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Materials Today: Proceedings 21 (2020) 1104–1110 www.materialstoday.com/proceedings

ICRACM-2019

Mechanical Characterization of Stir Cast Al-7075/B4C/Graphite

Reinforced Hybrid Metal Matrix Composites
B. Jayendraa, D. Sumantha, G. Dinesha, Dr.M. Venkateswara Raob*
a
Students, Department of Mechanical Engg, Bapatla Engineering College, Bapatla-522101, India
b
Professor, Department of Mechanical Engg, Bapatla Engineering College, Bapatla-522101, India

Abstract

The modern technology requires the materials with light weight, high strength, high stiffness and superior mechanical properties.
The mechanical properties of metal matrix composites (MMCs) are critical to their potential application as structural materials. A
systematic examination is required to study the effect of particulate weight fraction on the mechanical properties. Aluminium
based metal matrix composites find varied applications in aerospace, defence, automobile, sports equipment and electronics due
to their favourable properties. Al 7075 is a light weight castable alloy with moderate hardness and strength and finds applications
in automotive and aerospace. The addition of refractory reinforcement generally improves the hardness, tensile strength and high
temperature properties of the material. The present investigation focuses on characterization of Stir cast Al-7075/B4C/Graphite
reinforced Hybrid Metal Matrix Composites. Adding B4C with varying reinforcement of three cases, in first case 2% constant
with varying graphite 1%, 3%, and 5%, in second case 4%, and in third case 6% constant with varying same graphite percentage,
the aluminum matrix hybrid composites have been fabricated by stir-casting method at 650 °C. Castings for tensile testing were
prepared in circular metal mold of diameter 20 mm and length 120 mm. The specimens of 55×10×10 mm with 2 mm notch for
impact test, 20×10×10 mm for microscopy analysis and hardness test are cut from a cast ingot of 100×50×10 mm using CNC
EDM wire cutting. Specimens are prepared as per the ASTM standards and Microstructure investigation, ultimate tensile
strength, impact strength and hardness measurements have been correlated with the percentage of B4C and Graphite particles.
The effects of B4C and Graphite particle content on the mechanical properties were investigated. The grain size by using the
mean intercept length method, Standard deviation and 95% confidence intervals were determined at different weight fractions.
© 2019 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of SIXTH INTERNATIONAL CONFERENCE ON RECENT ADVANCES IN COMPOSITE
MATERIALS, ICRACM-2019.

Keywords: Metal matrix composites; Boron Carbide; Graphite; Stir Casting; CNC EDM Wire cutting.

* Corresponding author. Tel.: +91 94410 12134.

E-mail address: mvr2007rao@rediffmail.com

2214-7853© 2019 Elsevier Ltd. All rights reserved.

Selection and peer-review under responsibility of SIXTH INTERNATIONAL CONFERENCE ON RECENT ADVANCES IN COMPOSITE
MATERIALS, ICRACM-2019.
 B. Jayendra et al. / Materials Today: Proceedings 21 (2020) 1104–1110 1105

1. Introduction

Metal-matrix composites consist of two or more materials where tailor made properties are obtained by
systematic combinations of different constituents. Systematic design and synthesis procedures allow unique
combinations of properties in composites like fatigue strength, hardness, damping property, electrical and friction
coefficient, wear resistance and coefficient of thermal expansion. The quest for improved performance has resulted
in the development of MMC fabrication technology. These include both the preparation of the reinforcing phases
and fabrication techniques. Several composite fabrication techniques have been developed and classified into four
categories. They are: (i) liquid metallurgy, (ii) powder metallurgy (iii) diffusion bonding of filaments and foils, and
(iv)vapor phase infiltration. The liquid metallurgy technique is the least expensive of all

2. Literature review

Observed that Aluminum alloy (Al7075) with Bagasse Ash and Graphite give more enhanced mechanical
properties which signifies in Bagasse Ash selection criteria for fabrication [1]. Proved for solid lubrication graphite
is most important component [2]. Observed that for ceramic reinforcement graphite is essential for solid lubrication
[3]. Noticed that for different states like solid, liquid, both combination of metal matrix composites the mechanical
behavior results in differences in dislocations of composite particles [4].Worked on Interface Estimation Process
(IEP) and studied the microstructure behavior of composite material [5].Observed the properties like self-
lubrication, tribology, coefficient of friction with variation of Graphite over total composite [6]. Observed the
specific utility of Gr and SiC for better improvement of mechanical properties and noticed that more Gr results in
reduction of mechanical strength and more SiC makes difficulty in machining of specimen [7].Studied the dry
sliding wear behavior of Aluminum composite with 5% weight composite of SiC and B4C. Focused Ion Beam (FIB)
is the technique used for Characterization. An enhanced wear resistance is obtained with small addition of
reinforcement particles [8].Observed the wettability and porosity for uniform reinforcement distribution [9].
Calculations over microstructure for Grain Sizes, Standard Deviations, 95% Confidence Interval (95%CI) using
Degrees of Freedom relationship [10].
Most of the work reported in the literature has been found on Aluminum alloys, such as Al 357, Al 359, Al 2618,
Al 2214, Al 6063 and Al 6061.However, limited work has been reported on the use of Al 7075 as a matrix material
with two different reinforcement materials. No work has been reported in the literature on the use of AI7075 with
two different reinforcements i.e. Boron Carbide (B4C) and Graphite.

3. Experimental details

3.1. Material Selection

3.1.1. Matrix Material

Al 7075 alloy is chosen as matrix material owing to its wide application in many engineering sectors including
automotive and aerospace sectors. Further, this alloy exhibits good strength and formability. Table 1&2 shows the
material composition and chemical composition of Al 7075 alloy used in this study.

3.1.2. Reinforcement Material

Boron Carbide (B4C) and Graphite (Gr) are taken as the reinforcement materials.

3.2. Composite Preparation

Hybrid Al7075-B4C-Gr Composites were fabricated by Stir casting technique. Three types of Composites were
prepared as reported below.
1106 B. Jayendra et al. / Materials Today: Proceedings 21 (2020) 1104–1110

Table 1. Material Composition in percentage

S. NO Al 7075 B4C Graphite
1 97 2 1
2 95 2 3
3 93 2 5
4 95 4 1
5 93 4 3
6 91 4 5
7 93 6 1
8 91 6 3
9 89 6 5

Table 2. Chemical composition of Al 7075 alloy as matrix material (wt %)

Elements Zn Mg Cu Cr Al
% 5.6 2.5 1.6 0.23 Balance

Al 7075: 97% (ρ = 2.810 gm/cm3)

B4C :2% (ρ = 2.648 gm/cm3)
Gr : 1% (ρ = 2.28gm/cm3)
ρc= 2.80146 gm/cc
Mass = ρc × V= 2.80146× 87699.1/1000 gms =245.69 gms
Total Mass = 245.69 gms + 300 gms (slag) = 545.69 gms
Mass of Al 7075 = 0.97×545.69 =529.193 gms
Mass of B4C = 0.02×545.69 =10.9138 gms
Mass of Gr = 0.01×545.69 = 5.4569 gms
3.3. Methodology
The Composites used in this study are produced by Stir casting method. The matrix material used in the present
work is Al 7075 and the reinforcement materials are Boron carbide (B4C) and Graphite particulates of grain size
200-300 mesh.
3.4. Brinell Hardness Test
The specimens are prepared as per the ASTM standards (10×20 mm cross section). The specimens are machined
according to the specified dimensions and then polished to eradicate any burrs or irregularities on the surface. The
Brinell hardness test is carried on samples by applying 250 kgs load for 10 seconds using hardness tester IS
1500:2005 at Hyderabad Engineering Labs, Kukatpally, Hyderabad. Experimental data regarding the hardness for
different wt fractions of B4C are given in Table 3.
The Fig.1 shows that the hardness of the reinforced composites was much higher than the base material alloys. It
can also be seen from the Fig.1 that the hardness of the composite is found in increasing trend with the increase of
graphite percentage and is found maximum of 159 for 2% B4C, 3% graphite and 95% Al 7075 MMC.
Table 3. Effect of B4C on Hardness
S.NO Composition BHN BHN
Variation of BHN with B4C in Wt%
B4 C Graphite 1 2 3 Mean(M)
200 1 2% 1% 111 111 121 114.33
Hardness (BHN)

150 1% of 2 2% 3% 138 138 159 145

Graphite 3 2% 5% 121 138 138 132.33
100 3% of
Graphite 4 4% 1% 121 121 121 121
50
5% of 5 4% 3% 123 121 121 121.67
0 Graphite 6 4% 5% 121 138 138 132.33
2% 4% 6% 7 6% 1% 138 138 121 132.33
B4C in Wt% 8 6% 3% 121 121 121 121
Fig.1. Variation of BHN with B4C 9 6% 5% 121 121 138 126.67
3.5. Impact Test
The specimens for the impact test are prepared as per ASTM standards according to the dimensions shown in
Fig.2. The test is performed for determining the impact resistance of materials using Charpy impact testing machine.
 B. Jayendra et al. / Materials Today: Proceedings 21 (2020) 1104–1110 1107

Impact test is carried on the machine KRYSTAL ELMEC serial number 2006/912 KI-300 using test procedure IS
1757-1988 at room temperature at Hyderabad Engineering Labs, Kukatpally, Hyderabad.
Impact resistance is the measure of toughness. From Fig.3 it is noted down that the impact strength is increasing
with the increase of wt% of Graphite and the maximum value of 4 Joules is noticed at the wt% of graphite 3 and 5
for all the composites. Table 4 gives the information about the impact strength of specimens at various B4C wt%.

All dimensions are in mm

Fig.2. Impact test specimen

Table 4. Effect of B4C on Impact Strength

S NO Composition Impact strength (J)
Variation of Impact Strength with B4C in Wt% B4 C Graphite
1 2% 1% 2
Impact Strength (Jouls)

5
4 2 2% 3% 4
1% of Graphite
3 3 2% 5% 4
2 3% of Graphite 4 4% 1% 2
1 5 4% 3% 4
5% of Graphite
0 6 4% 5% 4
2% 4% 6% 7 6% 1% 4
B4C in Wt % 8 6% 3% 4
9 6% 5% 4
Fig.3. Variation of Impact Strength with B4C

3.6. Tensile Test

The specimens are prepared according to the ASTM standards as shown in the Fig.4. The ultimate strength and
yield strength values for different wt fractions of B4C are obtained by conducting tensile test on Universal Testing
Machine, with the standard ASTM B 557:2015 at Hyderabad Engineering Labs, Hyderabad, are given in Table 5
and Table 6.
The Fig.5 and Fig.6 shows the variation of ultimate tensile strength and yield tensile strength respectively with
respect to the B4C and graphite for different MMCs. These values are increasing with the increase of graphite
percentage but variation in the values is nominal. It is due to the fact that the B4C and graphite reinforcement
exhibits a good bonding with Al 7075.

All dimensions are in mm

Fig.4. Tensile test specimen
1108 B. Jayendra et al. / Materials Today: Proceedings 21 (2020) 1104–1110

Table 5. Ultimate Strength of Composites in MPa

S NO Composition UTS
B4 C Graphite Variation of UTS with B4C in Wt%

Ultimate Tensile Strength(UTS)

1 2% 1% 129.306 250
2 2% 3% 134.259 200
1% of Graphite
3 2% 5% 141.896 150

MPa
4 4% 1% 130.486 100 3% of Graphite

5 4% 3% 136.338 50 5% of Graphite
0
6 4% 5% 137.223
2% 4% 6%
7 6% 1% 132.301 B4C in Wt%
8 6% 3% 191.828
9 6% 5% 136.248
Fig.5. Variation of Ultimate Strength with B4C

Table 6. Yield Strength of Composites in MPa

S NO Composition Yield Strength
Variation of YTS with B4C in Wt%
B4 C Graphite
Yield Tensile Strenth(YTS)

200 1 2% 1% 118.785
2 2% 3% 125.331
150 1% of Graphite
3 2% 5% 133.588
100 3% of Graphite
MPa

4 4% 1% 121.273
50 5% of Graphite 5 4% 3% 129.922
0 6 4% 5% 133.312
2% 4% 6% 7 6% 1% 122.370
B4C in Wt % 8 6% 3% 172.678
9 6% 5% 129.534
Fig.6. Variation of Yield Strength in Tension with B4C

3.7. Microstructure
The Al-cast composites are polished to obtain mirror like smooth surface. It will expose the grain boundary,
secondary phases visible in the microscope, Fig. 9, at higher magnification. The properties of composites depend on
the microstructure and interface characteristics between reinforcements and matrix.Fig.9 shows the optical
microstructures of B4C and graphite reinforced MMCs. From microstructure analysis, there was no indication of
clustering or agglomeration of reinforcements in the MMCs. This was due to the non-variation of contact time
between B4C and Graphite particle in the liquid Al during composites processing and uniform distribution of
reinforcements during stirring process. The Fig.7 and Fig.8 shows the variation of Standard deviation and 95%
Confidence interval respectively with respect to B4C & Graphite for the Specimens tested under the microscope.
The mean intercept length, Standard deviation , 95% Confidence interval and the grain size obtained from the
microstructure for different weight fractions of B4C are given in Table 7.
95% confidence interval (CI) = t×S
(n − 1)
Here t & (n-1) are taken from the relationship from table 2.1 [10]
S is Standard Deviation; n is Degrees of freedom
n = (3N-5); N=3(since number of components are 3)

S=
 Xi − X

( )  n is number of intercepts; G= - 6.645 × log (l) - 3.298 (here l is mean intercept length)
 ( n − 1) 
 
 B. Jayendra et al. / Materials Today: Proceedings 21 (2020) 1104–1110 1109

Table 7. Effect of B4C on Microstructure

Composition Standard
ASTM Mean Intercept 95% Confidence Calculated
S.NO Intercepts deviation
B4 C Graphite Grain size length(µm) interval Grain size(G)
(SD)
1 2% 1% 7.5 250 21.9742 0.494 90.69 7.7205
2 2% 3% 7.5 252 21.7998 0.516 94.80 7.7430
3 2% 5% 7 181 30.3511 0.485 89.10 6.7880
4 4% 1% 7 192 28.6123 0.235 43.14 6.9584
5 4% 3% 7 191 28.7621 0.258 47.40 6.9400
6 4% 5% 7 183 30.0194 0.447 82.17 6.8190
7 6% 1% 7.5 213 25.7913 0.527 96.75 7.2570
8 6% 3% 7 199 27.6058 0.262 48.18 7.0620
9 6% 5% 7.5 228 24.0945 0.224 41.19 7.4546

Variation of Standard Deviation with B4C in Variation of 95% CI with B4C in Wt%

95% Confidence
0.6 Wt% 150
Standard Deviation

Interval(CI)
1% of 1% of
0.4 100 Graphite
Graphite
(SD)

0.2 50 3% of
3% of
Graphite 0 Graphite
0
2% 4% 6% 2% 4% 6%
5% of 5% of
B C in Wt% Graphite B4C in Wt% Graphite
4

Fig.7. Variation of Standard Deviation with B4C Fig.8. Variation of 95% CI with B4C

Al7075+2% B4C+1% Gr Al7075+4% B4C+1% Gr Al7075+6% B4C+1% Gr Al7075+2% B4C+3% Gr Al7075+4% B4C+3% Gr

Al7075+6% B4C+3% Gr Al7075+2% B4C+5% Gr Al7075+4% B4C+5% Gr Al7075+6% B4C+5% Gr

Fig.9. Micro Structures of Composites

Conclusions

In this experimental study, MMCs of varying B4C and Graphite content were prepared using stir casting
fabrication technique. Micro structural aspects, hardness, Ultimate tensile strength, yield tensile strength, impact
strength and grain size of the prepared composites were studied. Based on the experimental evaluation, following
conclusions can be drawn
• It was found that the hardness of the composite is in increasing trend with the increase of graphite
percentage and is found maximum of 159 for 2% B4C, 3% graphite and 95%Al7075 MMC. The hardness
of the MMC’s were found much higher than the base material alloys.
• The impact strength is increasing with the wt% of Graphite and the maximum value of 4 Joules is noticed
at the wt% of graphite 3 and 5 for all the composites.
• As B4C and graphite reinforcement exhibits a good bonding with Al7075, the tensile strength of composites
is increasing with the increase of graphite percentage.
1110 B. Jayendra et al. / Materials Today: Proceedings 21 (2020) 1104–1110

• It is apparent from the microstructures that there was no indication of clustering or agglomeration of
reinforcements in the MMCs.
• The Standard deviation and 95% confidence interval were determined for all the metal matrix composites.
• The grain sizes calculated using mean intercept length method is found nearer to the ASTM grain sizes.

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