MAULANA AZAD NATIONAL INSTITUTE OF

TECHNOLOGY BHOPAL

Mechanical Engineering Department

B. TECH. 4th YEAR
MAY 2020

MAJOR PROJECT REPORT

Study of Fabrication of SiC & Aloe Vera Powder

Reinforced Aluminium Matrix Composite

UNDER THE GUIDANCE OF SUBMITTED BY

Dr. Mohan K. Pradhan Aamir Hussain 161116205
PROFESSOR (Asst.) Malesh Para 161116215
DEPT. OF MECHANICAL ENGINEERING Toyesh Lilhore 161116216
MANIT BHOPAL Gule Haider Syed 161116217
Mohammad Faisal 161116220
 MAULANA AZAD NATIONAL INSTITUTE OF
TECHNOLOGY BHOPAL

CERTIFICATE

This is to certify that project titled “Study of Fabrication of SiC and Aloe Vera
Powder Reinforced Aluminium Matrix Composite” has been successfully
presented by

Aamir Hussain Scholar No.: 161116205

Malesh Para Scholar No.: 161116215
Toyesh Lilhore Scholar No.: 161116216
Gule Haider Syed Scholar No.: 161116217
Mohammad Faisal Scholar No.: 161116220

Under my guidance in the partial fulfilment of Bachelor’s Degree in Mechanical

Engineering from Maulana Azad National Institute of Technology, Bhopal during
the final semester as a working Major Project.

Dr. Mohan K. Pradhan

PROFESSOR (Asst.)
MECHANICAL DEPT. (MANIT BHOPAL)
 ACKNOWLEDGEMENT

It gives us immense pleasure to express our deepest sense of gratitude and

sincere thanks to our highly respected and esteemed guide Dr. Mohan K.
Pradhan Professor (Asst.), Department of Mechanical Engineering, MANIT
Bhopal, for his valuable guidance, encouragement and help for completing this
work. His useful suggestions for this whole work and co-operative behaviour are
sincerely acknowledged.

We also wish to express our gratitude to Dr. G. Dixit, HOD, Department of

Mechanical Engineering for his kind hearted support. We are also grateful to our
teachers for their constant support and guidance.

We also wish to express our indebtedness to our parents as well as our family
member whose blessings and support always helped us to face the challenges
ahead.

At the end we would like to express our sincere thanks to all our friends and
others who helped us directly or indirectly during this project work.
 CONTENTS

1. COVER PAGE 1
2. CERTIFICATE 2
3. ACKNOWLEDGEMENT 3
4. CONTENTS 4
5. ABSTRACT 5
6. INTRODUCTION 6
7. LITERATURE REVIEW 8
a. Introduction 8
b. Effects of Alloying Element 9
c. Effects of Reinforcements 10
d. Agricultural Waste as Reinforcement Particulate 12
e. Summary 14
8. MATERIALS AND METHODS 15
a. Materials 15
b. Methods 19
9. MEASUREMENT OF MECHANICAL PROPERTIES 32
10.CONCLUSION 35
11. REFERENCES 36
 ABSTRACT

Aluminium matrix composites (AMCs) refers to the class of light weight high performance
aluminium centric material systems. The reinforcement in AMCs could be in the form of
continuous/discontinuous fibers, whisker or particulates in volume fractions. Properties of
AMCs can be tailored to the demands of different industrial applications by suitable
combinations of matrix, reinforcement and processing route. Presently several grades of
AMCs are manufactured by different routes. Three decades of intensive research have
provided a wealth of new scientific knowledge on the intrinsic and extrinsic effects of ceramic
reinforcement vis-a-vis physical, mechanical, thermo-mechanical and tribological properties
of AMCs. In the last few years, AMCs have been utilized in high-tech structural and functional
applications including aerospace, defense, automotive, and thermal management areas, as
well as in sports and recreation. It is interesting to note that research on particle-reinforced
cast AMCs took root in India during the 70’s, attained industrial maturity in the developed
world and is currently in the process of joining the mainstream of materials.
In the current project, the effect of silicon carbide SiC on the properties of the Aluminium
alloy is considered. The influence of SiC and Aloe Vera on the mechanical properties of Al 7075
composites will be examined. The aluminium SiC composites thus produced will be
subsequently subjected to various tests. The samples of Al 7075 composites will be tested for
hardness, tensile, compression, flexural strengths and wear behavior.
In our project a metal matrix composite of Aluminium alloy (Al 7075) was fabricated with
reinforcements of aloe vera and silicon carbide. Stir casting method was used for this
fabrication and later on gravity die casting was employed. For the same, first Aluminium alloy
was melted in furnace and the powdered aloe vera and silicon carbide was dropped from
above after preheating into the molten aluminium alloy. A stirrer was used to properly mix
the molten mixtures and produce a homogenous mixture. Then molten mixture was poured
into molds and left to cool down. Later on, solid cast were removed from the moulds.
For the fabrication of the alloy, we will be creating samples having varying percentage of Aloe
Vera and SiC. Agro-wastes are gradually gaining grounds predominantly as material
particulates in the field of materials engineering, owing to the potential constituents that
reside in some of them thus agricultural waste are used as a particulate for AMCs. After
analyzing the results obtained from the testing methods, we will identify the percentage of
component which will give optimum result.

5
 INTRODUCTION
In this project we have carried out a study in finding the potential use of aloe vera powder as
particulate reinforcement in the metal matrix composite of aluminium.
A Composite material (also called a composition material or shortened to composite, which
is the common name) is a material made from two or more constituent materials with
significantly different physical or chemical properties that, when combined, produce a
material with characteristics different from the individual components. The individual
components remain separate and distinct within the finished structure, differentiating
composites from mixtures and solid solutions.
A metal matrix composite (MMC) is a composite material with at least two constituent parts,
one being a metal necessarily, the other material may be a different metal or another
material, such as a ceramic or ceramic or organic compound. When at least three materials
are present, it is called a hybrid composite. MMCs are made by dispersing a reinforcing
material into a metal matrix. The reinforcement surface can be coated to prevent a chemical
reaction with the matrix. For example, carbon fibres are commonly used in aluminium matrix
to synthesize composites showing low density and high strength. However, carbon reacts with
aluminium to generate a brittle and water-soluble compound on the surface of the fiber. To
prevent this reaction, the carbon fibers are coated with nickel or titanium boride.
The new material may be preferred for many reasons. Common examples include materials
which are stronger, lighter, or less expensive when compared to traditional materials.
Recently, researchers have also begun to actively include sensing, actuation, computation and
communication into composites, which are known as Robotic Materials.
Typical engineered composite materials include:

• Reinforced concrete and masonry

• Composite wood such as plywood
• Reinforced plastics, such as fibre-reinforced polymer or fiberglass
• Ceramic matrix composites (composite ceramic and metal matrices)
• Metal matrix composites.
Composite materials are generally used for buildings, bridges, and structures such as boat
hulls, swimming pool panels, bodies of racing car bodies, shower stalls, bathtubs, storage
tanks, imitation granite and cultured marble sinks and countertops. The most advanced
examples perform routinely on spacecraft and aircraft in demanding environments.
Composites are the combination of different materials in order to produce a new reinforced
material. An interesting studied had been done toward metal reinforcements over half the
decades. Although there were insufficient studies in this area, the enhancement of metal had
been proved useful especially automobile industry. A composite such as aluminium metal
matrix (Al-MMCs) was produced mainly for 7 reducing material usage since metal is quite

6
expensive due to its limited availability in future and also the fabrication cost which is lower
than conventional cost.
Fabrication of aluminum and it’s alloys based composite materials via stir casting is one of the
most prominent and economical technique for development and processing of MMCs and
widely used for applications which require high production volumes and low cost. Stir casting
is suitable for manufacturing composites with up to 30% volume fractions of reinforcements
and allows for the use of conventional metal processing methods with the aid of an
appropriate stirring system such as mechanical stirring; ultrasonic or electromagnetic stirring;
or centrifugal force stirring to achieve proper mixing of reinforcement into melt which
depends on material properties and process parameters such as the wetting condition of the
particles with the melt, strength of mixing, relative density, and rate of solidification
The growth of world population and increase of living standard due to technology
development have increased the quantity of waste materials generated through industrial,
mining and agriculture activities. The waste materials are hard to disposal and thus a major
concern to environmental pollution. Utilization of waste materials could reduce
contamination and spaces for disposal. Therefore, recycling of waste material by converting
it into green material for application in automobile and construction industries is a prime
concern among the current researchers. Aloe Vera, red mud, palm oil fuel ash (POFA), palm
oil clinker (POC), rice husks, coconut husk and sugarcane bagasse are some of the example of
waste materials which have potential to be utilized in construction and automobile industries.
Vast researches have been conducted but developments are still advancing for successful
utilization of waste materials as partial reinforcement in composite materials. Environment
friendly, energy efficient and cost-effective alternative materials produced from solid wastes
will exhibit a good market potential to fulfill people’s needs in rural and urban areas.

7
 LITERATURE REVIEW
Introduction
Literature review is scrutinized from last 10 years of papers published to get a clear picture of
the work done in the field of metal matrix composite using natural and synthetic
reinforcement. Boopathi et al. (2013), noted that addition of 15% fly-ash into AA2024
aluminium matrix has resulted in increased tensile strength, yield strength and hardness and
reduction in percentage elongation in comparison to base metal matrix. M. Uthayakumar et
al. (2013) in their experiment used Al1100 aluminium alloy as the base matrix and reinforced
it with SiC and B4C which shows reduction in wear rate and coefficient of friction up to 4m/s,
with increment in load and sliding velocity the wear happens along with plastic deformation.
S. Amir khanlou, B. Niroumand (2010) stir casted 356 cast aluminium alloy reinforced with SiC
particles. The resulted composite casting has shown improvement in impact energy,10%
increase in hardness and 68% decreased porosity. Agriculture and industrial waste are finding
prominent use in the composite to achieve reduction in cost as well as their ability to show
satisfactory enhancement in properties. (K.K.Alaneme & K.O.Sanusi, 2015). Gireesh et
al.,2018 have formed a composite by stir casting aloe vera reinforced aluminium matrix. The
resulting composite shows improvement of hardness and tensile strength in respect to fly ash
reinforced aluminium matrix. SiC and natural reinforcement in the form of coconut ash has
been used as reinforcement material by Surinder Paul & Gora Ram Sharma, 2017. They
confirmed presence and distribution of reinforcement by optical microscopy and also
reported improvement in tensile strength, impact strength and hardness of the composite in
comparison to AA6063. Sani A Salihu & I.Y. Suleiman, 2017 in their research used natural
reinforcement in the form of Marula seeds cake in AA6061 aluminium metal matrix. The
author observed improvement in tensile strength and hardness whereas there was reduction
in density, impact and percentage elongation with increasing percentage of reinforcement in
the metal matrix. Table 1 contains a full analysis of the literature review done. [1]
Source Gireesh et al. (2018)
Matrix Used Aluminium
Reinforcement Aloe Vera powder (2mm) and Fly Ash (0.1µm to 100µm)
1. Preheated Aloe Vera powder of 10% by weight of base metal.
Characterstic
2. 3% Mg to improve wettability of Aloe Vera
1. BHN was greater fro Aloe Vera than the apecimen with Fly Ash
2. There is an incriment in UTS while using Aloe Vera powder which
Mechanical Properties
directs to suitability of Aloe Vera composed Aluminium matrix for high
strength application.
Casting Technique Stir Casting
Melting Temperature (°C) 720
Pouring Temperature (°C) nil
Pre-reinforcement
680-720
Temperature (°C)
Reinforcement Pre-heat
Fly Ash - 100
Temperature (°C)
Stir Speed 300

Table 1. [1]

8
Effects of Alloying Elements –
The effects of various alloying elements are given below. Some of the effects, particularly
concerned with impurities, are not well documented and are specific to particular alloys or
conditions.

Chromium: Chromium is a common addition to many alloys of the aluminum–magnesium,

aluminum–magnesium–silicon, and aluminum–magnesium–zinc groups, in which it is added
in amounts generally not exceeding 0.35 wt%. Above this limit chromium tends to form very
coarse constituents with other impurities or additions such as manganese and titanium.
Chromium has a low diffusion rate and forms a fine dispersed phase in wrought products. The
dispersed phase inhibits nucleation and grain growth. Hence during hot working or heat
treatment, chromium prevents grain growth in aluminum– magnesium alloys and
recrystallization in aluminum –magnesium–silicon or aluminum–magnesium– zinc alloys. The
main drawback of chromium in heat treatable alloys is the increase in quench sensitivity when
the hardening phase tends to precipitate on the pre-existing chromium phase particles. [11]

Copper: Aluminum–copper alloys containing 2–10 wt% Cu, generally with other additions,
form an important family of Al alloys. Both cast and wrought aluminum– copper alloys
respond to solution heat treatment and subsequent ageing, with an increase in strength and
hardness and a decrease in elongation. The strengthening is maximum between 4 and 6 wt%
Cu, depending upon the influence of other constituents. N.B: the ageing characteristics of
binary aluminum–copper alloys have been studied in greater detail than for any other system,
but all commercial aerospace alloys contain other alloying elements. [11]

Copper–Magnesium: The main benefit of adding magnesium to aluminum– copper alloys

is the increased strength following solution heat treatment and quenching. In certain wrought
alloys of this type, ageing at room temperature (natural ageing) causes an increase in strength
accompanied by high ductility. Artificial ageing, at elevated temperatures, results in a further
increase in strength, especially the yield strength, but at a substantial sacrifice in tensile
elongation. [11]

Magnesium–Silicon: Wrought alloys of the 6XXX group contain up to 1.5 wt% each of
magnesium and silicon in the approximate ratio to form Mg2Si, i.e. 1.73:1. The maximum
solubility of Mg2Si in Al is 1.85 wt%, and this decreases with temperature. Precipitation upon
age-hardening occurs through formation of Guinier– Preston zones and a very fine
precipitate. Both results in increase in strength to these alloys, though not as great as in the
case of the 2XXX or the 7XXX alloys. Al–Mg2Si alloys can be divided into three groups. In the
first group the total amount of magnesium and silicon does not exceed 1.5 wt%. These
elements are in a nearly balanced ratio or with a slight excess of silicon. Typical of this group
is AA6063, which nominally contains 1.1 wt% Mg2Si and is widely used for extruded sections.
Its solution heat-treating temperature of just over 500 °C and its low quench sensitivity are
such that this alloy does not need a separate solution treatment after extrusion, but may be
air quenched at the press and artificially aged to achieve moderate strength, good ductility,
and excellent corrosion resistance. [11]

9
Several investigators found that aluminum alloys containing both zinc and magnesium
developed substantially higher strengths than those containing either of the alloying
elements added singly, and significantly higher strengths were obtained from these alloys.
These findings led to the development of the Al–Zn–Mg–Cu alloy AA7075 in the early 1940s.
A higher strength alloy, AA7178, was later developed, but low toughness led to alloys with
much lower Fe and Si contents, e.g. AA7050 and AA7475.

Effects of Reinforcements –
Effects of Aloe-Vera:
Aloe Vera composed aluminum composite has shown good strength to weight ratio. The
ultimate tensile strength of Aloe Vera composed matrix are significantly higher compared to
1000 series aluminum. Yield strength has shown comparatively better results in aloe-vera
composed aluminum composite. Impact strength, wear and hardness in case of aloe vera
composed composite was more or less the similar to fly-ash. The fabrication of agriculture
particulate aluminum composite is eco-friendly i.e. powder form of aloe vera in place of fly-
ash in the form of ash.

Figure 1. Dried Aloe Vera Powder [1]

10
Effects of Silicon Carbide:
Tamer Ozbenet al. investigated the mechanical and machinability properties of SiC particle
reinforced Al-MMC. With the increase in reinforcement ratio, tensile strength, hardness and
density of Al MMC material increased, but impact toughness decreased. Sedat Ozdenet
investigated the impact behaviour of Al and SiC particle reinforced with AMC under different
temperature conditions. The impact behaviour of composites was affected by clustering of
particles, particle cracking and weak matrix-reinforcement bonding. The effects of the test
temperature on the impact behaviour of all materials were not very significant. Palani Kumar
and Karthikeyan assessed the factors influencing surface roughness on the machining of
Al/SiC particulate composites. The parameters like feed rate, cutting speed, %volume fraction
of SiC were optimized to attain minimum surface roughness using response graph, response
table, normal probability plot, interaction graphs and analysis of variance (ANOVA) technique.
Feed rate is the factor, which has greater influence on surface roughness, followed by cutting
speed and % volume fraction of SiC. The recommended machining conditions are low cutting
speed with high feed rate and depth of cut for rough and medium turning process. Using
coated carbide cutting tool, high cutting speed and low feed rate produces better surface
finish. It has been found that the wear resistance of the composite is higher than the
conventional grey cast iron and it is a very suitable material for brake drum. However, it
cannot be used for lining material because of the presence of hard SiC particles. Quan
Yanming and Zhou Zehua investigated about the tool wear and its mechanism for cutting SiCs.
[12]

Figure 2. Silicon Carbide Powder from Advanced Material [1]

11
Agricultural Waste as a Reinforcement Particulate for Aluminum
Metal Matrix Composites (AMMCs):
This study has shown that agricultural waste materials are of very high economic value and
importance, owing to their various utilizations as reinforcement particulates to several
aluminum series in the form of aluminum metal matrix composites (AMMCs) and metal
matrix composites (MMCs). Agro-wastes are gradually gaining grounds predominantly as
material particulates in the field of materials engineering, owing to the potential constituents
that reside in some of them. Part of the added profiting of the waste from agriculture is the
reduction of excessive environmental pollution via the release of harmful oxides into the
atmosphere through the decomposition processes, being disposed of around human
communities, through incessant and indiscriminate littering and burning. The results of the
reviewed literature suggest and encourage researchers in the field and focus of materials,
production, and manufacturing engineering to further harness the potential of the agro-
wastes that are obtainable in our immediate environment. [3]

Utilization of Agro-Industrial Waste in Metal Matrix Composites towards

Sustainability:
Throughout the years, many researches had been done in order to reduce the cost of
producing reinforced material. With the availability of agro-waste with possible use of
combining with composites, the development kept on increasing with rapid experimentation
for producing the similar results as the existing material. With thorough review, following
conclusions can be made:
• Addition of agro-waste such as fly ash, palm oil clinkers, palm oil fuel ash, rice husk,
coconut shell enhanced the existing material.
• Agro-waste can be utilized in automotive, industrial and construction as reinforce to
produce better composites.
• An estimated value of particles content needed in order to increase the mechanical
properties of existing material.
The waste materials are hard to disposal and thus a major concern to environmental
pollution. Utilization of waste materials could reduce contamination and spaces for disposal.
Therefore, recycling of waste material by converting it into green material for application in
automobile and construction industries is a prime concern among the current researchers.
Fly ash, red mud, palm oil fuel ash (POFA), palm oil clinker (POC), rice husks, coconut husk and
sugarcane bagasse are some of the example of waste materials which have potential to be
utilized in construction and automobile industries. Vast researches have been conducted but
developments are still advancing for successful utilization of waste materials as partial
reinforcement in composite materials. Environment friendly, energy efficient and cost-
effective alternative materials produced from solid wastes will exhibit a good market
potential to fulfil people’s needs in rural and urban areas. Composites are the combination of
different materials in order to produce a new reinforced material. An interesting studied had
been done toward metal reinforcements over half the decades. Although there were

12
insufficient studies in this area, the enhancement of metal had been proved useful. By
applying the melting or powder metallurgy method on manufactured discontinuous short
fiber or particle strengthened light alloys, reuse of recycle of the composite material is
possible since it can be re-melt and recast to form the composite again. Due to the density
variation between the reinforcement particles and matrix metals, the composite part
containing the preform will still remain its shape and sink to the bottom of the crucible during
the re-melting process of composite. [13]
The multi axis surface tension in MMCs will decrease the ductility of matrix element of MMC.
As the tensions and pores in matrix are increased rapidly, the formation phase of pores will
be the factor to determine the ductility. Moreover, it has been stated that since these
tensions and pores in matrix increase rapidly, the factor that determine the ductility is the
formation phase of these pores.
It has been seen that these agro-waste has been used in:
1. Utilization of green material as reinforcement in construction Industry.
2. Utilization of agro-industrial material in automobile industry.
3. Utilization of material in agricultural development and growth.
The application of agro-industrial waste in Aluminum Metal Matrix Composites has been
getting more attention as they can reinforce particles in metal matrix which enhance the
strength properties of the composites. In addition, by applying these agro-industrial wastes
in useful way not only save the manufacturing cost of products but also reduce the pollutions
on environment. This paper represents a literature review on a range of industrial wastes and
their utilization in metal matrix composites. [1]
The palm oil clinker (POC) aggregates were used to fabricate lightweight aggregate concrete
(LWAC) to replace normal concrete in composite slab. LWAC contributed to the construction
for its lighter high rise building and safe disposal of waste materials. This concrete was used
in the construction of composite slabs with profiled steel sheet. As a result, the LWAC slabs
were lighter than the conventional concrete slabs by 18.3%. Conventional concrete slabs also
had low deflection compared to LWAC due to its elasticity. All composite slabs were
considered to have ductile behaviour since maximum applied load exceeded the load causing
0.5 mm end slip by 10%. This implied that POC can be adequately used in the construction of
composite slabs.
The effect of bagasse ash reinforcement on the behaviour of Al-Cu-Mg/Bagasse ash
particulate composites- The percentage of Bagasse ash particles were varied from 0wt%,
2wt%, 6wt%, 8wt% and 10wt% to be examined on a pin-on disc test. They found that bagasse
ash can be used as reinforcement material to improve wear properties of aluminium alloy.
The reinforced aluminium alloy exhibited better wear resistance than the unreinforced
aluminium alloy. The wear rate was observed to be decreasing as the amount of bagasse ash
increased in the alloy. The wear rate was also observed to be increasing as the sliding speed
and applied load increased. [3]

13
SUMMARY OF LITERATURE REVIEW

Effects of Aloe-Vera (AV):

• Aloe Vera composed aluminium composite has shown good strength to weight ratio.
• The ultimate tensile strength of Aloe Vera composed matrix are significantly higher
compared to 1000 series aluminium.
• Yield strength has shown comparatively better results in aloe vera composed
aluminium composite.
• Impact strength, wear and hardness in case of aloe vera composed composite was
more or less the similar to fly-ash.
• The fabrication of agriculture particulate aluminium composite is eco-friendly i.e.
powder form of aloe vera in place of fly-ash in the form of ash.

Effect of Silicon Carbide (SiC):

• Vickers hardness number and the tensile test has shown increment due to the
enhancement of the matrix with the use of SiC maximum improvement can be
observed when 20 wt.% SiC is added.
• Wear resistance is one among other properties to shown enhancement on addition of
SiC to the mix of aluminium alloy matrix.
• Better hardness, tensile strength and wear resistance are easily spotted on addition
of SiC to aluminium based matrix.
• Increase in hardness and decreases in porosity is evident.
• The impact energy of the composites increases with the addition of Al-SiC(p)
composite powder.

Research gaps on the thorough scrutiny of the published work on the Aluminium matrix
composite, the following observations have been made:
1. There is very little information available in the direction of using Aloe Vera as natural
reinforcement.
2. There is no research done in the pairing of SiC and Aloe Vera particles.
3. Aluminium has vast range of applications but its mechanical properties limits its use.
Hence its metal matrix composites are used.
4. Variety of waste products are used to enhance mechanical properties of certain elements.

14
 MATERIALS AND METHODS
MATERIALS:
In our test sample base metal of Aluminium 7075 alloy is used to which reinforcements of
silicon carbide and aloe vera were added. The resulting sample of composites was put to
different tests including tensile, compressive, wear and hardness testing.
MMC (Metal matrix composites) are metals reinforced with other metal, ceramic or organic
compounds. They are made by dispersing the reinforcements in the metal matrix.
Reinforcements are usually done to improve the properties of the base metal like strength,
stiffness, conductivity, etc. Aluminium and its alloys have attracted most attention as base
metal in metal matrix composites. Aluminium MMCs are widely used in aircraft, aerospace,
automobiles and various other fields. The reinforcements should be stable in the given
working temperature and non-reactive too. The most commonly used reinforcements are
Silicon Carbide (SiC) and Aluminium Oxide (Al2O3). SiC reinforcement increases the tensile
strength, hardness, density and wear resistance of Al and its alloys. The particle distribution
plays a very vital role in the properties of the Al MMC and is improved by intensive shearing.
Al2O3 reinforcement has good compressive strength and wear resistance. Boron Carbide is
one of hardest known elements. It has high elastic modulus and fracture toughness. The
addition of Boron Carbide (B4C) in Al matrix increases the hardness, but does not improve the
wear resistance significantly. Fires are the important class of reinforcements, as they satisfy
the desired conditions and transfer strength to the matrix constituent influencing and
enhancing their properties as desired. Zircon is usually used as a hybrid reinforcement. It
increases the wear resistance significantly. In the last decade, the use of fly ash
reinforcements has been increased due to their low cost and availability as waste by-product
in thermal power plants. It increases the electromagnetic shielding effect of the Al MMC.[4]
Some readily used inorganic and ceramic reinforcements are –

Silicon carbide reinforced AMMC:

With the increase in reinforcement ratio, tensile strength, hardness and density of Al MMC
material increased, but impact toughness decreased. The modulus, strength and the ductility
of the two composite microstructures decreased with an increase in temperature of sample.
The degradation in cyclic fatigue life was more pronounced for the under-aged microstructure
than the peak-aged microstructure Also, for a given ageing condition, increasing the load ratio
resulted in higher fatigue strength. The result showed that the composite materials exhibit
improved physical and mechanical properties, such as low coefficient of thermal expansion
as low as 4.6x10-6/N C, high ultimate tensile strength up to 23.68%, high impact strength and
hardness. The composite materials can be applied as potential lightweight materials in
automobile components. Experimentally it is found that with addition of AlSiC reinforcement
particles, the composite exhibited lower wear rate compared to Al-Al2O3 composites. During
the tensile deformation, the particle clustering has greater effects on the mechanical
response of the matrix than the elastic response and also the plastic deformation is affected
very much. The particle clustering microstructure will experience higher percentage of

15
particle fracture than particle random distribution. At lower stirring speed and time, the
particle clustering was more at some places, by increasing them the distribution resulted
better and also it had its effect on hardness of the composited reinforced metal matrix
composites. Using coated carbide cutting tool, high cutting speed and low feed rate produces
better surface finish could be achieved.

Aluminium oxide reinforced AMMC:

Increase in volume fraction of Al2O3 decreased the fracture toughness of the MMC. This is
due to decrease in inter-particle spacing between nucleated micro voids. The fatigue strength
of the powder metallurgy processed composite was higher than that of the unreinforced alloy
and liquid metallurgy processed composite. It was found that the reactive hot pressing of the
composites resulted in the formation of ceramic Al2O3 and TiB2 particulates as well as coarse
intermetallic showed high tensile.
the hardness and tensile strength of MMC increases and electromagnetic stirring action
produces MMC with smaller grain size and good particulate matrix interface bonding. It was
found that the addition of Al2O3 and Al4C3 increases the hardness and compressive strength.
The addition of Al4C3 improved the wear resistance of the MMC. Some conducted the
orthogonal cutting tests to study the effect of cutting parameters and particulate properties
on the micro-hardness variations on the machined Al2O3 particulate reinforced AMC. They
found that the micro-hardness is higher near the machined surface layer. Micro-hardness
variations were higher for low volume fraction and coarse particles.

Boron carbide reinforced AMMC:

The test result shows that the attributes like nano-scale dispersoids of Al2O3, crystalline and
amorphous AlN and Al4C3, high dislocation densities in both NC-Al and CG-Al domains,
interfaces between different constituents, and nitrogen concentration and distribution leads
to increase in strength. Studied the cryomilled aluminium alloy and boron carbide nano-
composite plates made in three methods, hot isostatic pressing (HIP) followed by high strain
rate forging (HSRF), HIP followed by two-step quasi-isostatic forging (QIF), and three-step QIF.
The test results showed that the HIP/HSRF plate exhibited higher strength with less ductility
than the QIF plates, which had similar mechanical properties. The increased strength and
reduced ductility of the HIP/ HSRF plate is attributed to the inhibition of dynamic
recrystallization during the high strain rate forging procedure. Some investigated the
characteristics of surface quality on machining hybrid aluminium-B4C-SiC metal matrix
composites using taguchi method. It was found that feed rate was the most important
parameter followed by the cutting speed. Moreover, it was concluded that the feed rate does
not have a significant effect on surface quality. Investigation of the effect of application of
traditional investment casting process in aluminium metal matrix composites. Aluminium
alloy reinforced with SiC and B4C were compared and the experiments showed the wear
resistance of SiC reinforced MMC is higher than that of B4C reinforced MMC.

16
Fly ash reinforced AMMC:
Fly ash particles are potential discontinuous dispersoids used in metal matrix composites due
to their low cost and low-density reinforcement which are available in large quantities as a
waste by product in thermal power plants. The major constituents of flyash are SiO2, Al2O3,
Fe2O3, and CaO. Comparing the effect of the three different stir casting methods on the
properties of fly ash particles reinforced Al-7Si-0.35Mg alloy. The three stir casting methods
are liquid metal stir casting, compocasting, modified compocasting followed by squeeze
casting. The compression strength of the composite processed by modified compocasting
cum squeeze casting is improved compared to the matrix alloy. However, the tensile strength
was found to be reduced. The modified compocasting cum squeeze casting process has
resulted in a well dispersed and porosity free fly ash particle dispersed composite. On studying
the electromagnetic interference shielding effectiveness property the composites have
effective shielding property in the addition of fly ash particulate decreases the tensile strength
of the composites. Experimentally it was found that the wear resistance of Al MMC increases
with the increase in flyash content, but decreases with increase in normal load and sliding
velocity, and also observed that the corrosion resistance decreases with the increase in fly
ash content.[2]

Some potential agro-industrial based reinforcements are (organics)-

Coconut Shell Ash:

Coconut shell has little or no economic value but they are suitable for preparation of carbon
black due to its excellent natural structure and low ash content. Reference concluded that
coconut shells ash can withstand a temperature up to 1500o C with a density of 2.05 g/cm3
and it is suitable in production of light weight metal matrix composites component with good
thermal resistance.

Fly Ash:
Fly Ash (FA) is a particulate-reinforcement that consists of a potential discontinuous
dispersoids used in metals to form composites. Cost of fly ask is quite low and it is less dense
reinforcement as well. It is available in large quantities as a waste by-product in thermal
power plants. Therefore, its usage in metal matrix composites is highly prevalent. The major
chemical constituents of fly ash are SiO2, Al2O3, Fe2O3 and CaO.

Rice Husk Ash:

Rice Husk Ash (RHA) is an agricultural waste and by-product of rice husk. It was estimated to
produce globally 21,000,000 tonnes in 2002 and is a major seasonal environmental and health
treat. Rice husk ash is one of the most silica rich raw materials which containing about 90-98
silica after combustion among the family of other agro wastes.

17
Palm Oil Fuel Ash (POFA):
Palm oil fuel ash (POFA) is an abundant agricultural solid waste in Malaysia and it is rich in
siliceous material. POFA is produced after the combustion of oil palm fiber, shell EFB and
mesocarp as boiler fuel to produce steam for palm oil mill. The silica or silicon dioxide (SiO2)
is perhaps the most essential substance which is found in POFA which contains up to 40%.
Beside silica, other chemical components that detected through X-Ray Diffraction (XRD)
analysis in POFA are potassium oxide, calcium oxide, magnesium oxide, aluminum oxide and
andiron oxide.

Sugarcane Bagasse:
The fibrous residue of sugarcane after the crushing and extraction of its juice, known as
‘bagasse’, is one of the largest agriculture residues in the world. Literature reveals the
versatility of the use of sugarcane residue; through its conversion inclusive but not limited to
paper, feed stock and biofuel (ethanol). An analysis of SCB reveals that its main properties are
cellulose, hemicellulose, lignin, ash, and wax. The composition of SCB properties make it an
ideal ingredient to be applied and utilised as reinforcement fibre in composite materials for
the purposes of creating new materials which posses’ distinct physical and chemical
properties. These in turn are desired for anticipated performances based on pre-set
objectives. The chemical constituent of SCB makes it an exceptional raw material for
composite fabrications. [3]

Figure 3. (a)Fly Ash (b)Coconut Shell Ash (c)Rice Husk Ash (d)POFA (e)Sugarcane Bagasse (Source: Google Images)

18
METHODS
In our project a metal matrix composite of Aluminium alloy (Al 7075) was fabricated with
reinforcements of aloe vera and silicon carbide. Stir casting method was used for this
fabrication and later on gravity die casting was employed. For the same firstly Aluminium alloy
was melted in furnace and the powdered aloe vera and silicon carbide was dropped from
above after preheating into the molten aluminium alloy. A stirrer was used to properly mix
the molten mixtures and produce a homogenous mixture. Then molten mixture was poured
into moulds and left to cool down. Later on, solid cast were removed from the moulds.
In total two kind of sample was casted out. In one of the sample aloe vera powder and silicon
carbide were both in 2% by weight of the sample and in other sample aloe vera powder was
kept as 1% by weight and silicon carbide was kept 2% by weight.

Process Parameters
Based on the literature review and number of trials performed, following parameters were
considered during Stir Casting to obtain the matrix without any formation of defects:

Rotational Speed:
In a paper published by Naher, S. et al. (2003) it has been observed that on varying the speed
of rotation of the blade the dispersion of the particles can be controlled effectively. It has
been concluded that maximum dispersion of particles can be achieved by keeping the stirring
speed in between 100-200 rpm. And the reinforcement settles within 60 to 180 seconds of
seizing of rotation. Based on these discussions the stirring speed had been kept 100-150 rpm
and is kept stirring after addition of reinforcement.

Temperature:
The wetting of the reinforcement is liquid aluminium alloy can be greatly influenced by the
temperature of addition of reinforcement in the melt. Higher temperature provides better
wettability and also the time of contact need to be monitored (Froyen, L., & Verlinden,
B.,1994). Hence, the temperature of the aluminium melt was kept constantly at 900˚C in the
furnace.
Preheating of reinforcement Preheating of reinforcement has been a rather common practice
as it serves two purposes. Firstly, it helps in getting rid of any moisture content, absorbed
gases etc in the reinforcement sample and secondly it increases the reinforcements
wettability with the molten aluminium. There has also been noticed improvement in
interfacial strength and dispersion of reinforcement particle (Razzaq, A.M. et al., 2017).
Adhering to these results the reinforcements added to the composite in this project where
preheated at 200 ˚C for two hours.

19
Experimental Methods
In this experimental work commercially available AA6061 is used as base matrix material for
the composite. In order to procure three sets of samples with different percentage of
reinforcement material. Stir casting method is used for the manufacturing of composite
samples.
The setup used for the fabrication of sample
consists mainly of electric furnace and
mechanical stirrer. The electric furnace used
in this process is equipped with a crucible,
the maximum temperature for operation of
the furnace is 1200ºC. The current rating as
mentioned of furnace is single phase 230V
AC, 50Hz. AA6061, an aluminium alloy, is
used. AA6061 is available in the plates form
of thickness 5mm. It amounts to 1 kg per
sample. The metal plates are kept inside the
crucible which in turn was placed into the
furnace. The furnace is further heated by
electric coils just above the liquidus
temperature of the aluminium matrix
converting it in semi liquid form at around
900ºC. The mixing is done uniformly with
the help of mechanical stirring of aluminium
alloy. The reinforcement that is to be added Figure 4. Electric Furnace
is measured beforehand and preheated to a temperature of 200°C. With the help of a
mechanical stirrer, rotating at a speed of 150 rpm, a vortex is created and, in this vortex,
additives are added to liquidous aluminium alloy inside the furnace. Again, reheating of the
aluminium matrix composite is done. Mechanical stirrer is in continuous stirring action during
reheating at 100 rpm. Aluminium composite reaches melting point at a temperature of about
700ºC so the temperature is maintained at 800°C. This liquid aluminium metal matrix is
poured into permanent mould that gave us the required specimen for further experiment. [6]

There are some other fabrication methods of composites as well as some other
reinforcements that could be used.

Processing Routes for Aluminium Matrix Composites:

A vast literature content is available on the formation of metal matrix composites. The
selection of the moulding and casting depends on many factors including type and level of
reinforcement proportion and the degree of micro structural integrity required. Fabrication
of composite materials is focused on obtaining materials with improved properties as
compared to the matrix material. A key challenge in the processing of composites is to
homogeneously distribute the reinforcement particles to achieve a defect-free

20
microstructure. Primary processes for manufacturing of AMCs at industrial scale can be
classified into two main groups. Various processes are used to manufacture MMCs as
discussed below. These processes are classified on the basis of temperature of the metallic
matrix during processing accordingly [7]; the processes can be classified into two categories:
1. Liquid State Processes.
2. Solid State Processes.

Liquid State Fabrication of MMCs:

In the liquid casting technique, the particulates are mechanically well distributed over the
liquid metal before casting and solidification.

Stir Casting:
Stir casting is currently the most popular commercial method of producing aluminium based
composites Stir casting of MMCs was invented in 1968, when S. Ray introduced alumina
particles into aluminium melt by stirring molten
aluminum alloys containing the ceramic fine particles.
Fabrication of aluminum and its alloys based
composite materials via stir casting is one of the most
prominent and economical technique for
development and processing of MMCs and widely
used for applications which require high production
volumes and low cost. Stir casting is suitable for
manufacturing composites with up to 30% volume
fractions of reinforcements and allows for the use of

Figure 5. Stir Casting Process [3]

conventional metal processing

methods with the aid of an
appropriate stirring system such as
mechanical stirring; ultrasonic or
electromagnetic stirring; or
centrifugal force stirring to achieve
proper mixing of reinforcement into
melt which depends on material
properties and process parameters
such as the wetting condition of the
particles with the melt, strength of
mixing, relative density, and rate of
solidification .The distribution of
the particles in the molten matrix Figure 6. Stir Casting Machine equipped with Inert Gas Source [7]

21
depends on various factors like geometry of the mechanical stirrer, stirring parameters,
placement of the mechanical stirrer in the melt, melting temperature, and the characteristics
of the particles added and finally the liquid composite material is then cast by conventional
casting methods and may also be processed by conventional Metal forming technologies. J.
Hashim et al reported that there are limitations which reveals that during the process are
non-uniform distribution, poor wettability between reinforcement particulate and matrix
material, porosity in casted MMCs and chemical reaction between particulate and matrix. To
overcome this limitations an interesting recent development in stir casting is a two-step
mixing process in which gas layer around the particle surface which impedes wetting between
the particles and molten metals are very effectively breached by mixing of the particles in the
semi-solid state and effectively break the present gas layer because the high melt viscosity
produces a more abrasive action on the particle surface. Breaking of the gas layer improves
the effectiveness of mixing in a fully liquid state. By giving heat treatment to the
reinforcement particles before dispersion into melt can be improved the wettability of
reinforcement particles within the molten matrix alloy and the adsorbed gases can be
removed from the particle surface. The resulting microstructure was found to have more
uniform than that processed with conventional stirring. Another problem is if the
reinforcement particles are distributed uniformly in molten matrix, they tend to sink or float
to the molten melt due to the density differences between the reinforcement particles and
the matrix alloy melt. If the dispersion of reinforcement particles is not uniform then they
have tendency to agglomeration and clustering. By injecting the particles with an inert gas
into the melt is useful in improving the distribution of the reinforcement particles. [5]

Compocasting:
Wettability and distribution of nano size reinforcement are the key challenge in stir casting
because very fine particles are having more surface energy and surface area resulting in
agglomeration of reinforcement particles at the surface. To achieve uniform distribution,
weak agglomeration and effective incorporation of the very fine reinforcement particles into
the metal matrix alloy we move towards Compo casting. Compocasting can mechanically
entrap the semisolid slurry and reinforcing particles, prevent their gravity segregation and
reduce their agglomeration and improve their mixing. Reduction in particle size to nano scale
results in greater improvement in ductility of compo-cast product compare to stir casting and
leads to better mixing due to increased surface area. In Compo-casting the particles are mixed
at semi-solid temperature of the alloy. Because of lower operating temperatures of liquid
metal matrices energy can be saved by compo casting and longer tool life achieved preferably.
Chemical reaction between molten aluminum and silicon carbide will not occur, due to the
low relative operating temperature, the formation of Al4C3 chemical compound can be
avoided via compo-casting. The melting process has two major problems, one is ceramic
particles are not wetted by the liquid metal matrix and secondly, the particles tend to float
according to their density relative to the liquid metal which results in nonuniform dispersion
of ceramic particles. Reduced porosity in composite material could be further achieved by
squeeze casting and die casting methods.

22
Squeeze Casting:
The concept of squeeze casting dates back to the 1800s. The idea was suggested by Chernov
in 1878 to apply steam pressure to molten metal while being solidified. Squeeze casting
experiment was not conducted until 1931. Squeeze casting technique is a liquid phase
fabrication method of AMCs in which metal solidifies under pressure within closed die halves,
using a movable mould part for applying pressure on the molten metal and force it to
penetrate into a preformed dispersed phase, placed in the lower fixed mould part . Squeeze
casting fabricated components have higher weldability, heat treatability, high degree of
surface finish and dimensional accuracy

Spray Forming:
Fabrication of composite by spray forming process involves melting of an alloy in a furnace to
molten form and forcing the molten metal through a small orifice, passing a stream of
compressed inert gas, injecting reinforcement through the jet and breaking the liquid metal
into fine semi solid droplets. These semi solid droplets are deposited over a stationary
substrate to form solid perform medium. It is difficult to attain uniform distribution of
reinforcements into the metal matrix by this method but the composites formed by spray
deposition process are of affordable cost.

In-Situ Synthesis:
In-situ synthesis is a process wherein the reinforcements
are mixed into the matrix by controlled metallurgical
reactions with various reinforcement ceramic particles like
SiC, AlN and TiC. During fabrication, one of the reacting
elements is usually a constituent element of the molten
matrix alloy. The other reacting elements may be either
externally-added fine powders or gaseous phases, final
reaction product is the reinforcement dispersed in matrix
alloy. It is difficult to disperse the reinforcing particles
uniformly in metal melts due to the low wettability with
the molten metal. The main difficulty in the process is the
reaction of particle size of less than 1mm and the problem
of agglomeration and health hazards reveals. The interface
bonding may be lowered due to the porosity and
segregation at the interface between the matrix and Figure 7. Mixing Molten Aluminium Matrix
reinforcement particles. It requires the higher reaction with Reinforcement

time temperature and longer holding time which in greatly

increases the cost of production and process requires that the reaction system be carefully
screened.

23
Liquid Metal Infiltration:
It is a forced infiltration method of liquid phase fabrication of AMCs and begins with a ceramic
preform of the desired shape and accomplished by the application of a pressure of inert gas.
The pressure required for combining matrix and reinforcement is a function of the friction
effects due to viscosity of the molten matrix as it fills the ceramic preform. Wetting of the
ceramic preform depends on: alloy composition, ceramic preform material, ceramic surface,
interfacial reactions, atmosphere, temperature and time. Precise shape, high degree of
surface finish and suitability for mass production are the advantages of this process. Some of
the drawbacks of this process include reinforcement damage, preform compression, non-
uniform microstructure, coarse grain size, and undesirable interfacial reactions.[5]

Solid State Fabrication of MMCs:

Powder Metallurgy:
Fabrication of AMCs via powder metallurgy includes uniform mixing of reinforcement with
metal alloy and blending of powders; degassing the solidified product in vacuum and sintered
under high temperature conditions. Powder metallurgy route can exploit the nano particles
and grain boundaries strengthening capability. This method is cost effective for producing
complex parts at very close dimensional tolerances, with minimum scrap and not suitable for
mass production due to high cost of powder.

Figure 8. Schematic of typical Powder Metallurgy Processing Scheme [7]

High Energy Ball Milling:

High energy ball milling utilizes high energy impacts, high frequency from balls to repeatedly
forge powder particles together and trapped between colliding balls and inner surface of the
vial which causes repeated deformation, rewelding, fragmentation of premixed powders to
form dispersed particles in grain refined matrix. In mixtures of ductile components, the
24
particles are initially flattened but the brittle component undergoes size reduction by
fragmentation. During milling process addition of ceramic hard particles to metal alloys
improve the strength, wear resistance and micro hardness of synthesize composite and
extensively employed to obtain, amorphous structures, nanocrystalline solids, and immiscible
components. The mechanical properties of particle reinforced composites are largely
dependent on the particle microstructure, distribution and volume fraction. This method
consume time for achieving required properties of composites and milling of powder require
inert atmosphere which is difficult to maintain therefore method is not suitable for mass.

Ultrasonic Probe Assisted Method:

Traditional fabrication methods cannot be used for mass production and net shape
fabrication of complex structural components without post processing. In recent years,
significant effort has been taken to develop metal matrix nano composites. Ultrasonic probe
assisted method is very effective in dispersing nano sized particles in the metal matrix. The
process generally requires resistance heating furnace for melting metal, nano particle feeding
mechanism, inert gas envelope for protection and an ultrasonic system. The ultrasonic
processing system consists of an ultrasonic probe, a transducer and power source. The
ultrasonic probe assisted method helps to achieve uniform distribution of particles in metal
matrix. The ultrasonic energy is widely used in the manufacturing for welding, casting and
non-destructive testing. Ultrasonic stirring is used for purifying, degassing and refinement of
metallic melt and utilized to generate nuclei in casting. The ultrasonic cavitation-based
processing of MMNCs has been successfully utilized by researchers to fabricate bulk MMCs.
Experimental results show a nearly uniform distribution and good dispersion of the nano-
particles within the Al matrix, although some of small agglomeration found. Both hardness
and tensile strength are enhanced by incorporation of nano materials into matrix., which was
confirmed by SEM pictures. It is difficult to distribute and disperse nano scale particles
uniformly in metal melts due to their large surface to volume ratio and their low wettability
in metal melts.

Diffusion Bonding:
Diffusion bonding is a solid-state processing technique which is commonly used to produce
mono filament reinforced AMCs. Inter diffusion of atoms between clean metallic surfaces
which is in contact at an elevated temperature leads to bonding due to the inter-diffusion of
atoms across the surfaces of particulates and metal. 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.[5]

25
 Table 2. Comparison among Liquid State Fabrication for MMCs [1]

Table 3. Comparison among Solid State Fabrication of MMCs [1]

Die Casting Process:

After molten homogenous mixture of mould was formed of aluminium alloy and
reinforcements through stir casting process, gravity die casting process was used to cool it
down into desired shapes. Die casting is one of the most economical and quickest forming
processes. The advantages of this production process are that hundreds of thousands of
castings can be produced relatively quickly by using just one mold. All components produced
have a uniform quality and involve relatively low unit costs.

26
Definition of "Die Casting":
Die casting is an automated casting process in which the liquid melt is pressed into a mold
under high pressure (150 to 1200 bar) and at a high filling speed (up to 540 km/h). Usually
alloys with a low melting point are used. Sometimes molten liquid is also allowed to settle
through gravity effect. This casting process is particularly suitable for series and mass
production of components because, unlike sand casting, for example, permanent metal molds
are used which do not have to be destroyed after casting. It is possible to produce large and
complex components with low wall thicknesses.

Molds:
The die casting molds, made of high-quality, heat-
resistant steel grades, consist of two halves which
form a cavity into which the liquid melt is pressed
during the casting process. The halves are located on
a fixed and a movable machine plate. During the
casting process a high pressure is applied to the mold
halves, which is why the mold is equipped with
latches. In addition, certain parts of the mold are
cooled and/ or heated so that the casting solidifies as
desired. The production of the molds is very expensive
and time-consuming, but several tens of thousands to
over a million castings can be produced with just one
of them. A further advantage of the reusable casting
molds is that the melt cools down quickly. Figure 9. Gravity Die Casting Molds

Functionality and Procedures:

In die casting, there are two different ways of
manufacturing components: hot chamber and cold
chamber die casting. In both manufacturing processes,
the mold is sprayed with a release agent prior to the
casting process in order to ensure that the subsequently
cast part can be easily removed from the mold. However,
the melt is not poured directly into the mold cavity, but is
first filled into the casting chamber of the die casting
machine. From there, the alloy is pressed into the mold by
a piston (the so-called casting set) through one or more
channels or allowed to settle through gravity. [8]

Figure 10. Gravity Die Casting

27
The difference between the two processes lies in the structure of the casting chamber as
described below:

Hot Chamber Die Casting Method:

A characteristic feature of hot chamber die casting machines is that the casting chamber is
constantly in contact with the liquid alloy. The melt passes through a valve into the casting
chamber, where it is pressed at high speed into the closed die casting mold by the piston. This
process is used for alloys with a low melting point, such as zinc, lead or tin. Molten alloy is
also allowed to settle through gravity.

Cold Chamber Die Casting Method:

Cold chamber die casting machines are designed in such a way that the casting set is located
outside the melt. To produce a component, the alloy is filled into the casting chamber and
pressed into the die casting mold through channels. This process is suitable for materials with
a higher melting point.
After the alloy has been pressed into the mold in both processes, the component solidifies
under the strong pressure, whereupon the latches of the mold can be opened. The part with
gate is removed from the mold by automatically operated ejection pins and can be further
processed if necessary. In simple words, the casting process can be divided into the following
steps and in practice takes place in hundredths of a second - or even only thousandths of a
second:
• Fast filling of the casting mold with the alloy
• Curing of the component under high pressure
• Opening of the mold and removal of the component

Cold chamber die casting is the most popular process in the mass production of light metal
castings. Aluminum is one of the most important materials with a share of more than 80 %,
followed by zinc and magnesium. However, copper, lead and tin can also be used. The alloys
have different properties. For example, aluminum (600°C) and magnesium (520°C) have a
high melting point, zinc (380°C) and lead (320°C) a low melting point.
Die casting alloys offer many advantages:
• High corrosion resistance
• High strength and hardness
• High thermal conductivity
• High electrical conductivity
• Very good EMI/ RFI isolation
• Good processing properties

28
Various processes are used in foundry practice. Castings can also be produced without high
pressure. In the Sand-Casting process, for example, the alloy is poured into a mold made of
sand, which must be destroyed in order to reveal the manufactured component (lost foam).
In Investment casting, which is used to manufacture very small cast parts, the molds and
models (usually made of wax or plastic) are also destroyed after the casting process. Another
example is Gravity Die Casting, which uses a permanent metal mold but does not use high
pressure to press the melt into the mold. Rather, the casting is manufactured or the mold
filled by gravity. [6]

Method of Stir Casting of Aluminum Metal Matrix Composites:

Stir casting process is mainly used for manufacturing of particulate reinforced metal matrix
composite (PMMC). It is a primary process of composite production whereby the
reinforcement ingredient material is incorporated into the molten metal by stirring. The stir
casting of metal matrix composites involves producing a melt of the selected matrix material
followed by the introduction of a reinforcement material into the melt before adding the
reinforcement material the melt should be subjected to degassing by a suitable medium,
because the molten metal reacts with atmospheric oxides and undergoes oxidation by
degrading the properties of the base material.
The next step is the solidification of the melt containing suspended dispersoids under selected
conditions to obtain the desired distribution of the dispersed phase in the cast matrix. In the
stir casting with bottom pouring technique, the mold is kept just below the furnace with an
opening at the bottom for pouring. This type of arrangement enhances the incorporation of
particulates and reduces the time of pouring. The reduction in time of pouring and due to a
better particulate introduction to the mold the composite properties are nearer to
improvement.
Fig.11 shows the matrix material melted in a crucible by heating it in a crucible furnace. The
stirring is activated by means of a motor at the top of the stirrer. The stirrer can be moved up
and down by means of a rack and pinion arrangement. Reinforcement is added to the matrix
after stirring the matrix material for a certain amount time. Preheating is also carried out to
avoid thermal distortion of the composite material. [7]

Figure 11. Stir Casting Process

29
 Figure 12. Mechanical Stirrer Design [4]

Mixing techniques are used for introducing and homogeneously dispersing the discontinuous
phase since most of the ceramic reinforcement materials are denser compared to matrix
alloy, otherwise the reinforcement material may settle at the bottom of the crucible if not
agitated properly. Mixing techniques generally used for mixing of ceramic reinforcement into
a melt are:
a. Adding particles to a vigorously agitated molten alloy.
b. Injection of the discontinuous phase into the melt with an injection gun.
c. Dispersion of pellets or briquettes of a discontinuous phase.
Stir casting is attractive since a conventional metal processing route is used and is the most
economical route of all the available routes of metal matrix composite production. The cost
of preparing composite material using this method is about one third to half of the other

30
competitive methods, and for high volume production, it is projected that the cost will fall to
one tenth. Some of the important factors that need attention during stir casting are:
a. The difficulty of achieving a uniform distribution of the reinforcement material.
b. Wettability between two main substances (matrix and reinforcement substances.
c. Porosity in the cast metal matrix composites.
d. Chemical reactions between the reinforcement material and matrix alloy.
e. Reaction of matrix and reinforcement substances with atmospheric elements.
The stir casting method generally involves the heating of the matrix material to a melting
temperature in a crucible which is chemically inert to the materials that are going to be
charged into it. The furnace generally being used is the electric resistance furnace. The
particulates are preheated in order to improve its mixing with the matrix material also to
avoid thermal mis-match. The melt may or may not be stirred prior to mixing the particulates.
The temperature of the crucible depends on the alloy material being melted. The mixing of
the particulates can be two-step or three-step which is a variation depending on the weight
percentages of the reinforcement. The mixing can be in semi-solid state or above liquidus
state. There have to be variations in the geometry of the stirrer and feeding mechanism to
get a homogenized material. An inert atmosphere may be maintained during stirring and
pouring the melt into the mold in order to avoid defects in the cast product. The problem of
gas entrapment due to vortex creation may be avoided by introducing the particulates by
means of an injection gun with an inert gas carrying it. The wettability between the matrix
and the reinforcement has to be appropriate in order to get a homogenized composite. The
overall conclusion is that the microstructure of the so produced composite has a fairly good
distribution of the particulates in the matrix material. The properties obtained have achieved
the tailor able characteristic of the composite material. Further from the literature it may be
concluded that the fabrication method, procedure adopted to form MMCs, particulates
temperature, degassing, stirring speed and duration, and pouring temperature of the mix and
finally the distribution of particulates etc. all have a significant influence on the final
properties of the metal matrix composites.[8]

Figure 13. Effect of Vortex Formation due to Stirrer [1]

31
 MEASUREMENT OF MECHANICAL PROPERTIES

The study of mechanical characterization of the AMCs with reinforced SiC and AV powder
requires the testing of the concerned specimens. In this work the mechanical behaviour of
the developed composite (AMC with SiC and AV powder) has been studied by comparing that
with the AMC with fly ash under the same criteria. In order to explore the mechanical
characterization of AMC with AV powder various mechanical tests have been conducted and
are discussed below.

Figure 14. Specimen

32
Density Measurement:
The Archimedes principle was employed to determine the density of the composites. The
AMC-FA and AMC-AV samples were weighed in air and then in distilled water separately.
According to Archimedes principle the following expression was used to determine the
density of the composites. [9]

𝑊
ρ={ } × ρ𝑤
𝑊 − 𝑊1

Where,
ρ = density of the metal matrix composite.
ρw = density of water.
W = weight of the composite sample in air.
W1 = weight of the same composite sample in water.

Tensile Test:
The tensile test is the most common method for determining the mechanical properties such
as ultimate tensile strength; yield strength, Young’s modulus etc. The materials used for
engineering applications are usually selected on the basis of these properties. The tensile
properties are usually measured during the development of new materials, so that different
materials can be compared. In the present work the tensile test was conducted on universal
testing machine (UTM) and the specimens of AMC-FA and AMC-AV were prepared as per
ASTM standards. The stress strain curve was plotted during the test for the determination of
ultimate tensile strength and elastic modulus. [9]

Hardness Test:
The hardness of a material indicates the resistance to permanent indentation. While testing
the hardness of a material an indenter is pressed into the surface of the material to be tested
under a specific load for a definite time interval. The diameter of the indentation left in the
test material is measured with a low powered microscope. In the present work Brinell
hardness tester with indenter diameter 5mm was used to determine the hardness of both the
specimens of AMC-FA and AMC-AV composites. A load of 500 kgf is applied for 30 seconds on
both the specimens and the average diameter of the indentation left is measured. The Brinell
Hardness Number (BHN) is calculated by dividing the load applied by the surface area of the
indentation. The formula for BHN is as follows –

33
 2𝑃
𝐵𝐻𝑁 =
𝜋𝑑(𝑑 − √𝐷2 − 𝑑 2 )

Where,
P = applied load in kg.
D = diameter of the steel ball in mm.
d = size of the indent in mm.

Impact Strength Test:

Impact strength is the ability of a material to absorb energy before actual fracture occurs. The
impact strength of the composites was tested using a standard impact testing machine using
Izod specimens. The Izod test is carried out by a pendulum-type testing machine, which
employs a cantilever test specimen 75 mm long with a 10×10 mm2 cross section, having a
standard 45° notch 2 mm deep.[10]

Wear Test:
Wear is a process of removal of material from one or both of two solid surfaces when their
surfaces are in solid contact during sliding or rolling under a load. In order to make the best
choice of material for a specific application, it is necessary to know the wear resistance of the
material because wear is the main cause of material wastage. In the present work the AMC-
FA and AMC-AV specimens were subjected to dry sliding wear test under dry conditions using
a horizontal pin-on-disc wear tester. Both the test specimen were in the form of cylindrical
pins of length35mm and 6mm in diameter, the rotating disc counterpart was made of EN
31steel (wt% C-1.08, Si-0.25, Mn-0.53%, S-0.015, P-0.022, Ni-0.33, Cr-1.46, Mo-0.06) having a
hardness of 60 HRC. The tangential friction force and wear were monitored with the help of
electronic sensors. These two parameters were measured as a function of load and sliding
distance. For each specimen, wear tests were carried out at room temperature without
lubrication. The photoelectric balance with an accuracy of ±0.1 mg is generally used to find
the mass of the specimens before and after the experiments. The wear for the specimens
AMC-FA and AMC-AV are observed from the wear test are 88 microns and 85 microns
respectively. Therefore, no significant change has been witnessed from this test. [10]

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 CONCLUSION

Several resistances must be cleared in order to strengthen the engineering usage of AMCs
such as processing methodology, influence of reinforcement, effect of reinforcement on the
mechanical properties and its corresponding applications. The major conclusions derived
from the prior works carried out can be summarised as below:

• Researches on the side-lines of using ultrasonic stirrer which can contribute to

improving particulate distribution in nano-particles reinforced aluminum metal matrix
composites can be a step-in right direction.
• Al2O3 reinforced Al MMCs have lower wear resistance than SiC reinforced MMCs.
• The wear resistance of B4C reinforced Al MMC is comparatively less than Si reinforced
Al MMC.
• The compressive strength and wear resistance and of Al MMCs is optimized with the
addition of Zircon sand reinforcement.
• The addition of flyash reinforcement in Al decreases the corrosion resistance but
increases the wear resistance.
• There was a good dispersibility of Si powder particles in aluminium matrix which
improves the hardness of the matrix material and also the tensile behaviour of the
composite.
• The Tensile strength of Si reinforced hybrid composite increases with increase in the
Si content. The best value for tensile strength for the composite was obtained at the
addition of 5% of Si to Al 7075. However, the addition of 7.5% Si does not improve the
Tensile Strength considerably.
• SiC reinforced Al MMCs are highly suitable materials for brake drums in automobiles
as they have high wear resistance but can’t be utilized in brake linings as it will damage
the brake drum.

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