Material Technology Group Colloquium, 18 February 2005

Development Of Al- Fly Ash Composites Using Stir Casting Technique

Mohd Harun, Hafizal Yazid, Shaiful Rizam Shamsudin, Zaiton Selamat, Mohd Shariff
Satta. Mohd Khairi Mohd Said and Muhammad Bin Jalil
Industrial Technology Division, Malaysian Institute For Nuclear Technology Research
(MINT),
Bangi 43000 Kajang, Selangor

ABSTRACT

A stir casting technique was used in producing the aluminum based composite reinforced
with fly ash particles. The ash particles obtained from power plant using coal
combustion. The objective was to obtain a well distribution of reinforced particles in the
metal matrix composites. Wettability factor is major obstacles in order to obtain good
distribution of the particles in the aluminum matrix. Thirteen procedures have been
carried out to obtain the optimum processing parameter. The pre-treated ash particles
with the correct processing parameters is used to introduce the ash particles into the
matrix. This paper discussed the design, development and production of aluminum based
composite reinforced with ash particles using the MINT`S bottom pouring furnace.

Keywords: Bottom pouring furnace; Stir casting; Metal Matrix Composites; Stirring
Speed; Reinforced Particles

1. Introduction

The aim involved in finding the best processing parameters to produce metal matrix
composite with homogeneous distribution of reinforcement particles, essential for
optimum mechanical properties. A stir casting process is carried out by using a furnace
completed with a controlled temperature system and stirring speed. The process
involves producing a melt of the selected matrix material, followed by introduction of a
reinforcement material into the melt, obtaining a suitable dispersion through stirring. The
melt containing stirred particles is solidified in the mould to obtain desired distribution of
the dispersed phase in the matrix. The particle distribution in the matrix depends on
process parameters during both the melt and solidification stages of the process [1]. The
parameters are viscosity of the liquid, heat transfer rate, wettability of materials, stirring
method, agglomeration of the reinforcement before and after mixing, and pattern or
mould shape and temperature. High speed of impeller rotation is needed to ensure an
even distribution of less dense reinforcing particles throughout the denser metal matrix.
For getting uniform distribution of secondary ceramic particles in liquid matrix metal,
proper understanding of the impeller parameters is essential (2). The stir casting process
is more suitable for making composites which contain up to 30 volume percentage of
particulate dispersoids. The composites can include combinations like metal-fly ash,
metal-oil ash, metal-graphite, metal-silicon carbide, metal-carbon etc. The combination
with low cost reinforcement particles such as fly ash will result in significant decreases in
cost of components, and significant improve in machinability, wear resistance and

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damping capacity [3]. The stir casting is generally accepted as a particular promising
route because of its simplicity, flexibility and applicability to large quantity production. It
also minimizes the final cost of product.

This paper provides some methods in producing of MMC using stir casting techniques
with a bottom pouring furnace developed at MINT.

2. Experimental

2.1 Composite Preparation

The cleaned and weighed aluminum ingot are super heated above its melting temperature
in a bottom pouring composite melting furnace. The melting also will be degassed with
argon gas to reduce the gas bubbles in the melt. At the same time, stirring is initiated to
homogenize the temperature. Cast iron coated with ceramic propeller is used for the
stirring. The propeller is attached to a variable speed motor with maximum speed of 3000
rpm. The impeller is fabricated in accordance with the law of fluid flow and particle
movement to create vortex motion. The depth of impeller shall be immersed
approximately one third of the height of the molten metal from the bottom of the crucible.
The temperature and stirring speed are noted. At this temperature the preheated fly ash
particles will be introduced into the melt surface of the Al melt along with Mg pieces
weighing a total of 1% by weight of melt in order to improve the wettability. The
temperature during the addition of fly ash particles is raised gradually and stirring is
continued until interface between particles and matrix promotes wetting. The melt is then
superheated above liquidus temperature of about 700-770oC and then poured into a
permanent mould. Table 1 shows the list of procedures used in this work.

2.2 Furnace Design

The schematic diagram and photo of the MINT`S furnace are shown in Figure 1 and 2
respectively.

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 Figure 1: Furnace schematic diagram. Figure 2: Furnace photo.

2.3 Parameters To Be Considered

In preparing metal matrix composites by the stir casting method, there are several factors
to be considered:

i. Difficulty of achieving a uniform distribution of the reinforcement

particles,
ii. Wettability between the reinforcement particles and matrix,
iii. Porosity in the cast metal matrix composites, and
iv. Chemical reaction between the reinforcement particles and matrix.

In order to achieve optimum properties of MMC, distribution of the reinforcement

particles in the matrix must be uniform, bonding or wetting between the reinforcement
particles and matrix should be optimized, the porosity level should be minimized and the
chemical reaction between the reinforcement particles and alloy matrix must be avoided.

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 Figure 3: Stirring speed set-up Figure 4: Mould heating

Figure 5: Sample removal Figure 6: Tensile test piece sample

.

3. Results and Discussion

3.1 Fly ash analysis

3.1.1 AAS Technique

Components Wt.%
Silica 64.58
Alumina 25.11

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 Iron oxide 6.24
Titanium oxide 1.77
Calcium oxide 0.13
Magnesium oxide 2.94
Sodium oxide 0.79
Potassium oxide 1.17
Sulphur trioxide 0.46
Phosphorous pentoxide 0.31

3.1.2 EDX Analysis

Table 4: Elemental Composition as obtained from EDX.

Elements Al Fe Si Ca K Ti O
(weight %)
Coal Fly ash 11.31 4.14 27.94 0.77 0.99 0.70 54.15
Incinerator

Figure 7: EDX Analysis

3.2 Crystallinity phases in fly ash

The results of XRD analysis for precipitator fly ash from coal combustion are shown in
Figure 8. All sharp peaks indicates the presence of quartz (SiO 2) and mullite
(3Al2O3.2SiO2).

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 Figure 8: XRD Analysis

3.1 Morphology and EDS Analysis

3.1.1 Optical Microscopy

Optical microscopy carried out on the as-cast samples of Aluminium-5% fly ash
produced using Procedure 7. The microstructure is shown in Figure 9. As a comparison,
Aluminium-5% SiC also has been produced (Procedure 6) as shown in Figure 10. The
present of small amount porosity and clustered of SiC and fly ash particulates are
observed. However, at many locations, free of porosity and particulates are also observed.

The samples are cut, polished and observed under optical microscope.

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Figure 9: Al-fly ash composites Figure 10: Al-SiC composites for
comparison

3.1.2 Scanning Electron Microscopy and EDS Analysis.

Electron morphology of fly ash and its EDX analysis were shown in Figures 11 and 12.
The results of electron microscopy on as-cast samples of Aluminium-5% fly ash and
Aluminium-5% SiC are shown in Fig. 13 and Fig. 18 respectively. They reveal poor
interfacial bonding between fly ash particles and the matrix. However, the good bonding
between SiC paricles and aluminum matrix was seen as shown in Figure 21.

Figure 11: Fly ash particles Figure 12: EDS of fly ash particles

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 E

A
B C D

Figure 13: Microstructure of Al-fly ash Figure 14: EDS on spot A, small round
composites. Spot A-E are fly-ash.
subjected to EDS analysis.

Figure 15: EDS on spot B, Al matrix. Figure 16: EDS on spot C, square fly ash.

Figure 15: EDS on spot D, silicon flake. Figure 16: EDS on spot E, big round fly ash.

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 Figure 17: Poor bonding between fly ash and Al matrix.

Figure 18: Microstructure of Al-SiC Figure 19: EDS on spot F, Al matrix.

composites.

Figure 20: EDS on spot G, SiC particle. Figure 21: Good bonding between SiC and
Al matrix.

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 4. Conclusions

Process parameters play vital role in getting uniform distribution of reinforcement

particles. The parameters are wettability of materials, agglomeration of the reinforcement
before and after mixing, pattern or mould shape, melt and pouring temperatures and
optimum impeller speed and impeller design.
The major problem to incorporate ash particles into matrix is wetting, the following
activities will be carried out to improve the wetting :

i.
Furnace must be sealed.
ii. Improve pre-treatment on fly ash (for good wettablity and reduce agglomeration).
iii. Use pure argon or cover with nitrogen gas to reduce formation of oxide layer on the
melt surface.
iv) Use 1% master alloy Mg+Zr or Mg+Al for wetting agent.
v) Make a mixture of ash and aluminum particles by mechanical alloying technique.
Acknowledgements

We would like to thanks to Dr Abd. Nassir Ibrahim, Director of Industrial Division, Dr

Azali Muhamad, Head of Materials Technology Group, MINT for their advice and
valuable discussion. We also like to thank to En. Romzie Ismail, Foundry Unit, SIRIM
for valuable discussion and technical advices on casting technology. We would also like
thanks to MOSTE for providing a research grant (IRPA 03-01-03-0009-EA001).

References

[1] J. Hashim et al., J. Mater. Processing Technology Vols. 123 (2002) 251-257
[2] N. Aniban et.a l., Materials and Design, Vol. 23 (2002) 553-556
[3] P. K. Rohatgi et al., Key Eng. Mater. Vols. 104-107 (1995) 283-292

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 Ja

List of Parameters Used in Each Procedure

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Soalan-soalan dan Perbincangan

1- Kenapakah fly-ash daripada stesen janakuasa Kapar yang dipilih? Apakah

kelebihannya? (Dr. Meor)

Setesen Janakuasa Kapar menggunakan sumber arang batu yang menghasilkan

abuterbang sama dengan mana-mana setesen janakuasa. Abuterbang ini adalah bahan
seramik yang bersifat ringan. Perbezaan kandungan kimia dalam abuterbang
bergantung kepada kualiti arang batu yang digunakan dan pembakaran yang berlaku.
Oleh itu kandungan kimia didalam abuterbang adalah berbeza-beza jika kadar
pembakaran yang berlaku adalah berbeza. Ia dipilih kerana mudah diperolehi dan
terdekat dengan MINT, bukan atas dasar ia mempunyai kelebihan kerana perbandingan
tidak dibuat dengan abuterbang dari setesen janakuasa yang lain.

2- Berapakah julat saiz fly-ash yang digunakan dalam kajian ini? (Dr. Wan)

Julat saiz fly ash yang digunakan adalah antara 30 hingga 50 µm.

3- Adakah menggunakan design propeller yang tertentu? Jika ada berapa banyak
design? (Dr. Che Seman)

Setakat kajian literature yang dilakukan terdapat 10 bentuk (design) yang telah
digunakan. Buat pada masa ini, propeller yang digunakan dalam kajian ini hanya satu
jenis design sahaja ia itu jenis `axial’ blade. Kos untuk menghasilkan satu propeller
adalah tinggi oleh itu tumpuan dilakukan terhadap satu blade ini sahaja.

4- Adakah pengiraan weight loss dilakukan sebelum dan selepas proses treatment?
(Pn. Norhayati)

Pengiraan `weight loss’ tidak dilakukan terhadap fly ash sebelum dan selepas proses
rawatan. Jika factor ini boleh membantu untuk melihat kesannya terhadap sifat
`wettability’ yang amat diperlukan maka ia akan dilakukan pada masa akan datang.
 

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