUSSIONS
HARDNESS TEST:

Brinell hardness test:

BRINELL SPECIMEN

BRINELL HARDNESS TEST

MACHINE
The actual Brinell hardness (HB) is calculated by factoring the indent size and the test force, such
that:
L - load
D - diameter of the ball indenter
D1 - diameter of the impression.

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 RESULTS AND DISCUSSIONS
The Brinell hardness tests were conducted in accordance with the ASTM standards
on KB3000H model Krystal Elmec Brinell Hardness Tester.

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 RESULTS AND DISCUSSIONS
The hardness of the material is as shown in Table, it is found that the hardness of Al6061
aluminium alloy with addition of 3% Red mud reinforcement the hardness is increased to 47 BHN
and with addition of 3% Silicon Carbide reinforcement the hardness found was 64 BHN.

Material Brinell Hardness Number

AL6061 38

AL6061+ 3% Red mud 47

AL6061+ 3% Silicon Carbide 64

Hardness of the material

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 RESULTS AND DISCUSSIONS
Density Measurement:
 The obtained density values of metal matrix Aluminium with the addition of 3% Red mud
and 3% Silicon carbide reinforcement are 2.63 & 2.72 gm/cc respectively.

Material Density( gm/cc)

AL6061 2.7

AL6061+ 3% Redmud. 2.63

AL6061+ 3% Silicon 2.72

carbide

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 RESULTS AND DISCUSSIONS

Effect of reinforcement on density of the material

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 RESULTS AND DISCUSSIONS
SURFACE ROUGHNESS:
 The average surface finish (Ra) in the direction of the tool movement was measured in
three different places of the machined composite surface using a surface roughness
tester- Mitutoyo SJ201(A Inductive type Diamond cone Surface roughness tester).

Measurement of Surface Roughness (Ra)

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 RESULTS AND DISCUSSIONS
Sl. No Speed (rpm) Feed(mm/sec) Depth of Cut (mm)

1 125 0.06 1

2 250 0.06 1

3 350 0.06 1

Machining Parameters
  Surface Roughness(Ra in micrometers)
Position Al6061+ 3% Red mud Al6061+ 3% SiC

First Position 5.9 6.30

Second Position 4.5 4.745
Third Position 3.4 3.701

Measurement of Surface Roughness (Ra)

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 RESULTS AND DISCUSSIONS

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 CONCLUSION
• The fabrication of composites namely aluminum metal matrix reinforced with

red mud and aluminum metal matrix reinforced with Silicon carbide is

performed using stir casting technique.

• The effect of addition of the reinforcements on the aluminum alloy is studied

with the changes in the mechanical properties.

• In addition to that study on the fabricated composites by stir casting method is

also analyzed. These analyses included the Hardness test, density measurement,

SEM analysis of the fabricated composite and surface roughness measurement.

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 CONCLUSION
 From the Hardness test point of view, it was inferred that the hardness of base metal is 38 BHN and

for 3% addition of Red mud the hardness valve obtained was 47 BHN and for 3% addition of

Silicon Carbide, it was found to be 64 BHN. From this it can be inferred that the composite

reinforced with Silicon Carbide exhibits maximum hardness compared to base material.

 The density of the composite material reinforced with Red mud found lesser compared to composite

reinforced with Silicon carbide.

 It is seen from the SEM that there is a uniform distribution of Red mud and silicon carbide in the

matrix.

 From surface measurement analysis, for the selected machining parameters it was found that at

constant feed, as the cutting speed increases the surface roughness decreases. The surface finish

obtained found better in Al-Red mud composite compared to Al-SiC composite.

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 SCOPE FOR FUTURE WORK
• Researchers are interested to develop the materials which are light in weight, more hardness,

have high stiffness, fracture toughness and offer good wear resistance. This can be achieved

by reinforcement of Aluminum alloy with harder particles like Red mud, SiC, Al2O3, SiO2 etc.

• The properties of the final component can be tailored based on specific requirements. This can

be done by using different size and weight fraction of reinforcement particles. Due to this

fundamental reason, metal matrix composites (MMC) are gaining acceptance. Hence, there

exists a considerable scope in carrying out research in this area.

• Limited research has been conducted on machining behavior of metal matrix composites.

Further the research can be extended to study the effect of heat treatment and effect of

different reinforcement size on machinability.

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 REFERENCES
M.A. Hassan, T.C. for, A.M. Usman and N.Y. Godi ‘‘Development of Aluminium Metal Matrix Composite

Using Stir Casting Method” , Department of Mechanical Engineering, Modibbo Adama University of

Technology, P.M.B. 2076, Yola, Adamawa state, Nigeria.

Lokesh K. S., Bandu Ummaji, Gururaj P., K. Rayappa, Yashavantha J. Effect of Red Mud Particles on Scratch

Resistance of Aluminum Based Metal Matrix Composites. American Journal of Aerospace Engineering. Vol. 5,

No. 1, 2018, pp. 24-29.

T. S. A. Suryakumai, S. Ranganathan, J. Sai Krishna, N. Sanjeev Sai Reddy, K. Loknath Reddy, “ Development

of Aluminium Metal Matrix Composite”, Saveetha University, Chennai, India VOL. 11, NO. 12, JUNE 2016.

M.D.Antony Arul Prakash and M. Arockia Jaswin, “Microstructural Analysis of Aluminum Hybrid Metal

Matrix Composites Developed Using Stir Casting Process”, India.2015, 1(3), 333 - 339 ISSN: 2394-9260

(printed version); ISSN: 2394-92.

Anthony M. Xavior Vamsi krishna Mamidi, “An Investigation on the Mechanical Properties of Hybrid Metal

Matrix Composites”, Procedia Engineering 97, (2014).

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 REFERENCES
 Pardeep Sharma, Satpal Sharma, Dinesh Khanduja. “A study on microstructure of aluminium matrix

composites”, Journal of Asian Ceramic Societies 3 (2015) 240-244.

 Kemal Deliji,Vanja Asanovi, Dragan Radonji. “Mechanical and corrosion properties ofaa8011 sheets and

foils”,2006 Defence Technology xx (2015) 1-6.

 Gurvishal Singh,Harwinder Lal,Daljit Singh,Gurdeshbir Singh "An Approach For Improving Wear Rate of

Aluminum Based Metal Using Red Mud, Sic And Al2O3 Matrix Composites "International Journal of

Mechanical Engineering and Robotics Research. ISSN 2278 – 0149,Vol. 2, No. 1, January 2013.

 Shaik Mujeeb Quader, B. Surya Narayan Murthy, Pinninti Ravinder Reddy, “Processing and Mechanical

Properties of Al2O3 and Red Mud Particle Reinforced AA6061 Hybrid Composites’’, Journal of Minerals and

Materials Characterization and Engineering, Vol.4 No.2, March 2016.

 Rajmohan Thiagarajan, Kayaroganam Palanikumar, S. Arumugam, “Synthesis and characterization of sintered

hybrid aluminium matrix composites reinforced with nanocopper oxide particles and microsilicon carbide

particles”, Composites Part B: Engineering, Volume-59, page 43-49, Elsevier.

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 THANK YOU

PRASAD J SHETTY
PRASAD GOWDA K N
SURYA V S
VARUN KUMAR R

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