FABRICATION AND EVALUATION OF MECHANICAL

PROPERTIES OF ALUMINIUM (LM16) REINFORCED

WITH GRANITE AND GRAPHITE POWDER
A project report submitted to
JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY ANANTAPUR,
ANANTAPURAMU
In partial fulfillment of the requirements for the award of the degree of

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
Submitted by

K SANKAR SRINIVAS (17BF1A0335)

M PAVAN KALYAN (18BF1A0309)

B RENUKA RAJU (17BF1A0307)

M THARUN (17BF1A0352)
Under the esteemed guidance of
T PRATHEEP REDDY, M.TECH, Ph.D
ASSISTANT PROFESSOR

SRI VENKATESWARA COLLEGE OF ENGINEERING

(AUTONOMOUS)
DEPARTMENT OF MECHANICAL ENGINEERING
(Approved by AICTE, New Delhi & Affiliated to JNTUA, Anantapuramu)
Accredited by NBA (B.Tech - CIVIL, EEE, MECH, ECE, CSE & IT)
Opp. LIC Training Center, Karakambadi road, Tirupati-517507, A.P
(2017 – 2021)
 SRI VENKATESWARA COLLEGE OF ENGINEERING
(AUTONOMOUS)
DEPARTMENT OF MECHANICAL ENGINEERING
(Approved by AICTE, New Delhi & Affiliated to JNTUA, Anantapuramu)
Accredited by NBA (B.Tech - CIVIL, EEE, MECH, ECE, CSE & IT)
Karakambadi road, Tirupati-517507, A.P
2017 – 2021

CERTIFICATE
This is to certify that the project report entitled,

“FABRICATION AND EVALUATION OF MECHANICAL PROPERTIES

OF ALUMINIUM (LM16) REINFORCED WITH GRANITE AND
GRAPHITE POWDER”

is a bonafide work done by

K SANKAR SRINIVAS (17BF1A0335)
M PAVAN KALYAN (18BF1A0309)
B RENUKA RAJU (17BF1A0307)
M THARUN (17BF1A0352)
For the partial fulfillment of the requirements for the award of the degree of
BACHELOR OF TECHNOLOGY in MECHANICAL ENGINEERING, JNTUA,
Ananthapuramu.

Project Guide Head of the Department

T Pratheep Reddy, M.Tech. Ph.D. Dr. M. Chandra Sekhara Reddy, M.Tech., Ph.D.
Assiatant Professor Professor and Head of the Department
Dept. of Mechanical Engineering Dept. of Mechanical Engineering
S.V. College of Engineering S.V. College of Engineering

Submitted for project viva-voce held on:

INTERNAL EXAMINER EXTERNAL EXAMINER
 ACKNOWLEDGEMENT

We are thankful to our guide T Pratheep Reddy for his valuable guidance and
encouragement. His helping attitude and suggestions have helped in the successful
completion of the Project.

We would like to express our gratefulness and sincere thanks to

Dr. M. Chandra Sekhara Reddy, professor and Head of Mechanical Engineering
Department, for his kind help and encouragement during the course of my study and in the
successful completion of the Project work.

We have great pleasure in expressing our hearty thanks to our beloved principal
Dr. N. Sudhakar Reddy for his constant encouragement & advices to complete this project.

Successful completion of any Project cannot be done without proper support and
encouragement. We sincerely thank to the Management for providing all the necessary
facilities during the Course of study.

We would like to express my deep gratitude to all those who helped directly or
indirectly to transform an idea into Project.

We would like to thank our parents and friends, who have the greatest
contributions in all my achievements for the great care and blessings in making as
successful in all my endeavors.

K SANKAR SRINIVAS (17BF1A0335)

M PAVAN KALYAN (18BF1A0309)

B RENUKA RAJU (17BF1A0307)

M THARUN (17BF1A0352)
 DECLARATION

We hereby declare that the Project report entitled “FABRICATION AND

EVALUATIN OF MECHANICAL PROPERTIES OF ALUMINIUM (LM16)
REINFORCED WITH GRAPHITE AND GRANITE POWDER” submitted to
the
Department of Mechanical Engineering, Sri Venkateswara College of
Engineering, Tirupati in partial fulfillment of requirements for the award of the
degree of Bachelor of Technology.

This Project is the result of our own effort and it has not been submitted to
any other University or Institution for the award of any degree or diploma other than
specified above.

K SANKAR SRINIVAS (17BF1A0335)

M PAVAN KALYAN (18BF1A0309)

B RENUKA RAJU (17BF1A0307)

M THARUN (17BF1A0352)
 CONTENTS

CERTIFICATE i

DECLARATION ii

ACKNOWLEDGEMENT iii

ABSTRACT iv

CONTENTS v

LIST OF FIGURES vi

LIST OF GRAPHS vii

CHAPTER 1: INTRODUCTION 1-21

1.1 Composite Material 1

1.1.1 Natural Composites 2

1.1.2 Man-Made Composites 3

1.2 Why composite 4

1.3 History of Composites 4

1.4 Constituents of a Composite Material 5

1.4.1 Matrix Phase 5

1.4.2 Reinforcement (Dispersed) Phase 5

1.5 Types of Composite Materials 7

1.5.1 Classification of Composites on Matrix Material 7

1.5.2 Classification of Composites Based on Material 8

v
 1.6 Trends and history of metal matrix composites 11

1.7 Possible applications of metal matrix composites 11

1.8 Aluminium matrix composites 11

1.9 Production and processing of MMCs 12

1.9.1 Diffusion bonding 13

1.9.2 Deformation processing 14

1.9.3 Powder processing 14

1.9.4 Deposition techniques 16

1.9.5 Squeeze casting 17

1.9.6 Reactive processing 18

1.9.7 stir casting 19

CHAPTER 2: LITERATURE REVIEW 22-25

CHAPTER 3: COMPOSITION AND PROPERTIES 26-31

3.1 Identification of Need 26

3.2 Selection of Matrix 26

3.2.1 Chemical Composition of A(LM16) Alloy 27

3.2.2 Mechanical Properties of A(LM16) Alloy 28

3.3 Selection of Reinforcements 28

3.3.1 Granite 29

3.3.2Types of granite 29

3.3.3Graphite 31

3.3.4Types of graphite 32
 3.3.5Properties of granite 36

3.3.6Application of granite 36

3.4 Selection of Process 37

3.5 Selection of Optimal Composition 37

CHAPTER 4: EXPERIMENTAL WORK 39-42

4.1 Construction of Stir Casting Furnace 39

4.1.1 Preparation of Furnace 39

4.1.2 Preparation of Stirrer: 40
4.1.3 Temperature controller 40
4.1.4Consumables and Miscellaneous Materials 41
4.1.5 Procurement of Raw Materials 41

CHAPTER 5: METHODOLOGY 43-44

CHAPTER 6: RESULTS AND DISCUSSIONS 45-48

6.1 Density 45

6.2 Hardness 46

6.3 Tensile Strength 47

6.4 Modulus of elasticity 48

CHAPTER 7: CONCLUSION 49

CHAPTER 9: REFERENCES 50-51

 LIST OF FIGUERS

Figure 1.1 Classification of Matrix 5

Figure 1.2 Classification of Reinforcements 6

Figure 1.3 Classifications of Composites Based on Matrix Material 7

Figure1.4 Classification of Composites Based on Reinforcements 8

Figure 1.5Composite Materials with Metal Matrices 10

Figure 1.6 Diffusion Bonding Process 13

Figure 1.7 Deformation Process 14

Figure 1.8 Powder Processing 15

Figure 1.9 Squeeze Casting 18

Figure 1.10 Unidirectional Solidification Technique for Insitu 19

Figure 1.11 Stir Casting Process 21

Figure 4.1 Furnace 32.

Figure 4.2 Stirrer 33

Figure 4.3 Temperature Controller 34

Figure 4.4 Specimens 35

vi
 LIST OF GRAPHS

Graph 5.1 Comparison of Density 45

Graph 5.2 Comparison of Hardness 46

Graph 5.3 Comparison of Tensile Strength 47

Graph 5.4 Comparison of Modulus of Elasticity 48

Vii
 1. INTRODUCTION

1.1 Composite Material

A composite is when two or more different materials are combined together

to create a superior and unique material.

A composite material is made by combining two or more materials – often

ones that have very different properties. The two materials work together to give
the composite unique properties. However, within the composite you can easily tell
the different materials apart as they do not dissolve or blend into each other.

1.1.1 Natural Composites

Many of us may not be noticed that several, naturally formed materials

around us are composites.

Wood is a composite made from cellulose and lignin. The advanced forms
of wood composites can be ply-woods. An excellent example of natural composite
is muscles of human body. The muscles are present in a layered system consisting
of fibers at different orientations and in different concentrations. These result in a
very strong, efficient, versatile and adaptable structure. The muscles impart
strength to bones and vice a versa. These two together form a structure that is
unique. The bone itself is a composite structure. The bone contains mineral matrix
material which binds the collagen fibers together.

The other examples include: wings of a bird, fins of a fish, trees and grass.
A leaf of a tree is also an excellent example of composite structure. The veins in
the leaf not only transport the food and water but also impart the strength to the
leaf so that the leaf remains stretched with maximum surface area. This helps the
plant to extract more energy from sun during photo-synthesis.

1.1.2 Man-Made Composites

These composites are made by artificial mixing of two or more materials in

definite proportions under controlled conditions. Mud mixed straw to produce
stronger mud mortar and bricks, Plywood, Chipboards, Decorative laminates, Fiber

3
Reinforced Plastic (FRP), Carbon Composites, Concrete and RCC, Reinforced
Glass etc. The composites exist in day to day life applications as well. The most
common existence is in the form of concrete. The concrete is a composite made
from gravel, sand and cement. Further, when it is used along with steel to form
structural components in construction, it forms one further form of composite.

1.2 Why composites

The biggest advantage of modern composite materials is that they are light
as well as strong. By choosing an appropriate combination of matrix and
reinforcement material, a new material can be made that exactly meets the
requirements of a particular application. Composites also provide design flexibility
because many of them can be moulded into complex shapes.

1.3 History of Composites

The first uses of composites date back to the 1500s B.C. when early
Egyptians and Mesopotamian settlers used a mixture of mud and straw to create
strong and durable buildings. Straw continued to provide reinforcement to ancient
composite products including pottery and boats.

Later, in 1200 BC, the Mongols invented the first composite bow. Using a
combination of wood, bone, and animal glue, bows were pressed and wrapped with
birch bark. These bows were extremely powerful and extremely accurate.
Composite Mongolian bows provided Genghis Khan with military dominance, and
because of the composite technology, this weapon was the most powerful weapon
on earth until the invention of gunpowder.

As said, “Need is the mother of all inventions”, the modern composites, that is,
polymer composites came into existence during the Second World War. Duringthis
period the fighter planes were the most advanced fighting means. The light weight
yet strong materials were in high demand. Further, for application like housing of
electronic radar equipment require non-metallic materials. Hence, the Glass Fiber
Reinforced Plastics (GFRP’s) were first used in these applications.
 In 1935, Owens Corning introduced the first glass fiber, fiberglass.
Fiberglass, when combined with a plastic polymer creates an incredibly strong
structure that is also lightweight. This is the beginning of the Fiber Reinforced
Polymers (FRP) industry as we know it today.

1.4 Constituents of a Composite Material

In a composite, typically, there are two constituents. One of the constituent

acts as a reinforcement and other acts as a matrix. Sometimes, the constituents are
also referred as phases.

1.4.1 Matrix Phase

The primary phase, the monolithic material into which the reinforcement is
embedded, and having a continuous character, is called matrix. Matrix is usually
more ductile and less hard phase.

1.4.2 Classification of Matrix

The matrix in a composite material can be grouped based on the type of material as
below

Matrix

Metal Matrix Ceramic Polymer

Figure 1.1 Classification of Matrix

Reinforcement (Dispersed) Phase

The second phase (or phases) is embedded in the matrix in a discontinuous

form. This secondary phase is called dispersed phase. Dispersed phase is usually
stronger than the matrix, therefore it is sometimes called reinforcing phase.
Classification of reinforcements

The reinforcements in a composite material come in various forms.

Reinforcements

Fibers Particulate Flakes Whiskers

Figure 1.2 Classifications of Reinforcements

Fiber: Fiber is an individual filament of the material. A filament with length to

diameter ratio above 1000 is called as a fiber. The fibrous form of the
reinforcement is widely used. The fibers can be in the following two forms:

Continuous fibers: If the fibers used in a composite are very long and unbroken
or cut then it forms a continuous fiber composite. The fibrous composite is the
widely used form of composite.

Short/chopped fibers: The fibers are chopped into small pieces when used in
fabricating a composite. A composite with short fibers as reinforcements is called
as short fiber composite.

Particulate: The reinforcement is in the form of particles which are of the order of
a few microns in the diameter. The particles are generally added to increase the
modulus and decrease the ductility of the matrix materials. The composite with
reinforcement in particle form is called as particulate composite.

Flake: Flake is a small, flat, thin piece or layer (or a chip) that is broken from a
larger piece. Since these are two dimensional in geometry, they impart almost
equal strength in all directions of their planes. Thus, these are very effective
reinforcement components. The flakes can be packed more densely when they are
laid parallel, even denser than unidirectional fibers and spheres.
Whiskers: These are nearly perfect single crystal fibers. These are short,
discontinuous and polygonal in cross-section.

1.5 Types of Composite Materials

There are two classification systems of composite materials. One of them is

based on the matrix material and the second is based on the reinforcing material
structure.

1.5.1 Classification of Composites Based on Matrix Material

Since composite materials does not limit to any specific materials or metals,
matrix can be any of the materials like plastics, glass, metals etc. all these materials
were grouped based on the type of material. Figure 1.3 shows the classification of
composites based on the matrix materials.

Figure 1.3 Classification of Composites Based on Matrix Material

Metal Matrix Composites (MMC)

Metal Matrix Composites are composed of a metallic matrix (aluminum,

magnesium, iron, cobalt, copper) and a dispersed ceramic (oxides, carbides) or
metallic (lead, tungsten, molybdenum) phase.
Ceramic Matrix Composites (CMC)

Ceramic Matrix Composites are composed of a ceramic matrix and

embedded fibers of other ceramic material (dispersed phase).

Polymer Matrix Composites (PMC)

Polymer Matrix Composites are composed of a matrix from thermo set

(Unsaturated Polyester, Epoxy) or thermoplastic (Polycarbonate,
Polyvinylchloride, Nylon, Polystyrene) and embedded glass, carbon, steel or
Kevlar fibers (dispersed phase).

1.5.2 Classification of Composites on Reinforcing materials

Reinforcing material in composites can be of different materials or the

combination of two or more materials (Hybrid Composites). One simple schema
for the classification of composites bases on reinforcing material is shown in figure

Figure1.4 Classification of Composites Based on Reinforcements

Particulate Composites

Particulate Composites consist of a matrix reinforced by a dispersed phase in

form of particles.
Composites with random orientation of particles.

Composites with preferred orientation of particles. Dispersed phase of these

materials consists of two-dimensional flat platelets (flakes), laid parallel to each
other.

Fibrous Composites

Short-fiber reinforced composites. Short-fiber reinforced composites consist

of a matrix reinforced by a dispersed phase in form of discontinuous fibers.

Composites with random orientation of fibers.

Composites with preferred orientation of fibers.

Long-fiber reinforced composites. Long-fiber reinforced composites consist

of a matrix reinforced by a dispersed phase in form of continuous fibers.

Unidirectional orientation of fibers.

Bidirectional orientation of fibers (woven).

Structural Composites

Structural composites are combinations of composites and homogeneous

materials. When a fiber reinforced composite consists of several layers with
different fiber orientations, it is called multilayer (angle-ply) composite.

Composite Materials with Metal Matrix

Particulate composites consist of particles immersed in matrices such as

alloys and ceramics. They are usually isotropic since the particles are added
randomly. Particulate composites have advantages such as improved strength,
increased operating temperature and oxidation resistance etc. Typical examples
include use of aluminum particles in rubber, silicon carbide particles in aluminum,
and gravel sand, cement to make concrete.

Flake composites consist of flat reinforcements of matrices. Typical flake

materials are glass, mica, aluminum, and silver. Flake composites provide
advantages such as high out-of plane flexural modulus, higher strength, and low
cost.

Figure 1.5Composite Materials with Metal Matrices

1.6 History and trends of metal matrix composites:

Researchers tried numerous combinations of matrices and reinforcements

since work on MMCs began in the 1950s. This led to developments for aerospace,
but resultant commercial applications were limited. Initial work in late 1960s was
stimulated by the high performance needs of the aerospace industry. In these
development efforts, performance was the primary driver rather than cost. Boron
filament, the first high-strength, high modulus reinforcement, was developed both
for metal and organic matrix composites. The introduction of ceramic whiskers as
reinforcement and the development of in-situ eutectics in the 1960s aided high
temperature applications in aircraft engines. In the late 1970s automobile industries
started to take MMCs seriously. In the last 20 years, MMCs evolved from
laboratories to a class of materials with numerous applications and commercial
markets.

When continuous fiber reinforced MMCs were no longer needed for the
critical strategic defense system/missions, the development of those MMCs for
space applications came to an abrupt halt. Major improvements were still
necessary, and manufacturing and assembly problems remained to be solved. In
essence, continuous fiber reinforced MMCs were not able to attain their full
potential as an
Engineered material for spacecraft applications. However, particle reinforced
metals provide very good specific strength and stiffness, isotropic properties, ease
of manufacturing to near net shape, excellent thermal and electrical properties, and
affordability, making discontinuous MMCs suitable for a wide range of space
applications. During the development of MMCs, significant advancements were
made on the fundamental science and technology front, including a basic
understanding of composite behaviour, Fiber matrix interfaces, surface coatings,
manufacturing processes, and thermal mechanical processing of MMCs.
Subsequently, the technology experience benefited the later development of high
temperature inter metallic matrix composites.

1.7 Possible application of mmc’s:

Light alloy composite materials have, in automotive engineering, a high

application potential in the engine area (oscillating construction units: valve train,
piston rod, piston and piston pin; covers: cylinder head, crankshaft main bearing;
engine block: part-strengthened cylinder blocks). The reason for the application of
composite materials is as already described the improved high temperature
properties. Potential applications are in the area of undercarriages, e.g. transverse
control arms and particle strengthened brake discs, which can be also applied in the
area of rail mounted vehicles, e.g. for undergrounds and railway. Other
applications are in case of longitudinal bracing beam (stringer) for planes,
aerospace industry (frames, reinforcements, aerials and joining elements), spot
welding electrodes, bearings etc.

1.8 Aluminium matrix composites (amcs):

Aluminium is the most popular matrix for the metal matrix composites.
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. Aluminium matrix
composites (AMCs) have been widely studied since the 1920s and are now used in
sporting goods, electronic packaging, armours and automotive industries. They
offer
a large variety of mechanical properties depending on the chemical composition of
the Al matrix. They are usually reinforces by AL2O3, SiC, C but SiO2, B, BN,
B4C, AlN may also be considered. The aluminium matrices are in general Al-Si,
Al-Cu, 2xxx or 6xxx alloys. As proposed by the American Aluminium Association
the AMCs should be designated by their constituents: accepted designation of the
matrix/ abbreviation of the reinforcement’s designation/arrangement and volume
fraction in % with symbol of type (shape) of reinforcement.

1.9 Production and processing of mmcs:

The primary manufacturing process of MMCs can be classified as following:

1. Solid phase processing:

• Diffusion bonding

• Deformation processing

• Powder processing

• Sinter forging

• Deposition techniques

2. Liquid phase processing;

• Casting or liquid infiltration

• Squeeze casting or pressure infiltration

• Stir casting

• Reactive processing

• Spray processing

1.9.1 Diffusion bonding:

Diffusion bonding method is normally used to manufacture fiber reinforced

MMCs from sheets, foils, powder, tape or wire of matrix coated fibers. The
methods of assembling reinforcement fibers and matrix alloys depend upon fiber
type and fiber array perform method. Diffusion bonding is a common solid state
processing technique for joining similar or dissimilar metals as shown in Fig 1.4.
Inter diffusion
of atoms between clean metallic surfaces, in contact at an elevated temperature,
leads to bonding. Composite consolidation is achieved by applying a high pressure
in a direction normal to the ply surfaces and a temperature sufficient to produce
atomic diffusion of the applicable matrix alloy. This process is performed in a
vacuum environment. The principal advantages of this technique are the ability to
process a wide variety of metal matrices and control of fiber orientation and
volume fraction. There are many variants of the basic diffusion bonding process,
although all of them involve simultaneous application of pressure and high
temperature. Vacuum hit pressing is an important step in the diffusion bonding
processes for metal matrix composites. Hot Iso-static pressing (HIP), instead of
uniaxial pressing, can also be used. Long processing times, high processing
temperatures and pressures are its main advantages.

Fig 1.6 Diffusion bonding process

1.9.2 Deformation processing:

In Deformation process metal-metal composites mechanical processing like

swaging, extrusion, drawing or rolling of a ductile two phase material causes the
two phases to co-deform, causing one of the phases to elongate and become
fibrous in nature within the other phase. Roll bonding is a common technique used
to produce a laminated composite consisting of different metals in layered form as
shown in Fig
1.5. Such composites are called sheet laminated metal matrix composites. Roll
bonding and hot pressing have also been used to make laminates of Al sheets and
discontinuously reinforced MMCs. Other examples of deformation processed
metal matrix composites are niobium based conventional filamentary
superconductors with a copper matrix and the high TC superconductors with a
silver matrix commonly swaging and drawing are used to make wires and rolling is
used for tapes.

Figure 1.7 Deformation process

1.9.3 Powder processing:

Powder processing method involves cold pressing and sintering or hot

processing to fabricate primarily particle or whisker reinforced MMCs. It is used to
fabricate particulate or short fiber reinforced composites as shown in Fig 1.6.
 Figure 1.8 Powder processing

In powder process, the matrix and the reinforcement powders are blended to
produce a homogeneous distribution. The blending stage is followed by cold
pressing to produce what is called a green body. The cold pressed green body is
canned in a sealed container and degassed to remove any absorbed moisture from
the particle surfaces. The material is hot pressed, uniaxially or isostatically to
produce a fully dense composite and extruded. The rigid particles or fibers cause
the matrix to be deformed significantly. In addition, during hot extrusion dynamic
recrystallization takes place at the particle/matrix interface, yielding randomly
oriented grains near the interface and relatively textured grains far from the
interface.
1.9.4 Deposition techniques:

Deposition techniques for metal matrix composite fabrication involve

coating individual fibers in a tow with the matrix material needed to form the
composite followed by diffusion bonding to form a consolidated composite plate
or structural shape. The main advantage of using deposition techniques is that they
are time consuming. However, there are several advantages.

The degree of interfacial bonding is easily controllable and complaint

coatings can be formed on the fiber prior to matrix deposition or graded interfaces
can be formed.

Filament wound thin monolayer tapes can be produced that are easier to
handle and easier to mould into structural shapes than other precursor forms,

Several deposition techniques are available immersion plating,

electroplating, spray deposition, chemical vapour deposition (CVD) and physical
vapour deposition (PVD). Dipping or immersion plating is similar to infiltration
casting expect that fiber tows are continuously passed through baths of molten
metal, slurry, sol or organ metallic precursor.

Electroplating produces a coating from a solution containing the ion of the

desired material in the presence of an electric current. Fibers are wounded on a
mandrel which serves as the cathode and placed into the plating bath with an anode
of the desired matrix material. The advantage of this method is that the
temperatures involved are moderate and no damage is done to the fibers. Problems
with electroplating involve void formation between fibers and between fiber
layers, possible poor adhesion of the deposit to the fibers and limited numbers of
alloy matrices available for this type of processing.

A spray deposition operation may also be used. This technique typically

consists of winding fibers onto a foil coated drum and spraying molten metal onto
them to form a monotape. The source of molten metal may be powder or wire
feedstock which is melted in a flame, arc or plasma torch. The advantages of spray
deposition are the easier control of fiber alignment and rapid solidification of the
molten matrix.
 In the CVD process, a vaporized component decomposes or reacts with
another vaporized chemical on the substrate to form a coating on that substrate.
The processing is generally carried out at elevated temperatures.

1.9.5 Squeeze casting or pressure infiltration:

Porous performs of reinforcement material are infiltrated by molten under

pressure to produce metal matrix composites. Reinforcement materials include
carbon, graphite and ceramics such as oxides, carbides or nitrides. Reinforcement
forms include continuous fiber, discontinuous fiber and particulate. Metals used
include aluminium, magnesium, copper and silver. The volume fraction of
reinforcement in the metal matrix composites varies from 10 to 70 % depending on
the particular application of the material. Generally, the matrix which is shaped to
match the contours of the mould is not wet by the molten metal and must be
infiltrated under pressure. In squeeze casting, a hydraulically activated ram applies
a low controlled pressure to the molten metal to attain infiltration of the form
without damaging it, infiltration may or may not be vacuum assisted as shown in
Fig 1.7. Once infiltration of the complete, a high pressure applied to eliminate the
shrinkage porosity that can occur when the liquid metal contracts as it transforms
into the solid state. This complete consolidation or absence of porosity provides
the squeeze cast metal matrix composite materials with excellent mechanical
properties. Composites fabricated with this method have the advantage of minimal
reaction between the reinforcement and molten metal because of the short
processing time involved. Such composites are also typically free from common
casting defects such as porosity and shrinkage cavities.
 Figure 1.9 Squeeze casting

1.9.6 Reactive processing (in-situ composites):

There are several different processes that would fall under this category.
Unidirectional solidification of eutectics as shown in Fig 1.8, which one of the
phases solidifies in the form of fiber is one such process. Inherent limitations in the
nature and volume fraction of the reinforcement and the morphological instabilities
associated with thermal gradients have resulted in a decrease in the interest in these
types of composites. Exothermic reactions, such as directed metal oxidation, are
one family of processes for the processes for the production of in-situ composites.
The major advantage of this class of composites is that the in-situ reaction products
are thermodynamically stable. The composite materials are produced in one step
from an appropriate starting alloy, thus avoiding the difficulties inherent in
combining the separate components as done in a typical composite processing.
Controlled unidirectional solidification of a eutectic alloy typically results in one
phase being distributed in the form of fibers or ribbon in the matrix phase. The
relative size and spacing of the reinforcement phase can be controlled by simply
controlling the solidification rate, although the volume fraction of reinforcement
will always be constant. The solidification rate in practice, however is limited to a
range of 1-5 cm/h because of need to maintain a stable growth front which
requires a high
temperature gradient. Typically, reinforcements used include Sic or TiB2 in an
aluminium, nickel or an inter metallic matrix.

Figure 1.10 Unidirectional solidification technique for in situ

1.9.7 Stir casting

Stir casting is a liquid state method of composite materials fabrication, in

which a dispersed phase (ceramic particles, short fibers) is mixed with a molten
matrix metal by means of mechanical stirring as shown in Fig 1.9. The liquid
composite material is then cast by conventional casting methods and may also be
processed by conventional Metal forming technologies. Among the variety of
manufacturing processes available for discontinuous metal matrix composites, stir
casting is generally accepted as a particularly promising route, currently practiced
commercially. Its advantages lie in its simplicity, flexibility and applicability to
large quantity production. It is also attractive because, in principle it allows a
conventional metal processing route to be used and hence minimizes the final cost
of the product. This liquid metallurgy technique is the most economical of all the
available routes for metal matrix composite production and allows very large sized
components to be fabricated.

In preparing metal matrix composites by the stir casting method, there are
several factors that need considerable attention including
The difficulty of achieving a uniform distribution of the reinforcement material.
Weld ability between the two main substances.
Porosity in the cast metal matrix composite and
Chemical reactions between the reinforcement material and the matrix alloy.
One of the problems encountered in metal matrix composite processing is
the settling of the reinforcement particles during melt holding or during casting.
This arises as a result of density differences between the reinforcement particles
and the matrix alloy melt. The reinforcement distribution is influenced during
several stages including distribution in the as a result of mixing distribution in the
liquid after mixing but before solidification and redistribution as a result of
solidification. Proper dispersion of the particles in a matrix is also affected by
pouring rate, pouring temperature and gating systems. The method of introduction
of particles into the matrix melt is one of the most important aspects of the casting
process.

Casting process helps in dispersing the reinforcement materials in the melt.

The vortex method is one of the better known approaches used to create and
maintain a good distribution of the reinforcement material in the matrix alloy. In
this method, after the matrix material is melted, it is stirred vigorously to form a
vertex at the surface of the melt and the reinforcement material is then introduced
at the side of the vortex. The stirring is continued for a few minutes before the
slurry is cast. During stir casting for the synthesis of composites, stirring helps in
two ways:

Transferring particles into the liquid metal, and

Maintaining the particles in a state of suspension
A successful casting process must be able to produce a composite in which
the particles are uniformly dispersed throughout the matrix.

Wet ability is another significant problem when producing cast metal

matrix composites. Wet ability can be defined as the ability of a liquid to spread on
a solid surface. It also describes the extent of intimate contact between a liquid and
a solid. Several approaches have been taken to promote the wetting of the
reinforcement particles with a molten matrix alloy, including the coating of the
particles, the addition of alloying elements to the molten matrix alloy, the
treatment of the
particles and ultrasonic irradiation of the melt. The addition of certain alloying
elements can modify the matrix metal alloy by producing a transient layer between
the particles and the liquid matrix. This transient layer a low wetting angle
decreases the surface tension of the liquid and surrounds the particles with a
structure that is similar to both the particles and matrix alloy.

Figure 1.11 Stir Casting

 2. LITERATURE REVIEW

In the last two decades, research has shifted from monolithic materials to
composite materials to meet the global demand for light weight, high performance,
environmental friendly, wear and corrosion resistant materials. Metal Matrix
Composites (MMCs) are suitable for applications requiring combined strength,
thermal conductivity, damping properties and low coefficient of thermal expansion
with lower density. These properties of MMCs enhance their usage in automotive
and tribiological applications. In the field of automobile, MMCs are used for
pistons, brake drum and piston block because of better corrosion resistance and
wear resistance.
There is a growing interest worldwide in manufacturing hybrid metal matrix
composites [HMMCs] which possesses combined properties of its reinforcements
and exhibit improved physical, mechanical and tribological properties.

DiASil (Die Cast Aluminium (Silicon) Piston, its application can be found on
Yamaha R series bikes. A conventional piston has a steel sleeve, but the
DiACpiston doesn’t need a steel sleeve because it is made of abrasion-resistant
aluminium alloy. The all-aluminium combustion chamber has a heat dissipation
rate that is three times better than steel, which means great cooling performance.
DiASilPiston adds a Silicon carbide content of 20% to the aluminium alloy to
achieve the required hardness to resist abrasion. Honda Company used AMMC for
piston liners in some of their engines like F20C, F22C and H22A.

M.L. Ted Guo and C.Y.A. Tao 2000 [1] contain considered tribology
performance of Al-SiC and graphite hybrid combination by unusual graphite
composition and found that friction coefficient decreases with the addition of
graphite up to 5% and no considerable change noticed with further increase in
graphite and also observed that hardness of the composite decreases with addition
of graphite M. Singh, et al. 2000 [14] and M Singh, et al. 2001 [2] has conducted
tribology tests on LM6 aluminium alloy reinforced with 10% Granite particles.
Samples were made by stir
casting method in an oil fired furnace. Sliding wear tests were conducted on pin-
on- disc machine at different applied loads. It was noticed that hardness and
tribological properties were improved by the addition of granite particles to the
matrix alloy and the seizure pressure of the complex be higher than the medium
alloy.

S.Naher, D.Barbizon and L. Looney 2003 [3] has simulated stir casting process
using different blade designs and studied the effects of stirring speed, blade angles
and number of blades on the uniform dispersion of SiC particles into different
liquid medium and time required for uniform dispersion of particles. They noticed
the excessive vortex height is responsible for air entrapment into the liquid and is
more in more viscous liquid. It was observed that settling times of particles only
depends on the viscosity of the liquid metal and does not depend on the stirring
speed and blade design.

Neelima, Mahesh, & Selvaraj, 2011has the maximum tensile strength has been
obtained at 15% B4C ratio. This indicates that the Aluminium Boron carbide
composite material is having less weight and more strength.

Dunia Abdul Saheb 2011 compared the micro and macro structural behavioural
of Al-B4C particulate composites by varing the weight fractions of B 4C. This study
reveals that increasing trend of hardness with the increase in carbide up to 4 wt%
weight fraction. Beyond this the hardness of composite decreases as graphite
particles interact with each other leading to clustering of particles.

Blaza 2009 studied on Hybrid aluminium metal matrix composits applications in

the automotive industries for the production of engines, piston rings, cadar shift &
sockets are studied. The use of hybrid aluminium metal matrix composites instead
of monolithic or metal matrix composites results in reduction of weight improves
the decrease fuel consumption of automobile vehicles

G. Sivakaruna 2009, conducted a survey was made on effects of reinforcement on

aluminium metal matrix composites. The reinforcement is ceramic material like
silicon carbide, aluminium –di-oxide, boron carbide & tungsten carbide which are
reinforced with aluminium & their properties were studied. The survey results the
ceramic reinforcement materials improves the mechanical properties like tensile
strength & hardness compared with base metal aluminium.
N. Venkatkishore 2007, studied on AL is reinforced with the boron carbide (B4C)
metal matrix was produced. The fabricated composites were introduced to study
the wear behaviour in wear testing machine. Wear rate decreases and an increasing
trend of hardness and tensile strength with increase in weight percentage of B4C.
This showed B4C reinforcement particulates improves the mechanical & wear
resistance
.

S. Naher, D. Brabazon and L. Looney 2003 has simulated stir casting process
using different blade designs and studied the effects of stirring speed, blade angles
and number of blades on the uniform dispersion of B4C particles into different
liquid medium and time required for uniform dispersion of particles. They noticed
the excessive vortex height is responsible for air entrapment into the liquid and is
more in more viscous liquid. It was observed that settling times of particles only
depends on the viscosity of the liquid metal and does not depend on the stirring
speed and blade design.

Dania Abdul Sahib 2011 [5] compared the micro and macro structural behavioral
of Al-SiC and Al-Gr particulate composites by varing the weight fractions of SiC
and Graphite. This study reveals that increasing trend of hardness with the increase
in graphite up to 4 wt% weight fraction. Beyond this the hardness of composite
decreases as graphite particles interact by every other most important to cluster of
elements.

G. G. Sozhamannan, S. Balasivanandha Probe and V. S. K. Venkatagalapathy

2012 [6] observed that production of Aluminium composite reinforced with
discontinuous ceramic particulates. By Stir casting route force have homogeneous
mix and is cost successful method. The most important difficulty in this equipment
is near obtain enough wet of elements in the water ceramic with to obtain a
standardized distribution of the stoneware particle.

Rohit Kumar, Ravi Rajan, & R K Tyagi, 2013 [7], The yield force with tensile
force of the combination reduce by rising the quantity part of the Sic element, as
the stiffness of the complex add to by growing the amount portion of the SiC
element
.so that impact strength increases by increase in amount fraction of reinforcement
at a certain limit (upto10 %) after starts decreasing.
Till now, significant work has been done on production of MMC’s especially on
producing light and durable composites using aluminium. Various works has been
done for strengthening aluminium with reinforcements. In this regard, number of
researchers conducted experiments on aluminium composite with graphite and
granite reinforcements separately. In that, aluminium with graphite and granite
reinforcement is very less tested. The present work will focus on fabrication
mechanical properties of aluminium composite with Granite and Graphite
reinforcements.

Additionally, composites are on the path towards being more

environmentally friendly. Resins will incorporate recycled plastics and bio-based
polymers. Composites will continue to make the world lighter, stronger, more
durable, and a better place to live.
 3. COMPOSITION AND PROPERTIES

3.1 Identification of Need

Usage of automobiles was increasing day to day. But at the same time, search
for alternate fuels increased as the conventional non-renewable sources of
petroleum getting depleted. Simultaneously, automotive industries promoting the
development of lighter and fuel efficient vehicles considering the manufacturing
costs and the life of the vehicle.

Composite materials have big advantages over steel in automobile

manufacturing. Composites are being considered to make lighter, safer and more
fuel-efficient vehicles. Affordability is an important issue in vehicle
manufacturing, which includes factoring in the costs associated with a car’s
complete life-cycle including manufacturing, operating and disposal costs.

In view of developing less dense, low cost, highly durable materials for the
automobile components, composites were the best choice for obtaining materials
with such type of properties. Even though aluminium has replaced most of the
ferrous based engine components like piston head, piston, piston block etc., its
usage was restricted to very few applications due to very less wear resistance of
aluminium alloys. This can be improved by pairing aluminium alloy with the
materials having good tribiological properties.

3.2 Selection of Matrix

Aluminium is a relatively soft, durable, lightweight, ductile and malleable metal.

Aluminium is remarkable for the metal's ability to resist corrosion due to the phenomenon of
passivation. Aluminium has a lower density of 2.7 glee compared to 7.8 glee of steel.
Aluminium alloys are lightweight with good corrosion resistance, ductility and strength. The
greater use of aluminium can decrease vehicle weight, improve its performance and reduce
fuel costs.
Pure aluminium possesses relatively poor casting features, for this reason castings are
prepared from aluminium alloys. The main alloying elements are silicon, copper, magnesium,
zinc, etc. Aluminium silicon alloys have good casting and corrosion resistance properties.
The fluidity increases with silicon addition. The addition of copper to aluminium increases its
strength and hardness. The aluminium copper alloys are heat treatable and possess good
machinability. Nowadays, aluminium alloys are replacing the ferrous alloys in manufacturing
of automobile components.

Even though aluminium alloys have such remarkable properties usage of aluminium is
limited to some components because, compared to ferrous alloys, aluminium alloys possess
less hardness and wear resistance which can be improved by mixing suitable reinforcement.
Among various aluminium alloys LM16 (Al – SiSCuMg0.5) is one of the most popular
aluminium alloy used for water-cooled cylinder heads, valve bodies, water jackets, cylinder
blocks, fire hose couplings. air compressor pistons, fuel pump bodies, aircraft supercharger
covers and similar applications where leak-proof castings having the high strength produced
by heat- treatment are required. The physical properties of composite materials are generally
not isotropic (independent of direction of applied force) in nature, but rather are typically an.
Isotropic (different depending on the direction of the applied force or load). For instance, the
stiffness of a composite panel will often depend upon the orientation of the applied forces
and/or moments. Panel stiffness is also dependent on the design of the panel.
3.2.1 Chemical Composition of Aluminium (LM16) Alloy
The chemical composition of aluminium (LM16) alloy is as below

Copper 1.0 - 1.5

Maru1esium 0.4 - 0.6
Silicon 4.5 - 5.5
Iron 0.6 max
Mang anese 0.5 max
Nickel 0.25 max
Zinc 0.1 max
Le ad 0.1 max
Tin 0.05 max
Titanium 0.2 max
Aluminium Remaining

3.2.2 Mechanical properties of LM16 alloy:

The mechanical properties of aluminium LM16 is as follows

Tensile Stress (N/mm2) 270 - 280

Impact ResistanceIzod (Nm) 1.4

Brinell Hardness 100 - 110

Modulus of Elasticitv (xl 03 71

N/mm2)
 3.3 Selection of Reinforcements

Aluminium has very poor wear resistance compared to ferrous alloys. To

increase the hardness and wear properties of aluminium alloy, reinforcement must
possess relatively high hardness and wear resistance. Ceramics are the materials
which stood in the top and well ahead of ferrous alloys. If we can make a sound
composite with ceramics as reinforcement, then the composite may possess
superior qualities equivalent or better than the ferrous alloys.

In this regard, the reinforcement should also possess the chemical stability
while mixing with aluminium. Materials having corrosion resistance, self-
lubricating properties etc. will be an added advantage in this process.

Research has already been started to improve the tribological properties of

aluminium alloy. Different experiments showed that the materials like B 4C,
graphite, granite, garnet, silicon carbide, Boron nitride and titanium carbide etc.
improved the hardness and wear properties of aluminium alloys.

This work is mainly concentrated to develop a hybrid composite reinforced

with granite powder and graphite powder particulate.

3.3.1 Granite

Coarse- or medium-grained intrusive igneous rock that is rich in quartz and

feldspar; it is the most common plutonic rock of the Earth’s crust, forming by the
cooling of magma (silicate melt) at depth.

3.3.2 Types of Granite

Granite may occur in dikes or sills (tabular bodies injected in fissures and inserted
between other rocks), but more characteristically it forms irregular masses of extremely
variable size, ranging from less than eight kilometers (five miles) in maximum dimension to
larger masses (batholiths) that are often hundreds or thousands of square kilometers in area.

The principal constituent of granite is feldspar. Both plagioclase feldspar and alkali
feldspar are usually abundant in it, and their relative abundance has provided the basis for
granite classifications. In most granite, the ratio of the dominant to the subdominant feldspar
is less than two. This includes most granites from the eastern, central, and south-western
United States, south-western England, the Fennoscandian (Baltic Shield) area, western and

central France, Spain, and many other areas.

Rocks containing less than 20 percent quartz are almost never named granite, and
rocks containing more than 20 percent (by volume) of dark, or ferromagnesian, minerals are
also seldom called granite.

The minor essential minerals of granite may include muscovite, biotite, amphibole,
or pyroxene. Biotite may occur in granite of any type and is usually present, though
sometimes in very small amounts. The sodic-amphiboles and pyroxenes (riebeckite,
arfvedsonite, aegirine) are characteristic of the alkali granites.

There are two major source regions for producing molten granite: igneous and
sedimentary protoliths (source rocks). These result in I-type granitoids, derived from igneous
protoliths and containing moderate amounts of Al2O3 and high amounts of Na2O, and S-type
granitoids, derived from sedimentary protoliths and containing high amounts of Al2O3 and
relatively low amounts of Na2O. Amphibole and pyroxene are more common in I-type
granitoids, while S-type granitoids may have garnet, cordierite, and sillimanite. Both types of
granitoids may also contain biotite and muscovite.

H-type or hybrid granites are formed following a mixing of two granitic magmas
from different sources, e.g. M-type and S-type. Most geologists today accept that a
combination of these phenomena can be used to explain granite intensions, and that not all
granites can be explained entirely by one another mechanism.

A-type or androgenic granites are formed above volcanic "hot spot"

activity and have peculiar mineralogy and geochemist1y. These granites are formed by
melting of the lower crust under conditions that are usually extremely dry. The rhyolites
of the Yellowstone caldera are examples of volcanic equivalents of A-type granite.
The properties of granite are as follows:-

SiO2 72.04
(Silica)
Al2O3 14.42
(Alumina)
K2O 4.12
Na2O 3.69
Cao 1.82
FeO 1.68
Fe2O3 1.22
MgO 0.71
TiO2 0.30
P2O5 0.12
MnO 0.05
..

3.3.3 Graphite

The mineral graphite is an allotrope of carbon. Unlike diamond

(another carbon allotrope), graphite is anelectrical conductor, a semimetal.
It is, consequently, useful in such applications as arc lamp electrodes.
Graphite is the most stable form of carbon under standard conditions.
Therefore. It is used in thermochemistry as the standard state for defining
the heat of formation of carbon compounds. Graphite may be considered
the highest grade of coal, just above anthracite and alternatively called
meta- anthracite, although it is not normally used as fuel because it is
difficult to ignite.

Graphite and graphite powder are valued in industrial applications

for their self-lubricating and dry lubricating properties. And hence,
graphite may support granites hardness by providing a layer self-
lubrication between contact surfaces resulting in increase of wear
resistance.
3.3.4Types of granite
The Different types of graphite:
1. Natural Graphite
1. High Crystalline graphite
2. Amorphous graphite
3. Flake graphite
2. Synthetic Graphite.
1. Natural Graphite

Natural graphite is a mineral form of graphitic carbon. It varies considerably in crystallinity.

Most of the commercial graphite is mine and usually contains other minerals. After graphite
is mine, it usually requires a considerable amount of mineral processing like froth flotation to
concentrate the graphite.

Natural graphite is an excellent conductor of heat and electricity that is stable over a wide
temperature range and is a high-strength material with a high melting point of 3650 ° C. It is
mostly used for refractories, batteries, steelmaking, expanded graphite, brake linings, foundry
facings, and lubricants.

Natural graphite is available in three forms, all of which are processed from naturally sourced
graphite material. The three forms each have unique properties that make them well-suited
for certain applications.

1.1 Crystalline Graphite

It is said that crystalline vein or lump graphite is considered to be the rarest, most valuable,
and highest quality form of natural graphite. It is formed by direct deposition of solid
graphitic carbon from underground high-temperature fluids such as crude oil and has been
converted to graphite by time, temperature and pressure.

Sri Lanka is the only jurisdiction currently producing crystalline vein graphite. Crystalline
venous graphite is easy to shape and can be formed into solid shapes without the aid of a
binder additive, resulting in significant cost savings over lower quality raw materials.
Crystalline vine graphite cracks typically have a thickness between 1 cm and 1 m and usually
have a purity of more than 90% Cg. It has a purity of 95-99% carbon without refining. It is
suitable for many uses as flake graphite and provides a distinct competitive advantage in
terms of market prices and product applications such as lubricants, batteries, grinding wheel,
and powder metallurgy.

1.2 Amorphous Graphite

Amorphous graphite is commonly formed by contact metamorphosis between an anthracite

coal seam and a metamorphic agent. The result is microcrystalline graphite, commonly
known as amorphous graphite. Amorphous graphite is the most limited graphite among
natural graphite. The graphite content varies between 25% and 85% depending on the
geological environment.
It was found as extremely small, crystal-like particles in beds of mesomorphic rocks such as
coal, slate, and slate. The comparatively low carbon purity varies between 70 and 85%
carbon after refining. It is not visible unless viewed under magnification.

It is used for low-quality graphite products such as pencils, lubricants, refractories, paint
making, metallurgy, coatings, brake pads, and rubber additives. It’s the cheapest form of
graphite. Large deposits of amorphous graphite are found in China, Mexico, and the United
States.

1.3 Flake Graphite

Natural flake graphite is formed when carbon material is exposed to high pressure and
temperature. The carbon source material can be either organic or inorganic, although most
commercially available flake graphite is derived from organic deposits. The pressure required
is usually greater than 1 gigapascal and the temperature required is usually greater than 750
degrees Celsius.

Flake graphite can be found in metamorphic rocks that are evenly distributed throughout the
ore body or in concentrated lens-shaped pockets. The range of carbon concentrations varies
between 5% and 40%. Flake graphite can be found as a lamellar or flaky shape in certain
metamorphic rocks such as limestone, gneiss, and schists.
Foam flotation is used to extract flake graphite. “Floating” graphite has a graphite content of
80% -90%. More than 98% of the layer was made using graphite chemical preparation
processes. Flake graphite can be found in many places around the world.

2. Synthetic Graphite

Synthetic graphite can be generated from coke and pitch. Although this graphite is not as
crystalline as natural graphite. It is possible to have highly ordered pyrolytic graphite or
highly oriented pyrolytic graphite (HOPG) refers to graphite with an angular spread between
the graphite sheets of less than 1°.

There are basically two types of synthetic graphite. One is electro graphite; pure carbon
produced from coal tar pitch, and calcined petroleum coke in an electric furnace.
The second is synthetic graphite, created by heating calcined petroleum pitch to 2800 °C.

Basically, synthetic graphite has higher electrical resistance and porosity, and lower density.
Its enhanced porosity makes it unsuitable for refractory applications.

Synthetic graphite contains mainly graphitic carbon that has been attained by graphitization,
heat treatment of non-graphitic carbon, or chemical vapor deposition from hydrocarbons at
temperatures over 2100 K.

Application of synthetic graphite aerospace applications, carbon brushes, graphite electrodes,

batteries, and moderator rods in nuclear power plants

The high level of porosity of synthetic graphite makes it unsuitable in refractory applications.

Uses of Graphite

Graphite has been used since ancient times. It has a wide range of applications in the modern
world too.
 Writing Materials
 Lubricants
 Refractory
 Nuclear Reactors
  Batteries
 Graphene Sheets
1. Writing Materials

The word graphite is from the Greek language which translates as ‘to write’. So the most
common use of graphite is in making the lead in pencils. This lead is a mixture of clay and
graphite which is in an amorphous form.

2. Lubricants/Repellents

Graphite is one of the main ingredients in lubricants like grease, etc. This mineral reacts with
atmospheric water vapour and creates a thin film or layer over the surface applied and thus
reduces friction. Graphite is also used in car brakes and clutches.
The powdered form of lump graphite is also used in paints. Why? Well, graphite by nature is
water-repellent. So it offers a protective coating on wood and other surfaces.

3. Refractories

Due to its high tolerance to heat and unchangeability, Graphite is a widely used refractory
material. It finds its use in the manufacturing industry and it helps in the production of glass
and steel as well as processing of iron.

4. Nuclear Reactors

Graphite can absorb fast-moving neutrons. As a result, it is used in reactors to stabilize

nuclear reactions.

5. Electrical Industry

Crystalline flake graphite is used in the manufacturing of carbon electrodes, brushes, and
plates needed in dry cell batteries and the electrical industry. Interestingly, natural graphite is
also processed into synthetic graphite. This type of graphite is useful in lithium-ion batteries.

6. Graphene Sheets

Graphite can be used to make graphene sheets. These sheets are said to be 100 times stronger
and 10 times lighter than steel. This derivative of graphite is further used in making
lightweight
and strong sports equipment. Many are considering future applications in the field of the
medical and aerospace industry.

3.3.5 properties of Graphite

The properties of graphite:

Graphite has a high melting point, similar to that of a diamond. It is a soft, slippery feel, and
is used in pencils and as a dry lubricant for things like locks. It has a lower density than
diamond. It is insoluble in water and organic solvents.
Graphite is used in pencils and lubricants. It is a good conductor of heat and
electricity. Its high conductivity makes it useful in electronic products such as electrodes,
batteries, and solar panels. Due to its high tolerance to heat and unchangeability, Graphite is
widely used in refractory material.
Graphite is a medium gray color. As a color name, it is used interchangeably with
“charcoal”. It refers to the “lead” in wooden pencils, which are actually made from a
graphite-based pigment and a clay binder.

Graphite structure
3.3.6 Applications of graphite

 Batteries

 Steelmaking

 Brake linings

 Foundry facing and lubricant Pencils

3.4 Selection of Process

There were many advanced process for producing metal matrix composites
with discontinuous particulate reinforcement. Among all the processes, stir casting
route by producing vortex in the crucible by means of mechanical stirring is the
most suitable and cost effective method for producing larger components with
homogeneous mixture of metal-ceramic particulates.

Most of the automobile components were produced by means of liquid

metallurgy technique. This type of process is simple and cost effective technique
of producing components. Stir casting is also one of the liquid metallurgy
techniques for producing metal matrix composite.

3.5 Selection of Optimal Composition

It is obvious that the properties of the final composite depend on the optimal
composition of the

Boron carbide. According to various studies conducted on Al-Gr MMC’s, better

properties were obtained up to 4% of graphite in the Al matrix and the grain size of
graphite particulates varies from 40 to 150 microns based on process parameters.
And the best suitable size is 80 microns.

It was observed that very less work has been conducted on Al – granite and
graphite00 MMC’s. It was observed that the conducted studies were only on 4%
w/w Graphite and up to 20% W/W in Al matrix. In this regard, Graphite ranging
from 4% to 8% w/w will be sufficient for the present work for the research
purpose.
Since very less work was carried out on Graphite and Granite, by comparing with
similar ceramic particulates like silicon and boron carbide, the grain size of
graphite and granite particulates ranging from 50µm to 200µm may give better
results.

Since a hybrid composite is going to be prepared. Composition of

reinforcements for obtaining better composite may differ from the results obtained
from studies done with a single reinforcement. The resulting composite may show
combined results of aluminium and granite and graphite. By studying Al-graphite
and granite composites, it was observed that the graphite can be limited to 10%
w/w. If we get the increasing trend with increase of graphite, this work can be
further extended to graphite and granite composition up to 25% w/w.
 4. EXPERIMENTALWORK

4.1 Construction of Stir Casting Furnace

For the present work we require a stir casting furnace with 3 blade graphite
stirrer. Since stir casting is not a conventional casting method we have to design a
suitable one. Even though some stir casting furnaces are readily available in the
market, a custom made conventional stir casting furnace is a lot cheaper and is best
suited for the present work to vary process parameters according the requirements.

A conventional stir casting furnace consists of the following basic components.

Furnace
Crucible
Temperature Controller
Stirring Equipment
4.1.1 Preparation of Furnace

A furnace is prepared by using a cylindrical thick sheet metal drum. The

inner wall of furnace is lined with refractory ceramic material to prevent heat
losses and is sealed with glass wool material which is prepared form glass.

figure. 4.1 furnace

Total furnace was made with kanthaal wire. It is applicable to produce heat up
to 13500C. It is protected by 15mm thickness of ceramic material integrated with
10% of iron.
4.1.2 Preparation of Stirrer:

Non-homogeneous particle distribution is one of the greatest problems in

casting of metal matrix composites (MMC’s), because of different materials have
different density, melting point and boiling point. But other light materials like
Aluminium, copper and magnesium etc. have less density of melting point and
boiling point, so particle mixing is very difficult to light materials.

So, 200 rpm high torque reversible motor is taken and connected with a
potentiometer for varying speeds as per the requirement. The motor shaft is
coupled to a stainless steel rod and the other end is connected to a graphite three-
blade impeller and grinded to the desired angle for producing vortex and it is tested
by stirring water in the crucible.

Figure 4.2 stirrer

4.1.3 Temperature controller

A temperature controller is an instrument used to control temperature. The

temperature controller takes an input from a temperature sensor and has an output
that is connected to a heating element.
 To accurately control process temperature without extensive operator
involvement, a temperature control system relies upon a controller, which accepts
a temperature sensor such as a thermocouple as input. It compares the actual
temperature to the desired control temperature and provides an output to a control
element. The controller is one part of the entire control system, and the whole
system should be analyzed in selecting the proper controller.

Figure. 4.3 Temperature controller

4.1.4 Consumables and Miscellaneous Materials

A 15 litre silicon carbide crucible is bought for this purpose and is preheated
to red hot condition (6500C) to relieve from internal stress. A stand is prepared for
mounting of stirrer assembly above the furnace. To avoid vibrations in the stirrer,
motor is mounted on springs which damp the vibrations. A ceramic cap is used to
prevent motor from exposing to direct heat from the furnace. The stand is made as
such that some small adjustments can be made to centre the stirrer to the crucible.

4.2 Procurement of raw materials

A project is carried with the help of SIBAR Auto Parts Limited. Aluminium alloy
(A356) is given from the company’s inventory which was used for the production of
some engine parts. Boron carbide powder is purchased from the Metrex powder
metallurgy in vizag with the help of our guides. Graphite blade is purchased from a
metal powders shop in Chennai and is also designed for desired particle size and
shape.

Final tested specimens in the figure 4.5

 5. METHODOLOGY

Metal is melted in a furnace and the stirrer is mounted on the top of the furnace. The
molten metal is transferred to the cavity by using M.S ladle which carries 400 grams of
molten aluminium. The metal is maintained at 710oC temperature in the stir casting furnace.

At first raw aluminium of weight 4 kg is taken in to the stir casting furnace and it
melted to 6650C. And taken sample with 0% of composite. After that graphite and granite of
4% and 5% (i.e. 50 grams) by weight is measured separately and simultaneously preheated in
LPG Gas burner with the help of stainless steel ladle. When the temperatures in the furnace
were settled nearly above 700oC metal treatment is carried out by adding coverall to the
molten metal which removes oxides and other impurities in the metal. Later, stirrer is inserted
and allowed to rotate and create vortex in the crucible. The speed of the stirrer is controlled
using potentiometer to get desired vortex. After the desired speed is maintained in the
crucible reinforcements were added slowly to the vortex and after the completely adding the
reinforcements the stirrer is further allowed to rotate for ten more minutes for uniform
distribution of particulates.

After stirring, molten metal form the crucible is poured using ladle into the mould
cavity and allowed to cure for about two minutes and removed from the cavity. The
remaining metal in the crucible is also used for taking the test samples. Same procedure is
followed for producing samples of 4% graphite and 10%granite and 4% of graphite and
15%granite. All the samples were grouped and marked based on the composition of
reinforcements and is sent to heat treatment process.

All the samples were fully heat treated which includes solution heat treatment for 12
hours at 520-530oC and quenched in hot water followed by precipitation treatment of 8 hours
at 170oC.
 After heat treatment on samples the following operations were performed.
 Specimens were analysed for variation in density as per Archimedes principle.

 Specimens were freed from risers and turned to required dimensions on a lathe
machine portions were shaped to rectangular sections and polished.

 Hardness test was conducted on the riser sections.

 Tensile test was conducted on turned samples with the help of Universal testing
machine. And average values of each composition were noted.
 6. RESULTS AND DISCUSSIONS
TEST REPORT

The following values were obtained for the Aluminium (LM 16)-Graphite and Granite
composite for the tests conducted.

TABLE4: UTM TEST RESULTS

S.no Parameters Sample Sample Sample

1 2 3
1 Hardness(BHN) 109 145 152
2 Tensile Strength (N/mm2) 283 292 298
3 Modulus of Elasticity (x103 73 76.2 78.4
N/mm2)
4 Density (kg/m3) 2706 2687 2680

RESULTS WITH DISCUSSIONS

Following temperature behavior of each sample, every example is present individually
experienced used for the mass, resistance with tensile force with the normal standards be
through evaluate by the not anything example. It outcome in a range of test be discussed
below.

Used for hardness in arrangement with intrigues, starting at this point beyond clean.
LM-16 alloy sample were referred because Group 0, LM-16 by 4% Graphite and 5%
Granite samples were referred as Group 1and LM-16 with 4% Graphite and 10% Granite
samples were referred as Group 2.

PHYSICAL PROPERTIES OF SAMPLES

6.1Density:

Thickness of every sample to be present calculated stand resting on Archimedes standard

within a calibrate beaker pot. it can be noticed near the mass of set1 is a smaller amount of
evaluate near the other groups as the mass in graphite face dust be a smaller amount balance
to aluminum and granite extra, in mass of set 2 be increased as in the add to the granite
composition into a complex but not more than the density of Group 0, which may be due to
the volume occupation by the 4% graphite particles in the composite.

45
 5.1comparision of density

6.2Hardness:

At some point except can affect interfacial. Since the granite is superior by aluminum and
graphite, in general it can be expected that the domination of granite within add to
resistance to the compound. The sensible explanation exposed to the stiffness of the
combination improved significantly. It be note toward the add to stiffness starting Group 0
near Group1 is has a difference and the increase form Group 1 to Group 2. This can be
considered that the inclusion of granite in the aluminium gives hardness to the composite
but the further increase of granite has given a little increase in hardness due to the
domination of aluminum alloy over the composite since the composition of granite is only
10% of weight. Further addition of graphite may give considerable increase hardness

5.2Comparison of hardness
6.3Tensile Strength:

When the material can resist high pressure still as individual extended, interfacial
connection can influence to the highest amount on tensile strength of the composite. We
observe the tensile strength to be improved by the composites but don’t have equal
difference. Less interference bond can be reduce the tensile strength

Composite material samples

5.3Comparsion of tensile strength

6.4Modulus of elasticity:

Modulus of Elasticity is linear relative with tensile strength as similar as traditional

equipment. In capable of survey to the modulus of softness to be improved however not
really as identical tensile strength. The elongation of objects is comparable toward the bottom
alloy, since all the samples are entirely heat treated, the samples will increase fragility and
stability down ductility which capacity exist resulted in propensity of frail.

5.4 comparison of modulus of elasticity

 7. CONCLUSION

CONCLUSION:-

From the experimental of present work, the following conclusions are drawn.

1. Addition of granite determination increases the mechanical property of the composite.

2. By comparing with amount of granite in the composite LM-16 with 4% graphite and 5%
granite is most suitable for regular casting process.

3. Hardness of the composite increased by 25.9% for 4% Graphite - 5% Granite and 37%
for 4% Graphite - 10% Granite.

4. It was noticed that the density of the composite is slightly reduced due to less density of
graphite.

5. From the analysis the total deformation has been decreased by 5.7% for 4% Graphite -
5% Granite and 8.7% for 4% Graphite - 10% Granite. So, it can be concluded that this
composite material in engine cylinders can be used for higher capacities than that of which
they are now using
 8. REFERENCES

[1] Royal Society of Chemistry. [Online]

httpJ/\V\Vw.rsc.org Education/Teachers/Resources/Inspirational/resources/4.3.1.pdf.
[2] Todd Johnson History of Composites. [Online]
http://composite.about.com/odlaboutcompositesplastic/asiRistoryofC omposites.htm.
[3] Dr. P. M. Mohite. Composite Materials and Structures. N"PTEL. [Online] IIT.
http://nptel.iitm.ac.in/cuorses/101104010/.
[4] Fractography, fluidity, and tensile properties of aluminium/hematite particulate composites.
S. C. Sharma, et al. 3, s.l: Springer US, June 1999, Journal of Materials Engineering and
Perfo1mance, Vol 8, pp. 309-314.
[5] Aluminium Metal-Matrix Composites for Automotive Applications: Tribological
Consideration. SS. V. PRASAD and R. ASTHANA 3,
s.l: Kluwer Academic Publishers-Plenum Publishers, October 2004, Tribology Letters, Vol. 17,
pp. 445-453.
[6] Tribological Behaviour of Aluminium/Alumina/Graphite Hybrid Metal Matrix Composite
Using Taguchi's Techniques. R Subramanian, N Radhika and S. Venkat Prasat.5, s.l.: Scientific
Research Publishing Inc., 20 Apt 2011, Journal of Minerals & Materials Characterization &
Engineering, Vol. 10, pp. 427-443.
[7] 16 Secrets of Yan1aha Technology. http J/www.yamaha-motor i.ndia.com. [Online] India
YA.t\.1AHA Motor Pv1. Ltd. http://www.yamaha-motor-
india.com/16secrets/cylinder/index.html.
[8] MANUFACTURING OF Aiv1MCS USING STIR CASTING PROCESS AND TESTING
ITS MECHANICAL PROPERTIES. Kandpal, Bhaskar Chandra, et al. III,
s.l.: Technical journals online, July-Sept. 2013, International Journal of Advanced Engineering
Technology, Vol. IV, pp. 26-29. E-ISSN 0976-3945.
[9] Investigation on the Mechanical Perfom1ance of Silicon Carbide Reinforced Using Stir Cast
and Grain Refined 6069 Matrix Composites. Rohit Kumar, Ra, Rajan and R K Tyagi. 1, s.l.
Journal of Machinery Manufacturing and Automation, March 2013, Vol. 2.
[10] Effect of Processing Parameters on Metal Matrix Composites: Stir Casting Process.
G. G. Sozhamannan, S. Balasivanandha Prabu and
V.S. K. Venkatagalapathy. 1, January 2012, Journal of Surface Engineered Materials and
Advanced Technology, Vol. 2, pp. 11-15.
[11] Mechanical characterization of Aluminium silicon carbide composite. Neelima
Devi C, Mahesh V and Selvaraj N. 4, s.l. International Journal of Applied Engineering
Research, 2011, Vol. I.
[12] Aluminum Silicon Carbide and Aluminum Graphite Particulate Composites.
Dunia Abdul Saheb. 10, October 2011, ARPN Journal of Engineering and Applied Sciences,
Vol. Vol. 6, pp. 42-48.
[13] Simulation of the stir casting process. S. Naher, D. Brabazon and L. Looney. s. l. Elsevier,
December 2003, Journal of Materials Processing Technology, Vols. 143- 144, pp. 567- 571.
[14] Preparation and properties of cast aluminium alloy-granite particle composites. M.
Singh, et al. 1, 7 s.l.: Kluwer Academic Publishers, 2000, Journal of Materials Science, Vol. 35,
pp. 4421-4426. 0022- 2461.