MAULANA AZAD NATIONAL INSTITUTE OF

TECHNOLOGY BHOPAL

Mechanical Engineering Department

B. TECH. 4th YEAR
NOVEMBER 2019

MAJOR PROJECT PROGRESS REPORT

Optimization & Fabrication of B4C & Aloe Vera 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
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 MAULANA AZAD NATIONAL INSTITUTE OF
TECHNOLOGY BHOPAL

CERTIFICATE

This is to certify that project titled “Optimization and Fabrication of B4C and Aloe
Vera 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 VII semester as a working Major Project.

Dr. Mohan K. Pradhan

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

We would like to express our sincere thanks to Dr. N. S. Raghuwanshi, Director,

MANIT, Bhopal for giving us this opportunity to undertake this project. We would
also like to thank Dr. G. Dixit for whole hearted support.

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 behavior 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.

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 CONTENTS

• Cover Page 1
• CERTIFICATE 2
• ACKNOWLEDGEMENT 3
• CONTENTS 4
• ABSTRACT 5
• INTRODUCTION 6
• LITERATURE REVIEW 8
• METHODOLOGY 11
• WORK PLAN 12
• EXPECTED OUTCOMES 12
• References 13

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 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 boron carbide B4C on the properties of the
Aluminium alloy is considered. The influence of B4C and Aloe Vera on the mechanical
properties of Al 7075 composites will be examined. The aluminium B4C 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.

For the fabrication of the alloy, we will be creating samples having varying percentage of
Aloe Vera and B4C. After analyzing the results obtained from the testing methods, we
will identify the percentage of component which will give optimum result.

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 Introduction

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.

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:

1. Reinforced concrete and masonry

2. Composite wood such as plywood
3. Reinforced plastics, such as fibre-reinforced polymer or fiberglass
4. Ceramic matrix composites (composite ceramic and metal matrices)
5. 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

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reducing material usage since metal is quite expensive due to its limited availability in
future and also the fabrication cost which is lower than conventional cost.

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.

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 Literature Survey

Several investigators found that aluminium 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

Wrought Alloys

A four-digit numerical designation system is used to identify wrought aluminium and

aluminium alloys. As shown below, the first digit of the four-digit designation indicates
the group.

Aluminium, >99.00% - 1XXX. Aluminium alloys grouped by major alloying

element(s); Copper—2XXX; Manganese—3XXX; Silicon—4XXX; Magnesium— 5XXX;
Magnesium and Silicon—6XXX; Zinc—7XXX; Other elements—8XXX; Unused series—
9XXX.

Cast Alloys

A system of four-digit numerical designations incorporating a decimal point is used to

identify aluminium and aluminium alloys in the form of castings and foundry ingots. The
first digit indicates the alloy group.

Aluminium, >99.00 %—1XX.X. Aluminium alloys grouped by major alloying

element(s); Copper—2XX.X; Silicon with added copper and/or magnesium—3XX.X;
Silicon—4XX.X; Magnesium—5XX.X; Zinc—7XX.X; Tin—8XX.X; Other elements—9XX.X;
Unused series—6XX.X

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Effects of Alloying Elements

The effect(s) of various alloying elements are given below. Some of the effects,
particularly with respect to impurities, are not well documented and are specific to
particular alloys or conditions.

Chromium: Is a common addition to many alloys of the aluminium–magnesium,

aluminium–magnesium–silicon, and aluminium–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 aluminium– magnesium
alloys and recrystallization in aluminium–magnesium–silicon or aluminium–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 preexisting chromium-
phase particles.

Copper: Aluminium–copper alloys containing 2–10 wt% Cu, generally with other
additions, form an important family of Al alloys. Both cast and wrought aluminium–
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 aluminium–copper alloys have
been studied in greater detail than for any other system, but all commercial aerospace
alloys contain other alloying elements.

Copper–Magnesium: The main benefit of adding magnesium to aluminium– 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

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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 by formation of Guinier– Preston zones and a
very fine precipitate. Both confer an 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.

Mechanical Properties

To finalize the material for an engineering product or application, is it important to

understand the mechanical properties of the material. The mechanical properties of a
material are those which affect the mechanical strength and ability of a material to be
molded in suitable shape. Some of the typical mechanical properties of a composites to
be evaluated in this project are –

• Tensile strength
• Impact strength
• Hardness
• Wear resistance
• Erosion resistance

These are defined as -

Tensile Strength – Ultimate Tensile Strength (UTS), often shortened to Tensile Strength
(TS) or Ultimate Strength, is the maximum strength that a material can withstand while
being stretched or pulled before necking, which is when the specimen's cross section
starts to significantly stretch.

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Impact Strength – Impact resistance is material’s ability to withstand intense force or
shock applied to it over short period of time. Impact strength is an important
consideration for fall protection equipment. It also gives an indication of life or
durability of materials.

Hardness – Hardness is usually defined in terms of ability of material to resist to

scratching, abrasion, cutting, indentation and penetration. It is also defined as measure
of a material’s resistance to deformation by surface indentation. Material hardness can
be increased by alloying.

Wear Resistance – Wear is process of removal of material from one or both of two solid
surfaces in sliding or rolling motion. Wear can also be caused by chemical processes.
Resistance of material to wear is defined as Wear Resistance.

Erosion Resistance – Erosion is defined as cutting of material by hard particles in a high

velocity fluid impinging on a surface. Resistance of a metallic surface to erosion is
defined as Erosion Resistance.

Methodology

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 Work Plan

Following Work-Plan was performed during the entire project:

Strategy for 7th semester

➢ Topic was decided for the project i.e. optimization and fabrication of boron and
Aloe Vera reinforcement AL composites.
➢ Aluminium 7075 series was selected for the project work because it was easily
available in the market at economic price. Also, because it was best available
metals for aerospace applications.
➢ Our aim was to optimize wear resistance and other mechanical properties.
➢ To optimize the wear resistance, we found that materials like silicon carbide and
Boron Carbide are suitable. Further, we found that Boron Carbide is better for
property improvement.
➢ Aloe Vera would be mixed with Aluminium to reduce the density of the
component.
➢ Composites would be manufactured from outsourced vendors.
➢ All tests namely impact, tensile, hardness, wear and erosion would be performed
on composites.
➢ Obtained results would be thoroughly studied for optimized results.

Expected Outcomes

During the project following outcomes are expected:

1) Organic Compound like Aloe Vera mixed with Aluminium will reduce density of the
component. Also, Aloe Vera which is a waste can also be utilized and the component will
be light weight.

2)Boron Carbide is used in the mixture which will improve the wear resistance Erosion
resistance, durability, strength.

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 References

[1] Deepak Singla, and S.R. Mediratta. Evaluation of Mechanical Properties of Al 7075-Fly Ash
Composite Material. International Journal of Innovation Research in Science, Engineering and
Technology. 2013; Volume 2, Issue 4.

[2] Ch. Hima Gireesh, K.G. Durga Prasad, K. Ramji, P.V. Vinay. Mechanical Characterization of
Aluminium Metal Matrix Composite Reinforced with Aloe vera Powder. Science Direct. 2018;
Proceedings 5 (2018) 3289-3297.

[3] Alaa Mohammed Razzaq, Dayang Laila Majid, Mohamad R. Ishak and Uday M. Basheer.
Effect of Fly Ash Addition on Physical and Mechanical Properties of AA6063 Alloy
Reinforcement. Metals 2017, 7, 477. Retrieved from http://www.mdpi/journal/metals

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