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ABSTRACT

Nowadays Aluminium metal matrix composites finds wide-ranging

applications in the field of aerospace, automobile and military owing to its
unique properties such as high strength, high hardness, low wear resistance
and low density. Many of the research work has been carried out to synthesis
metal matrix composites founded on the traditional particulate reinforcement
such as Al2O3, TiO2, SiC, TiC and Gr particles. Limited research work has
been carried out by using Boron Carbide (B4C) as reinforcement synthesized
via Powder Metallurgy (P/M) technique. There has been increased demand
for composites containing high strength, hardness and low density. B4C
possess extreme hardness and low density.

The present research work objective is to develop new class of

material with desirable properties of AA8079 (Al-Fe-Cu-Si-Zn) was
synthesized by mixing pure Al powder with other elemental powders such as
0.05%Cu, 1.3%Fe, 0.3%Si, 0.15%Zn. The particle size of elemental powders
used was Al 100 µm, Cu 10 µm, Fe 10 µm, Si 8 µm and Zn 10 µm. B 4C with
an average particle size of 100 µm has been used. The compositions of the
composites are AA8079, AA8079-5wt%B4C, AA8079-10wt%B4C &
AA8079-15wt%B4C. The composites were synthesized by mechanical
alloying method and powder metallurgy technique. The milled powder was
characterized by X-ray diffraction (XRD) and Scanning Electron Microscopy
(SEM) analysis. Green cylindrical compacts of pure AA8079,
AA8079-5wt%B4C, AA8079-10wt%B4C and AA8079-15wt%B4C were
prepared via a 200 kN hydraulic press using appropriate punch and die. The
green compacts were sintered at a temperature of 575 οC by using electric
muffle furnace under controlled atmosphere for a time period of 3 h. Hot
extrusion was conducted on the sintered samples.
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The effect of mechanical alloying as a function of milling time on

the microstructure and properties of AA8079 (Al-Fe-Cu-Si-Zn) was studied.
The apparent density and tap density was determined for the different hours
milled AA8079 powders. It was detected that the apparent density and tap
density was uppermost for 20 h milled AA8079 powders. The XRD analysis
was carried out on the ball milled AA8079 powders. The morphology of
AA8079 alloy powders milled at different hours (1, 5, 10, 15 and 20 h) was
investigated by using SEM. The green and sintered densities were calculated
by using archimed’s principle. The characterization studies X-ray diffraction
(XRD), energy dispersive analysis (EDAX) and scanning electron microscopy
(SEM) analysis was made on the sintered samples. The mechanical properties
such as micro Vickers hardness and compressive strength was investigated.
The micro vickers hardness test was conducted on the sintered and cold
forged samples. The extreme Vickers hardness and compressive strength was
achieved for 20 h milled powders. The optical micrographs show the grain
boundaries and accumulation in the cold forged samples.

The effect of B4C on the microstructure, mechanical and corrosion

behavior of AA8079–B4C composites was investigated. The green and
sintered densities were calculated. The characterization studies X-ray
diffraction (XRD), Energy Dispersive Analysis (EDAX) and Scanning
Electron Microscopy (SEM) analysis was made on the sintered samples. XRD
analysis of the sintered preforms evident the presence of B4C reinforcement
with minor peaks. EDAX analysis of the sintered preforms witnessed the
presence of B4C reinforcement and elemental powders presence in the matrix
alloy. SEM analysis of the sintered preforms shows the homogenous
distribution of B4C within the matrix alloy. The mechanical properties such as
micro vickers micro hardness and compressive strength was investigated.
SEM micrographs of cold forged sintered preforms shows the formation of
grain boundaries due to the deformation of the samples during cold forging.
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The effect of hot extrusion and the amount of boron carbide on the
Properties and microstructure of AA8079- B4C composites were studied. The
SEM analysis was carried out on the ball milled powders. The
characterization studies X-ray diffraction (XRD) and Scanning Electron
Microscopy (SEM) analysis was carried out on the sintered and extruded
samples. XRD pattern of hot extruded samples shows the lower angle peak
shifting and decrease in peak intensity. The densities of the sintered and
extruded samples were measured. Extrusion process improved the density of
all samples when compare with sintered samples. Porosity evaluation was
made on the sintered and extruded samples. The mechanical properties such
as micro Vickers hardness and compressive strength examination were
conducted on the sintered and extruded samples. The extruded sample
exhibits superior hardness and compressive strength. SEM analysis of
sintered samples exhibits voids, pores and agglomeration. SEM analysis of
hot extruded samples evident the uniform distribution of B4C in the matrix
and also the proper bonding between the matrix and reinforcement. The
fracture analysis was made on the sintered and extruded samples after
compressive loading. The SEM fractographs after compressive loading
shows more voids, pores and cracks in sintered composites and these defects
were eliminated for the extruded samples.

Analysis of variance (ANOVA) was used to study the effect of the

powder metallurgy process parameters and extrusion process parameters on
both the hardness and the compressive strength for AA8079 and
AA8079–B4C composites. Based on the experiments, it was revealed that the
better hardness and the compressive strength were achieved for the extruded
samples than that of sintered samples. The complete results exposed that
extruded composites can be considered as an exceptional material with
superior harness and compressive strength.