1KS18ME415-HARSHITH M P - Duly Signed Project Report

VISVESVARAYA TECHNOLOGICAL UNIVERSITY
Jnana Sangama, Belgaum-590018
A PROJECT REPORT
ON
“CORROSION BEHAVIOUR OF Al (0.4Mg,0.3Si) ALLOY REINFORCED

WITH SiC AND B4C HYBRID MMC PRODUCED BY CONVENTIONAL
STIR CASTING”
Submitted in partial fulfilment of the requirements for the award of the degree of
BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING
Submitted by
DILEEP KUMAR H S 1KS18ME411
LOHITH B M 1KS18ME419
DHANUSH S 1KS18ME410
HARSHITH M P 1KS18ME415
Under the Guidance of

Mr. RAJESH G L
Assistant Professor
DEPARTMENT OF MECHANICAL ENGINEERING
K S INSTITUTE OF TECHNOLOGY
RAGHUVANAHALLI, BANGALURU - 560109
2020-2021
i
Department of Mechanical Engineering
CERTIFICATE
Certified that the project work entitled “CORROSION BEHAVIOUR OF Al (0.4Mg,0.3Si)

ALLOY REINFORCED WITH SiC AND B4C HYBRID MMC PRODUCED BY
CONVENTIONAL STIR CASTING” is a bonafide work carried out by
DILEEP KUMAR H S 1KS18ME411

LOHITH B M 1KS18ME419
DHANUSH S 1KS18ME410
HARSHITH M P 1KS18ME415
in partial fulfilment for the award of Bachelor of Engineering in Mechanical Engineering of
the Visvesvaraya Technological University, Belgaum during the year 2020-2021. It is certified
that all corrections/suggestions indicated for Internal Assessment have been incorporated in the
report deposited in the departmental library. The project report has been approved as it satisfies
the academic requirements in respect of project work prescribed for the said Degree.
Mr Rajesh G L Prof. Umashankar M

Guide Head of Department
Dr. Dilip kumar K
Principal/Director KSIT
NAME: HARSHITH M P
USN: 1 K S 1 8 M E 4 1 5
External Viva
Name of Examiners Signature with date
1.
2.
ii
Department of Mechanical
Engineering
DECLARATION
We, the students of final semester of Mechanical Engineering, K S Institute of Technology,

declare that the work entitled “CORROSION BEHAVIOUR OF Al (0.4Mg,0.3Si) ALLOY
REINFORCED WITH SiC AND B4C HYBRID MMC PRODUCED BY CONVENTIONAL
STIR CASTING" has been successfully completed under the guidance of Mr. Rajesh G L,
Department of Mechanical Engineering. This dissertation work is submitted to Visvesvaraya
Technological University in partial fulfillment of the requirements for the award of Degree of
Bachelor of Engineering in Mechanical Engineering during the academic year 2020 - 2021.
Further the matter embodied in the project report has not been submitted previously by anybody
for the award of any degree or diploma to any university.
Place: Bangalore
Date:
HARSHITH M P
Name
Signature
iii
ACKNOWLEDGEMENT
The sense of contentment and elation that accompanies the successful completion of this Work
would be incomplete without mentioning the names of the people who helped us in
accomplishment of this project, people whose constant guidance, support and encouragement
resulted in realization.
We take this opportunity to thank Dr. Dilip kumar K, Principal/Director, K S Institute of

Technology for providing the guidance and healthy environment in college which help in
concentrating on project.
We thank Prof. Umashankar M, HOD, Department of Mechanical Engineering, K S Institute

of Technology for providing us a handful of support during the course of project.
We thank Rajesh G L, Assistant Professor, Department of Mechanical Engineering, K S

Institute of Technology for encouragement and handful of support during the course of project.
Last but not the least, we would like to thank all the teaching and non-teaching staff K S
Institute of Technology, Bangalore, our parents, friends and all for helping us directly or
indirectly during the completion of the project.
iv
CONTENTS
TITLE PAGE................................................................................................................................................ i
CERTIFICATE ............................................................................................................................................. ii
DECLARATION ........................................................................................................................................ iii
ACKNOWLEDGEMENT .......................................................................................................................... iv
CHAPTER-1.................................................................................................................................................1
INTRODUCTION ........................................................................................................................................1
1.1 BACKGROUND OF THE PROJECT ...............................................................................................1
1.2 METAL MATRIX COMPOSITES ....................................................................................................2
1.2.1 Classification of MMCs based on the matrix material ................................................................2
1.3 MATRIX ............................................................................................................................................3
1.3.1 The most important MMC systems are: ......................................................................................4
1.3 REINFORCEMENT ...........................................................................................................................4
1.4 TYPES OF MARINE CORROSION .................................................................................................5
1.4.1 Crevice corrosion .........................................................................................................................5
1.4.2 Uniform corrosion .......................................................................................................................6
1.4.3 Pitting corrosion ..........................................................................................................................6
1.4.4 Erosion corrosion.........................................................................................................................7
1.4.5 Galvanic corrosion .......................................................................................................................8
1.4.6 Electrolytic Corrosion..................................................................................................................8
CHAPTER -2..............................................................................................................................................10
LITERATURE SURVEY...........................................................................................................................10
2.1 Analyzing the Mechanical Properties and Corrosion Phenomenon of Reinforced Metal Matrix
Composite by Subramani Nanjan and Janakiram Ganesh Murali. .........................................................10
2.2 Corrosion Behavior of Alumina Reinforced Aluminum (6063) Metal Matrix K. K. Alaneme and
M. O. Bodunrin.......................................................................................................................................10
2.3 Corrosion Behavior of Alumina-Aluminum and Silicon Carbide-Aluminum Metal-Matrix
Composites by P.C.R. Nunes and L.V. Ramanathan..............................................................................11
2.4 Corrosion Behavior of SiC/AI Metal Matrix Composites by P. P. Trzaskoma and E. McCafferty. 11
2.5 Silicon Carbide Reinforced Aluminum Metal Matrix Composites for Aerospace Applications by
Suryanarayanan K. , R. Praveen, S. Raghuraman. .................................................................................12
2.6 Properties and Applications of Silicon Carbide by Rosario Gerhardt ..............................................12
CHAPTER-3...............................................................................................................................................13
MATERIAL USED ....................................................................................................................................13
3.1 ALUMINIUM 6061 ALLOY ...........................................................................................................13
3.1.1 Chemical Composition of AL-6061: .........................................................................................14
3.1.2 Properties of aluminum alloy-6061: ..........................................................................................14
v
3.2 SILICON CARBIDE (SiC): .............................................................................................................15
3.2.1 Properties of silicon carbide (SiC):............................................................................................16
3.3 BORON CARBIDE (B4C): ..............................................................................................................16
3.3.1 Properties of Boron Carbide (B4C): ..........................................................................................17
4.2 CASTING .........................................................................................................................................19
4.2.1 Stir casting .................................................................................................................................19
4.3 THE MAIN COMPONENTS OF CASTING ..................................................................................20
4.3.1 Resistance furnaces....................................................................................................................20
4.3.2 Crucible .....................................................................................................................................21
4.3.3 PERMANENT MOULD ...........................................................................................................21
4.3 TESTING METHOD .......................................................................................................................22
4.3.1 Microstructure analysis..............................................................................................................22
4.3.2 Hardness test ..............................................................................................................................24
4.4 CORROSION TEST.........................................................................................................................26
4.4.1 Potentiodynamic polarization measurement ..................................................................................26
4.4.2 Immersion test method ..............................................................................................................28
4.4.3 Preparing a Sodium Chloride Solution (NaCl) ..........................................................................30
4.5 SCANNING ELECTRON MICROSCOPE (SEM) .........................................................................31
4.5.1 Fundamental Principles of Scanning Electron Microscopy (SEM) ...........................................31
CHAPTER -5..............................................................................................................................................33
RESULT AND ANALYSIS .......................................................................................................................33
5.1 MICROSTRUCTURE ANALYSIS .................................................................................................33
5.2 HARDNESS TEST...........................................................................................................................34
5.3 CORROSION TEST.........................................................................................................................34
5.3.1 Expected Outcomes ...................................................................................................................34
CHAPTER -6..............................................................................................................................................35
REFERENCE .............................................................................................................................................35
vi
LIST OF FIGURES
Figure 1 The usage volume of different matrix materials in MMCs ............................................................2

Figure 2 Aluminum based MMC's ...............................................................................................................3
Figure 3 Crevice corrosion ...........................................................................................................................6
Figure 4 Uniform corrosion ..........................................................................................................................6
Figure 5 Pitting corrosion .............................................................................................................................7
Figure 6 Erosion Corrosion ..........................................................................................................................7
Figure 7 Galvanic corrosion .........................................................................................................................8
Figure 8 Electrolytic corrosion .....................................................................................................................9
Figure 9 Aluminum ....................................................................................................................................14
Figure 10 Silicon Carbide ...........................................................................................................................15
Figure 11 Boron Carbide ............................................................................................................................17
Figure 12 Stir casting technique .................................................................................................................19
Figure 13 Resistance Furnace .....................................................................................................................20
Figure 14 Crucible ......................................................................................................................................21
Figure 15 Permanent mould .......................................................................................................................22
Figure 16 Optical microscope.....................................................................................................................23
Figure 17 Al-B4C (5%)-Graphite (15%) [8] ..............................................................................................24
Figure 18 Brinell hardness testing machine................................................................................................25
Figure 19 Parameters of potentiodynamic polarization curves ..................................................................28
Figure 20 Immersion corrosion test setup containing 5 wt% NaCl Solution containing 3%NaCl Solution
....................................................................................................................................................................29
Figure 21 Scanning electron microscope (SEM) .......................................................................................32
Figure 22 SEM microstructure of aluminum matrix nanocomposites (a) Al-Al 2 O 3 , (b) Al-SiO 2 ,(c)
Al-CNTs and (d) Pure Al............................................................................................................................32
Figure 23 Microscopic image of Al+5wt%SiC+1wt%B4C ........................................................................33
LIST OF TABLE
Table 1 Composition of aluminum 6061 ....................................................................................................14
Table 2 Properties of aluminum .................................................................................................................15
Table 3 Properties of Silicon Carbide.........................................................................................................16
Table 4 Properties of Boron Carbide ..........................................................................................................17
Table 5 Hardness test result ........................................................................................................................34
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CORROSION BEHAVIOUR OF Al (0.4MG,0.3SI) ALLOY REINFORCED WITH SiC AND
B4C HYBRID MMC PRODUCED BY CONVENTIONAL STIR CASTING
CHAPTER-1
INTRODUCTION
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,
corrosive strength etc. Aluminium and its alloys have attracted most attention as base metal in
metal matrix composites, Recent advances in the fabrication and characterization of 6061Al-
0.4Mg-0.3Si alloy reinforced with Silicon carbide (SiC) and Boron carbide (B4C) hybrid metal
matrix composites (MMC) have resulted in a new generation of engineering materials that are
under consideration for a variety of structural, defense, marine and aerospace applications. In our
project work, we are going to study the corrosion behavior of 6061Al-0.4Mg-0.3Si reinforced with silicon
carbide (SiC) and boron carbide (B4C) metal matrix composites produced using two - step stir casting
process is investigated. Stir casting was selected because it is an economical and efficient process route
which also has the advantage of adaptability to the use of improvised facilities. The investigation is
intended to assess the corrosion behavior of the Al-0.4Mg-0.3Si reinforced Silicon carbide (SiC)
and Boron carbide (B4C) metal matrix composites in immersion test method (3.5wt% NaCl for
28days at 25°C) and polarization electrochemical method.
1.1 BACKGROUND OF THE PROJECT
Scientist and Engineers have ingeniously designed various composite materials by the
combination of metals, ceramics and polymers to produce new generation of extra-ordinary
materials having combination of superior mechanical characteristics such as toughness, stiffness
and high temperature strength. Nowadays, MMCs replace various conventional alloys in
applications such as automobiles, marine, recreation industries and defence etc. Aluminium based
metal matrix composites attract much attention in today’s world due to their potential to be used
as top choice material in various engineering applications. They have good mechanical properties,
good corrosion and wear resistance. The production of Aluminium metal matrix composites is
also cheaper when compared to other metal matrix composites. The major limitations in the
applications of MMC are their corrosion behaviour. The heterogeneities in MMC tend to affect
its corrosion characteristics. Galvanic Coupling, micro crevices, porosity, voids and high
reactivity interfacial phases are some of the corrosion-related problems in MMC. The reported
Department of Mechanical Engineering, KSIT Page 1

works on corrosion behaviour of MMC’s is also less when compared to other behaviours of
composites. Various reporters had used various tests namely Stress Corrosion Crack (SCC),
immersion test and Potentiodynamic test to study the corrosion behaviour of MMC’s.
1.2 METAL MATRIX COMPOSITES
A metal matrix composite (MMC) is 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 organic compound. When at least three materials are present, it is called a hybrid
composite.
1.2.1 Classification of MMCs based on the matrix material
MMCs are classified into different categories depending upon their matrix materials. Some
examples of most commonly used metallic matrix configurations are:
a. Aluminum-based composites; aluminum as matrix can be either cast alloy or
wrought alloy (i.e., AlMgSi, AlMg, AlCuSiMn, AlZnMgCu, AlCu, AlSiCuMg)
b. Magnesium-based composites
c. Titanium-based composites
d. Copper-based composites
e. Super alloy-based composites
Figure 1 the usage volume of different matrix materials in MMCs

Aluminum–matrix composites are most commonly studied MMC as they are widely used in the
automotive and aerospace industries. Reinforcement compounds such as Sic, Al2O3, and B4C can

be mixed easily and effectively in molten aluminum. Magnesium–matrix composites have similar
advantages, but due to limitations in fabrication and lower thermal conductivity, they are not
widely used as compared with aluminum-based MMCs. Magnesium–matrix composites have
been developed for the space industry thank to the low density of magnesium and its
alloys. Titanium alloys are used as matrix material in fabricating MMCs due to their good strength
at elevated temperatures and excellent corrosion resistance. Compared with aluminum, titanium
alloys hold their strength at higher temperature, which is advantageous in manufacturing aircraft
and missile structures, whose operating speeds are very high. However, their main problem lies
with processing of highly reactive titanium with reinforcement materials. Fiber-based titanium
composites are widely used in developing aircraft structures. In terms of thermal conductivity and
high-temperature strength properties, copper–matrix composites are superior compared with other
MMCs. Super alloys are commonly used as candidate materials for manufacturing gas turbine
blades, where they operate at higher temperatures and speeds.
Figure 2 Aluminum based MMC's
1.3 MATRIX
The matrix is the monolithic material into which the reinforcement is embedded, and is
completely continuous. This means that there is a path through the matrix to any point in the
material, unlike two materials sandwiched together. In structural applications, the matrix is usually
a lighter metal such as aluminum, magnesium, or titanium, and provides a compliant support for
the reinforcement. In high-temperature applications, cobalt and cobalt–nickel alloy matrices are
common.
The selection of suitable matrix alloys is mainly determined by the intended application of the
composite material. With the development of light metal composite materials that are mostly easy
to process, conventional light metal alloys are applied as matrix materials. In the area of powder
metallurgy special alloys can be applied due to the advantage of fast solidification during the

powder production. Those systems are free from segregation problems that arise in conventional
solidification. Also the application of systems with oversaturated or metastable structures is
possible.
1.3.1 The most important MMC systems are:
• Aluminum matrix
o Continuous fibers: boron, silicon carbide, alumina, graphite
o Discontinuous fibers: alumina, alumina-silica
o Whiskers: silicon carbide
o Particulates: silicon carbide, boron carbide
• Magnesium matrix
o Continuous fibers: graphite, alumina
o Whiskers: silicon carbide
o Particulates: silicon carbide, boron carbide
• Titanium matrix
o Continuous fibers: silicon carbide, coated boron
o Particulates: titanium carbide
• Copper matrix
o Continuous fibers: graphite, silicon carbide
o Wires: niobium-titanium, niobium-tin
o Particulates: silicon carbide, boron carbide, titanium carbide.
• Super alloy matrices
o Wires: tungsten
1.3 REINFORCEMENT
The reinforcement material is embedded into a matrix. The reinforcement does not always serve
a purely structural task (reinforcing the compound), but is also used to change physical properties
such as wear resistance, friction coefficient, or thermal conductivity. MMC reinforcements can be
divided into five major categories: continuous fibers, discontinuous fibers, whiskers, particulates,
and wires. With the exception of wires, which are metals, reinforcements generally are ceramics.
Reinforcements for metal matrix composites have a manifold demand profile, which is determined

by production and processing and by the matrix system of the composite material. The following
demands are generally applicable.
➢ low density,
➢ mechanical compatibility (a thermal expansion coefficient which is low but adapted to the
matrix),
➢ chemical compatibility,
➢ thermal stability,
➢ high Young’s modulus,
➢ high compression and tensile strength,
➢ good process ability,
➢ Economic efficiency.
These demands can be achieved only by using non-metal inorganic reinforcement components.
For metal reinforcement ceramic particles or, rather, fibers or carbon fibers are often used. Due to
the high density and the affinity to reaction with the matrix alloy the use of metallic fiber usual
fails. Which components are finally used, depends on the selected matrix and on the demand
profile of the intended application. Information about available particles, short fibers, whiskers
and continuous fibers for the reinforcement of metals is given, including data of manufacturing,
processing and properties. The production, processing and type of application of various
reinforcements depend on the production technique for the composite materials. A combined
application of various reinforcements is also possible (hybrid technique).
1.4 TYPES OF MARINE CORROSION
1.4.1 Crevice corrosion
Crevice corrosion refers to localized attack due to the contact with a corrosive environment. It can
occur between narrow spaces between metals or between metal and other non metal parts like
gaskets. A concentration cell forms with the crevice being depleted of oxygen. This differential
oxygen content between the crevice and the external surface gives the crevice an anodic character.
This can contribute to a highly corrosive condition in the crevice. This type corrosion always
occurs in components where gaskets, washers, o rings, fasteners and lap joints are used.

Figure 3 Crevice corrosion
1.4.2 Uniform corrosion
Uniform or general corrosion refers to the corrosion of steel. As this is a uniform process the life
of the product can be estimated based on relatively simple immersion test results. So allowances
can be given to the products by proper calculation based on the amount of material being corroded
during a particular period of time. The environment to which the metal is exposed is also important
.Uniform or general corrosion usually occurs in stagnant or low flow seawater rate of
approximately 10 microns per year on mild and low-alloy steels. Uniform corrosion on these types
of steels is the most common form of corrosive attack on ships
Figure 4 Uniform corrosion
1.4.3 Pitting corrosion
Pitting corrosion is a form of extremely localized corrosion that leads to the creation of small holes
in the metal. The driving power for pitting corrosion is the lack of oxygen around a small area.
This area becomes anodic while the area with excess of oxygen becomes catholic; leading to very
localized galvanic corrosion. The corrosion area tends to burrow into the mass of the metal, with

limited diffusion of ions, further pronouncing the localized lack of oxygen Addition of about 2%
of molybdenum increases pitting resistance of stainless steels. The presence of chlorides in sea
water, significantly aggravate pit formation through an auto catalytic process. Stagnant water
conditions also favor pitting.
Figure 5 Pitting corrosion
1.4.4 Erosion corrosion
Erosion corrosion deals with the corrosion taking place on metal surface due to the removal of the
coating from the surface of the metal typically, erosion corrosion is greater with metals that are
exposed to seawater with higher salinity than to those that are in a brackish (lower salinity) or
fresh water. A more specific form of erosion corrosion that typically occurs on the propellers of
ships and submarines is caused by capitation. The formation and immediate collapse of vapor
bubbles (cavitations) repeatedly hitting a particular location will often result in surface damage on
the propeller.
Figure 6 Erosion Corrosion

1.4.5 Galvanic corrosion
Galvanic corrosion requires three conditions to thrive: the two metals must be widely separated
on the galvanic series, they must be in electrical contact and their surfaces must be bridged by an
electrically conducting fluid, such as seawater. Dissimilar metals and alloys have different
electrode potentials and when two or more are in contact with an electrolyte, such as seawater,
one metal will act as an anode and the other as a cathode. The anode metal dissolves into the
seawater and solid deposits will accumulate on the cathode metal.
In order to prevent galvanic corrosion, one must eliminate mixed metal fabrications. However, in
the marine industry this may not be practical. Fortunately, you can still prevent galvanic corrosion
by removing the electrical contact by the use of plastic or rubber washers or sleeves. Another
option is to remove the electrolyte from the equation. This could be accomplished by improving
your drainage system or by utilizing protective hoods.
Figure 7 Galvanic corrosion
1.4.6 Electrolytic Corrosion
Electrolytic Corrosion can be caused by stray currents that develop from a power source. This
type of corrosion can damage bearings, washers, oil and water coolers or even your engine. The
causes can come from one of two places:
➢ Shore Power: When your vessel is plugged in to marina shore power, your vessel’s
submerged metal is connected to others in the marina. Unless your vessel is isolated, it
may endure a damaging current that could put your metals at risk.

➢ On Board: Check to see if your vessel has a damaged appliance or wiring that is leaking
current. This could be your source of Electrolytic Corrosion.
In order to prevent this type of corrosion, take the time to make some quick observations. Look
for obvious signs of leakage or have an experienced marine electrician perform an earth leakage
test from the marina or on board your ship. To help avoid electrolytic corrosion, it is recommended
to schedule an annual earth leakage test for your vessel.
Figure 8 Electrolytic corrosion

CHAPTER -2
LITERATURE SURVEY
2.1 Analyzing the Mechanical Properties and Corrosion Phenomenon of

Reinforced Metal Matrix Composite by Subramani Nanjan and Janakiram
Ganesh Murali.
• In this research, a Metal Matrix hybrid composite (MMHC) is prepared by reinforcing the
following reinforcements like Graphite, Aluminum oxide, silicon carbide and boron
carbide at a percentage of 4 and 5 is added with A6061.
• This preparation is carried out by using the stir casting method. In particular, the corrosion
properties of the untreated A6061 reinforced composites samples were evaluated using in
3.5% NaCl solution and immersion tests in 1% HCl acidic water solution.
• The highest percentage of depicts the positive result. In addition to that the SEM, wear,
hardness tests are carried out to bring out the positive impact of the newly prepared
samples.
• In accordance with that the fundamental spotlight is given on Aluminum network
composites on account of its novel blend of good corrosion protection, wear properties and
outstanding mechanical properties.
• According to this research, Aluminum 6061 alloy and its composites have been effectively
fabricated by stir casting method using two-step additions of particulates in the melt.
• The wear resistance of Aluminum 6061 alloy increased after the addition of SiC and
graphite and B4C. The results obtained by tests in this work clearly designate that
Aluminum has improved corrosion resistance to the action of 3.5 NACL solutions than its
A6061 alloy.
2.2 Corrosion Behavior of Alumina Reinforced Aluminum (6063) Metal

Matrix K. K. Alaneme and M. O. Bodunrin.
• The influence of alumina volume percent and solution heat-treatment on the corrosion
behavior of Al (6063) composites and its monolithic alloy in salt water, basic and acidic
environments is investigated.

• The unreinforced alloy exhibited slightly superior corrosion resistance than the composites
in NaCl and NaOH media but the composites had better corrosion resistance in H2SO4
medium.
• The corrosion tests were carried out in 3.5wt% NaCl (pH 7.4), 0.3M H2SO4 (pH 0.9), and
0.1M NaOH(pH12.7) solutions which were prepared for immersion test. The specimensfor
the test were cut to size 20×20×5mm, after which the sample surfaces weremechanically
polished with emery papers.
• From the results, it is observed that Al (6063) – Al2O3 composites exhibited excellent
corrosion resistance in NaCl medium than in the NaOH and H2SO4 media.
• The unreinforced alloy exhibited slightly superior corrosion resistance than the composites
in NaCl and NaOH media but the composites had better corrosion resistance in H2SO4
medium.
2.3 Corrosion Behavior of Alumina-Aluminum and Silicon Carbide-

Aluminum Metal-Matrix Composites by P.C.R. Nunes and L.V. Ramanathan.
• Particle-reinforced, aluminum-based metal-matrix composites (MMCs) are being

considered for a range of applications. Their mechanical properties have been investigated
in detail, but more information about their corrosion behavior is needed. Overall and
corrected weight-loss data for the composite specimens following 28 days of immersion in
3.5% NaCl.
• Weight loss from corrosion was considerable in all cases. The loss was due to matrix
corrosion and to particle loss originating from preferential dissolution of the interfacial
regions. The weight loss of SiC-reinforced composites was found to be higher than that of
the Al2O3-reinforced composites.
• In this paper we understand that the number of pit initiation sites was significantly higher
in the composites than in the alloys. Pits were crystallographic in nature, and pits in the
SiC composites were deeper than those in the Al2O3 composites.
2.4 Corrosion Behavior of SiC/AI Metal Matrix Composites by P. P.

Trzaskoma and E. McCafferty.
• Recent advances in the fabrication and characterization of SiC/A1 composites have

resulted in a new generation of engineering materials that are under consideration for a

variety of structural, defense, and aerospace applications. Composite materials have

particular appeal because within limits, they can be designed and fabricated to fit the
mechanical requirements of a applications.
• The susceptibility to pit initiation is unaffected by the presence of SiC for all alloys except
A1 2024. For this system, the composite exhibits less resistance to pit initiation than the
base alloy. Of the specimens tested, A1 2024 is least susceptible to pit initiation in chloride
solutions.
2.5 Silicon Carbide Reinforced Aluminum Metal Matrix Composites for

Aerospace Applications by Suryanarayanan K. , R. Praveen, S. Raghuraman.
This paper considers the potential of use Al-SiC metal matrix composite (MMC) with particular
reference to the aerospace industry. Initially, the required properties are identified, after which,
the work explores pure aluminum and its importance in the industry along with its limitations. It
is seen that for any material to be used in aerospace applications, certain criteria must be met.
Although the exact set of required properties depend on the specific application, certain properties
such as low density, good fatigue performance, and high wear and corrosion resistance are seen
as universal requirements for effective functioning in the industry. Therefore, this paper makes a
case for Al-SiC MMC and its application in the aerospace industry by exploring its properties.
One of the main reasons for its consideration was the material’s low density and its good (wear
and corrosion) resistance.
2.6 Properties and Applications of Silicon Carbide by Rosario Gerhardt
Silicon carbide (Greenwood and Earnshaw, 1997) has been widely used for various purposes, such
as dummy wafers and reactor parts, in silicon semiconductor device production processes, due to
its high purity and significantly small gas emission. In many other industries, silicon carbide has
been used for coating various materials, such as carbon, in order to protect them from corrosive
environment. For the experimental study, micro-laser assisted scratch tests were successful in
demonstrating the enhanced thermal softening of the material resulting in a greater ductile to
brittle transition depth. This paper results the thermal softening behavior due to simulated laser
heating, which reduces the hardness of the material. The interaction between stress and
temperature was also determined from the boundary condition simulation outputs. It showed that
the dominance of stress decreases with increase in temperature.

CHAPTER-3
MATERIAL USED
3.1 ALUMINIUM 6061 ALLOY
Aluminum alloy 6061 is one of the most extensively used of the 6000 series aluminum alloys. It
is a versatile heat treatable extruded alloy with medium to high strength capabilities. Aluminum
6061 is a precipitation-hardened aluminum alloy, containing magnesium and silicon as its major
alloying elements. Originally called "Alloy 61S", it was developed in 1935. It has good
mechanical properties, exhibits good weld ability, and is very commonly extruded It is one of the
most common alloys of aluminum for general-purpose use. According to the given content in
references papers the aluminum 6061 is mostly used for making metal foams with low density
and high porosity.
Aluminum 6061 is used for the construction of aircraft structures, such as wings and fuselages,
more commonly in homebuilt aircraft than commercial or military aircraft. 2024 alloy is somewhat
stronger, but 6061 is more easily worked and remains resistant to corrosion even when the surface
is abraded, which is usually used with a thin Al-clad coating for corrosion resistance.
Aluminum 6061 has very good weldability and the vibration absorption capability of the
component is improved by making the AA6061 foam which leads to 9 better efficiency. The
aluminum foam needs to have porosity and this porosity is produced by blowing agents to
continuously produce gases in the material.
Usually it is purchased in the form of blanks and used for casting .Features of AL-6061 is,
➢ Good Machinability and weld ability.

➢ Impermeable and odorless.
➢ It has medium fatigue strength.
➢ Lightweight yet durable.
➢ Non-corrosive.
➢ Good heat and electrical conductor
➢ Non-magnetic and non-sparking

Figure 9 Aluminum
3.1.1 Chemical Composition of AL-6061:
The alloy composition of 6061 is:
Component Weight percentage (wt %)

Aluminum 97.08%
Magnesium 0.8-1.2%
Silicon 0.4-0.8%
Iron Max 0.7
Copper 0.15-0.40
Zinc Max 0.25
Titanium Max 0.15
Manganese Max 0.15
Chromium 0.04-0.35
Other 0.05
Table 1 Composition of aluminum 6061
3.1.2 Properties of aluminum alloy-6061:
SL.no Properties Values
1 Density (g/cc) 2.7
2 Elastic Modulus (GPa) 68.2

3 Poisson’s Ratio 0.33
4 Melting Point 585°c
5 Hardness(kg/mm2) 95-97
6 Thermal Conductivity(w/mk) 173
Table 2 Properties of aluminum
3.2 SILICON CARBIDE (SiC):
Silicon carbide (SiC) can be utilized as reinforcement in the form of particulates, whiskers or fibers to
enhance the properties of the composite Silicon carbide is commonly called as carborundum, is a
compound silicon and carbon. SiC certainly improves the overall strength of the composite along with
corrosion and wear resistance. Silicon carbide is a compound which is composed of carbon and silicon
atoms with a strong bond in the crystal lattice. This leads to the production of the strong and hard
material. SiC has high thermal conductivity, low thermal expansion, and impressive strength and it gives
the material a very good thermal shock resistance property. SiC is considered as a very good abrasive and
used to produce grinding wheels and some other abrasive products. SiC is used to produce many parts
like turbine components, seals and bearings, ball halve parts, heat exchangers, semiconductor process
equipment, floor tiles etc.
Figure 10 Silicon Carbide

3.2.1 Properties of silicon carbide (SiC):
SL. NO Properties Values
1 Density 3.16 g/cm3
2 Elastic Modulus 401 GPa
3 Poisson’s Ratio 0.192
4 Hardness 2800 kg/mm2
5 Melting Point 2200-2700 ̊C
6 Co-Efficient of thermal 4 μm/m ̊C

expansion
7 Thermal conductivity 360 w/mk
Table 3 Properties of Silicon Carbide
3.3 BORON CARBIDE (B4C):
Boron Carbide (B4C) is one of the hardest materials known, ranking third behind diamond and
cubic boron nitride. It is the hardest material produced in tonnage quantities.
Boron carbide(B4C), crystalline compound of boron and carbon. It is an extremely hard,

synthetically produced material that is used in abrasive and wear-resistant products, in lightweight
composite materials, and in control rods for nuclear power generation.
Boron carbide is a ceramic material which is obtained by decomposing B2O3 with carbon in the
electric furnace: 2 B2O3 + 7 C → B4C + 6 CO
Boron carbide's structure is only approximately B4C, and it shows a clear depletion of carbon
from this suggested stoichiometric ratio. This is due to its very complex structure. The substance
can be seen with empirical formula B12C3 (i.e., with B12dodecahedra being a motif), but with
less carbon as the suggested C3 units are replaced with B-C chains, and there are smaller (B6)
present as well.

The repeating polymer plus semi - crystalline structure of boron carbide gives it great structural
strength per weight. It is used in tank, bullet proof vests, and numerous other structural
applications.
Figure 11 Boron Carbide
3.3.1 Properties of Boron Carbide (B4C):
SL. NO Properties Values
1 Density (g/cm3) 2.52
2 Melting Point 2445°c
3 Hardness (kg/mm2) 2900-3580
4 Young’s Modulus (GPa) 450-470
5 Compressive Strength (MPa) 2585
6 Tensile Strength (MPa) 261- 569
7 Thermal Conductivity (w/mk) 30 – 40
8 Poisson's Ratio 0.18
9 Fracture Toughness 2.5-5
Table 4 Properties of Boron Carbide

CHAPTER-4
METHODOLOGY
4.1 FLOW CHART
Charge 6061Al
Melting - Resistance furnace - 7500C
Degassing – C2Cl6
Vigorous stirring using zirconia coated steel rod – Vortex
Addition of Preheated SiC/B4C along into vortex in two

stages
Again stirring for a period of 5minutes.
Pouring into permanent mould
Preparation of specimens for microscopy & corrosion

test as per ASTM standards.

4.2 CASTING
4.2.1 Stir casting
In stir casting we use stirrer to agitate the molten metal matrix. The stirrer is generally made up of
a material which can withstand at a higher melting temperature than the matrix temperature.
Generally graphite stirrer is used in stir casting. The stirrer is consisting of mainly two components
cylindrical rod and impeller. The one end of rod is connected to impeller and other end is
connected to shaft of the motor. The stirrer is generally held in vertical position and is rotated by
a motor at various speeds. The resultant molten metal is then poured in die for casting. Stir casting
is suitable for manufacturing composites with up to 30% volume fractions of reinforcement.
A major concern in associated with the stir casting is segregation of reinforcement particles
due to various process parameters and material properties result in the non-homogeneous metal
distribution. The various process parameters are like wetting condition of metal particles, relative
density, settling velocity etc. The distribution of particle in the molten metal matrix is also
affected by the velocity of stirrer, angle of stirrer, vortices cone etc. In this method first the
matrix metal is heated above its liquid temperature so that it is completely in molten state.
After it is cooled down to temperature between liquid and solidus state means it is in a
semi-solid state. Then preheated reinforcement particles are added to molten matrix and again
heated to fully liquid state so that they mixed thoroughly each other.
Figure 12 stir casting technique

4.3 THE MAIN COMPONENTS OF CASTING
4.3.1 Resistance furnaces

Resistance furnaces are used extensively because of their numerous advantages. Any temperatur
e up to 3000°C can be obtained in the furnace chamber. Articles can be uniformly heated either
by appropriately locating the heating elements along the walls of the furnace chamber or by mea
ns of forced circulation of the furnace atmosphere. Automatic control of the power and, consequ
ently, of the temperature conditions in such a furnace is easily implemented. Resistance furnaces
are readily mechanized and automated, thus alleviating the work of personnel and facilitating th
e inclusion of such furnaces in automatic transfer lines. In addition, they are compact. Such furn
aces provide a secure environment for various processes. A resistance furnace may be well seale
d, in which case the heating is carried out in a vacuum, or it may contain either a gaseous mediu
m that prevents oxidation or a special atmosphere for chemical case hardening, for example, for
carburization or nitriding.
Most resistance furnaces are of the indirect type. In indirect-heat resistance furnaces, electric energy
is converted into heat when a current flows through the heating elements. The heat is transmitted to t
he articles to be heated by radiation, convection, or conduction. Such a furnace consists of a working
chamber formed by a lining composed of a layer of firebrick that supports both the articles to be hea
ted and the heating elements and that is insulated from a metal casing by a layer of heat insulation (F
igure 1). The parts and mechanisms that operate in the chamber, as well as the heating elements, are
made of heat resistant steels, refractory steels, or other refractory materials.
Figure 13 Resistance Furnace

4.3.2 Crucible
A crucible is a pot that is used to keep metals for melting in a furnace. Furnace crucibles are
designed to withstand the highest temperatures encountered in the metal casting works. The
crucible should essentially be made of materials with a much higher melting point than that of the
materials to be melted. The crucible materials should also have good strength even when
extremely hot.
Furnace crucibles come in a variety of metal constructions, such as clay-graphite, silicon-carbide,

and more. These materials can resist the extreme temperatures in typical foundry operations.
Silicon carbide has the additional benefit of being a highly durable material. Some common shapes
for crucibles include “A” shape and bilge shape.
Figure 14 Crucible
4.3.3 PERMANENT MOULD
• Permanent mould casting is a process for producing a large number of castings using a
single reusable mould.
• The casting process simply involves pouring molten metal into a mould where it cools and
solidifies.
• Molds for the casting process consist of two halves. Casting molds are usually formed
from gray cast iron because it has about the best thermal fatigue resistance, but other
materials include steel, bronze, and graphite.
• These metals are chosen because of their resistance to erosion and thermal fatigue.

• Permanent mold casting is typically used for high-volume production of small, simple
metal parts with uniform wall thickness. Non-ferrous metals are typically used in this
process, such as aluminum alloys, magnesium alloys, and copper alloys. However, irons
and steels can also be cast using graphite molds. Common permanent mold parts include
gears and gear housings, pipe fittings, and other automotive and aircraft components such
as pistons, impellers, and wheels.
• They are usually not very complex because the mold offers no collapsibility to
compensate for shrinkage. Instead the mold is opened as soon as the casting is solidified,
which prevents hot tears. Cores can be used and are usually made from sand or metal.
• The mould is then opened, the casting removed, and the mould is reused. The mould is
made from a high-temperature metallic material, such as cast iron or hot work die steel,
which can withstand the repeated heating and cooling involved with large volume
production.
• Permanent mould casting produces metal with better dimensional tolerance, superior
surface finish, and higher and more uniform mechanical properties when compared with
metal solidified using sand casting which is another popular casting process.
Figure 15 Permanent mould
4.3 TESTING METHOD
4.3.1 Microstructure analysis
Microstructure analysis is a core technique in Materials Science. Here we will

introduce the techniques of optical microscopy and scanning electron microscopy,

and use these instruments for the analysis of the microstructure for several
materials. Some specific objectives are:
1. Skill development for bulk specimen preparation, metallographic polishing and etching to
reveal microstructure, digital image capture via optical microscopy.
2. Principles of optical microscopy and training on MSE 360 Nikon optical microscopes.
3. Introduction to Scanning Electron Microscopy and microstructure interpretation.
4. Quantitative microstructural analysis by manual methods
5. Automated digital image techniques for quantitative microstructural analysis.
6. Statistical analysis of aggregate data to determine standard deviation, confidence levels and
accuracy.
7. Skill development in constructing technical reports.
Figure 16 Optical microscope

In an optical microscope the light is incident on the sample and a magnified image is produced by
the combined action of objective and eyepiece lenses. Typical maximum magnifications achieved
in this type of microscope are in the range of 1000–2000x. Most features of common interest can
be observed and quantified using quantitative microscopy methods. These include observation
and determination of grain sizes and also shapes, sizes, and amounts of the different phases in

multi-phase systems. Figure 6 shows an example optical micrograph showing the grain structure
and annealing twins in a polished and etched sample of alpha brass.
By observing the microstructure, one will also be able to decide (or at least estimate) whether the
sample indicates that the material is in the cast, annealed, or cold-worked condition. The way the
microstructure is normally observed is referred to as the bright-field mode, where the features of
interest appear dark on a bright background. However, there are several other observation modes
that can be used to derive useful information about the sample. These include dark-field
microscopy (where the features of interest appear bright on a dark background); polarized light
(when the presence of optically anisotropic phases can be determined); interference microscopy
(to obtain information about specimen relief or surface topography); and phase contrast
microscopy (to differentiate between phases at (slightly) different surface levels.
Figure 17 Al-B4C (5%)-Graphite (15%) [8]
4.3.2 Hardness test
Hardness is a characteristic of a material, not a fundamental physical property. It is defined as the

resistance to indentation, and it is determined by measuring the permanent depth of the
indentation. A brinell hardness tester machine used for the hardness measurement. The surface
being tested generally requires a metallographic finish and it was done with the help of 100, 220,
400, 600 and 1000 grit size emery paper. Most commonly it is used to test materials that have a
structure that is too coarse or that have a surface that is too rough to be tested using another test
method, e.g., castings and forgings. Brinell testing often use a very high test load (3000 kgf) and

a 10mm diameter indenter so that the resulting indentation averages out most surface and sub-
surface inconsistencies.
The Brinell method applies a predetermined test load (F) to a carbide ball of fixed diameter (D)
which is held for a predetermined time period and then removed. The resulting impression is
measured with a specially designed Brinell microscope or optical system across at least two
diameters – usually at right angles to each other and these results are averaged (d). Although the
calculation below can be used to generate the Brinell number, most often a chart is then used to
convert the averaged diameter measurement to a Brinell hardness number.
Common test forces range from 500kgf often used for non-ferrous materials to 3000kgf usually
used for steels and cast iron. There are other Brinell scales with load as low as 1kgf and 1mm
diameter indenters but these are infrequently used.
Where
BHN = Brinell Hardness Number (kgf/mm2)
P= applied load in kilogram-force (kgf)
D= diameter of indenter (mm)
d= diameter of indentation (mm)
Where
Figure 18 Brinell hardness testing machine

4.4 CORROSION TEST

4.4.1 Potentiodynamic polarization measurement
Potentiodynamic polarization measurement (PDP) belongs to one of the most commonly used DC
electrochemical method in corrosion measurements. In the PDPs, the potential in a wide range is
applied on the test electrode, due to which on the metal surface dominantly oxidation or reduction
reaction happens (depending on the direction of polarization) and as a result of that, an adequate
current is generated. The presentation of the potential in the function of current density (I) (or log
I) for each measured point results in obtaining the polarization curve. The polarization curve can
be used to determine the corrosion potential and the corrosion rate of the metal in the given
condition (Tafel slope). The advantage of this method is reflected in the possibility of a localized
corrosion detection, easy and quick determination of the corrosion rate, efficiency of the corrosion
protection, etc., but very often for calculating the Tafel slope, we have to use data farther away
from the corrosion potential, and thus can incorporate other reactions, which may bring to
significant errors in the obtained result.
Polarization methods such as potentio dynamic polarization, potentiostaircase, and cyclic

voltammeters are often used for laboratory corrosion testing. These techniques can provide
significant useful information regarding the corrosion mechanisms, corrosion rate and
susceptibility of specific materials to corrosion in designated environments. Polarization
methods involve changing the potential of the working electrode and monitoring the current
which is produced as a function of time or potential.
1. Anodic polarization: the potential is changed in the anodic (or more positive direction)
causing the working electrode to become the anode and causing electrons to be withdrawn
from it.
2. Cathodic polarization: the working electrode becomes more negative and electrons are
added to the surface, in some cases causing electro deposition.
3. Cyclic polarization: Both anodic and cathodic polarization is performed in a cyclic
manner.
Several methods may be used in polarization of specimens for corrosion testing. Potentiodynamic
polarization is a technique where the potential of the electrode is varied at a selected rate by
application of a current through the electrolyte. It is probably the most commonly used

polarization testing method for measuring corrosion resistance and is used for a wide variety of
functions:
1. Cyclic polarization tests: These tests are often used to evaluate pitting susceptibility. The
potential is swept in a single cycle (or slightly less than one cycle), and the size of the
hysteresis is examined along with the differences between the values of the starting open
circuit corrosion potential and the return passivation potential. The existence of the
hysteresis is usually indicative of pitting, while the size of the loop is often related to the
amount of pitting.
2. Cyclic voltammeters: Cyclic voltammeters involves sweeping the potential in a positive

direction until a predetermined value of current or potential is reached, then the scan is
immediately reversed toward more negative values until the original value of potential is
reached. In some cases, this scan is done repeatedly to determine changes in the current-
potential curve produced with scanning.
3. Potentiostaircase method: This technique polarizes an electrode in a series of potential

steps where the time spent at each potential is constant, while the current is often allowed
to stabilize prior to changing the potential to the next step. The step increase may be small,
in which case, the technique resembles a potentiodynamic curve, or it may be large.
4. Electrochemical potentiodynamic reactivation (EPR): This technique allows

measuring the degree of sensitization of stainless steels such as S30400 and S30403 steels.
This method uses a potentiodynamic sweep over a range of potentials from passive to
active (called reactivation).
5. Linear polarization resistance (LPR): A widely used technique, the

polarization resistance of a material is defined as the slope of the potential-current density
curve at the free corrosion potential, yielding the polarization resistance, as described in
the next section.
Some other parameters that can be determined from the potentiodynamic polarization curves
(Fig. 3.9) are the primary passivation potential (Epp, potential positive to which passive surface
layers are formed), the critical current density (Icc, minimum current required before surface
layers are formed), the breakdown potential (Eb, potential positive to which passive surface

layer is destroyed and transpassive region starts), the protection potential (Eprot, potential at
which passive layers are stable and protective), passive current (Ip, current of the electrode
in Eprot) and the area of the hysteresis loop. Many of these parameters determined are based
on empirical observations. As with any empirical method, it is beset with many questions
about the extent of its validity. The results obtained by this method can be function of scan
rate, pit size or depth, polarization curve shape and specimen geometry. Therefore the results
should be considered as qualitative rather than quantitative.
Figure 19 parameters of potentiodynamic polarization curves
4.4.2 Immersion test method
Immersion tests measure the progress of corrosion damage obtained from the immersion length
within a corrosive environment, as well as other factors that can accelerate the corrosion process.
These tests can involve alternative drying or immersions, such as in cases of cyclical tests.
Moreover, test instrumentations may be included throughout immersion like electrochemical
instrumentation connections in order to facilitate the measurements.
Immersion tests are capable of generating uniform data for alloy corrosion and are utilized in
industries subjected to immersion conditions.
Environmental conditions that should be created and the acceleration degree needed usually
identify which laboratory tests should be used. Proper acceleration is obtained by the following:

• Prolonging the exposure to vital conditions which are believed to lead to corrosion
damage. For instance, if a certain vessel is to undergo batch processing with a chemical
for 24 hours, the corrosion exposure in the laboratory should be 240 hours.
• Making the conditions more intense in order to boost corrosion rates. This can be achieved
by increasing one or more of the following: pressure, salt concentration, temperature or
solution acidity.
When the conditions for the environment have been identified and the test has been created, this
should be conducted again several times to verify whether this test meets the acceptable
reproducibility standard. Generally, immersion tests can be separated into these categories:
• Alternate immersion test - This immersion test involves a cyclic procedure that involves a
specimen being immersed for a certain period of time. Then, the specimen is removed and
undergoes drying prior to re-submerging to the cycle. Typically, about a hundred cycles
are completed throughout the test.
• Simple immersion test - In this test, small batches of the material are subjected to the
medium under testing, while loss of weight is being gagged for a particular period.
The immersion test remains the most reliable method in terms of screening. It also serves as the
most simple and economical way to determine the most suitable material to protect against
corrosion in certain environments.
Figure 20 Immersion corrosion test setup containing 5 wt% NaCl Solution containing 3%NaCl
Solution

4.4.3 Preparing a Sodium Chloride Solution (NaCl)
A solution of sodium chloride -- better known as table salt -- and water is known as a saline
solution; there are many reasons why you would need one. For example, a normal saline
solution, which is one that matches the salinity of the body, is the best one for making a dental
rinse or flushing out the eyes. You can mix a percentage-by-weight saline solution by weighing
the salt you add to a specific amount of water, or you can mix a molar solution -- useful for lab
work -- by calculating the molecular weight of a sodium chloride molecule.
MIXING A PERCENTAGE-BY-WEIGHT SOLUTION
Pour clean water into a graduated flask large enough to hold the amount of solution you need.
To get a pure saline solution that is free of impurities, you should use distilled water. Fill the
flask with about 80% of the water that will be in the final solution. For example, if you're making
100 milliliters of solution, fill the flask to the 80-milliliter mark.
Calculate the weight of salt you need. The weight -- measured in units compatible with the water
volume units -- determines the percentage of the solution. Divide it by the volume of water and
multiply by 100 to get the percentage. For example, to make 100 milliliters of normal saline
solution, which is a 0.9% solution, you need nine grams of salt. If you need a pint of solution,
you should add 2.9 tablespoons of salt.
Measure the salt and add it to the water. Swirl the flask until all the salt is dissolved. Once all
the salt is dissolved, add water to increase the volume to the originally-intended amount.
Mixing a Molar Solution
Mix a molar solution in one liter of water. Molar concentrations are expressed as the number of
gram-molecular masses of solute in this case sodium chloride you add to this liter of water. Look
up the molecular weights of sodium and chlorine on a periodic table. A salt molecule has one of
each element, so you can add their weights together to get 58.44, the molecular weight of sodium
chloride. Fill a flask with 0.8 liters of water, weigh out the amount of sodium chloride you need,
add it to the water and shake until it dissolves. To make a 1M solution, add 58.44 grams of salt;
to make a 0.1M solution, add 5.84 grams; to make a 2M solution, add 116.88 grams and so on.
Add water to the flask to bring the final level to one liter after all the salt has dissolved.

4.5 SCANNING ELECTRON MICROSCOPE (SEM)
The scanning electron microscope (SEM) uses a focused beam of high-energy electrons to
generate a variety of signals at the surface of solid specimens. The signals that derive
from electron-sample interactions reveal information about the sample including external
morphology (texture), chemical composition, and crystalline structure and orientation of materials
making up the sample. In most applications, data are collected over a selected area of the surface
of the sample, and a 2-dimensional image is generated that displays spatial variations in these
properties. Areas ranging from approximately 1 cm to 5 microns in width can be imaged in a
scanning mode using conventional SEM techniques (magnification ranging from 20X to
approximately 30,000X, spatial resolution of 50 to 100 nm). The SEM is also capable of
performing analyses of selected point locations on the sample; this approach is especially useful
in qualitatively or semi-quantitatively determining chemical compositions (using EDS),
crystalline structure, and crystal orientations (using EBSD). The design and function of the SEM
is very similar to the EPMA and considerable overlap in capabilities exists between the two
instruments.
4.5.1 Fundamental Principles of Scanning Electron Microscopy (SEM)
Accelerated electrons in an SEM carry significant amounts of kinetic energy, and this energy is
dissipated as a variety of signals produced by electron-sample interactions when the incident
electrons are decelerated in the solid sample. These signals include secondary electrons (that
produce SEM images), backscattered electrons (BSE), diffracted backscattered electrons
(EBSD that are used to determine crystal structures and orientations of minerals), photons
(characteristic X-rays that are used for elemental analysis and continuum X-rays), visible light
(cathodoluminescence--CL), and heat. Secondary electrons and backscattered electrons are
commonly used for imaging samples: secondary electrons are most valuable for showing
morphology and topography on samples and backscattered electrons are most valuable for
illustrating contrasts in composition in multiphase samples (i.e. for rapid phase discrimination). X-
ray generation is produced by inelastic collisions of the incident electrons with electrons in
discrete orbital’s (shells) of atoms in the sample. As the excited electrons return to lower energy
states, they yield X-rays that are of a fixed wavelength (that is related to the difference in energy
levels of electrons in different shells for a given element). Thus, characteristic X-rays are produced
for each element in a mineral that is "excited" by the electron beam. SEM analysis is considered

to be "non-destructive"; that is, x-rays generated by electron interactions do not lead to volume
loss of the sample, so it is possible to analyze the same materials repeatedly.
Figure 21 Scanning electron microscope (SEM)
Figure 22 SEM microstructure of aluminum matrix nanocomposites (a) Al-Al 2 O 3 , (b) Al-SiO
2 ,(c) Al-CNTs and (d) Pure Al.

CHAPTER -5
RESULT AND ANALYSIS
5.1 MICROSTRUCTURE ANALYSIS
Nature of sample: AMMC’s (Al+5wt%SiC+1wt%B4C)
Nature of test: Microstructure
Test method: IS: 7739 PART III – 1976(RA 2007) ASM METAL HANDBOOK, Vol-9
Equipment used: Optical metallurgical microscope (Nikon Epiphot 200/clemex vision PE)
Figure 23 microscopic image of Al+5wt%SiC+1wt%B4C
Result
Microstructure consists of interdendritic precipitates in a matrix of aluminium
solid solution.

5.2 HARDNESS TEST
Nature of sample: AMMC’s (Al+5wt%SiC+1wt%B4C)

Nature of test: Hardness
Machine model: 2003/390
Testing method brinell hardness testing machine
Ball diameter 5mm
Applied load 250kg
Brinell hardness number (BHN) 58.4
Table 5 hardness test result
5.3 CORROSION TEST
• Due to lockdown of state during the current semester, conduction of corrosion test on
prepared samples was not possible.
5.3.1 Expected Outcomes
• As per the literature survey, corrosion rate of 6061Al base alloy increases with addition of
reinforcements which could be due to incorporated particles act as nucleation sites for
pitting corrosion and decreases the corrosion resistance of Al alloy.

CHAPTER -6
REFERENCE
1. Sankara Papavinasam, Electrochemical polarization techniques for corrosion monitoring,

science direct.
2. Subramani Nanjan and Janakiram Ganesh Murali, Analyzing the Mechanical Properties
and Corrosion Phenomenon of Reinforced Metal Matrix Composite.
3. K. K. Alaneme and M. O. Bodunrin, Corrosion Behavior of Alumina Reinforced
Aluminum (6063) Metal Matrix.
4. P.C.R. Nunes and L.V. Ramanathan, Corrosion Behavior of Alumina-Aluminum and
Silicon Carbide-Aluminum Metal-Matrix Composites.
5. Suryanarayanan K. , R. Praveen, S. Raghuraman, Silicon Carbide Reinforced Aluminum
Metal Matrix Composites for Aerospace Applications.
6. P. P. Trzaskoma and E. McCafferty, Corrosion Behavior of SiC/AI Metal Matrix
Composites, Naval Research Laboratory, Washington, DC 20375.
7. Rosario Gerhardt, Properties and Applications of Silicon Carbide.
8. Janakiram Ganesh Murali, Analyzing the Mechanical Properties and Corrosion
Phenomenon of Reinforced Metal Matrix Composite.
9. Soheila Faraji a, Afidah Abdul Rahima, and Norita Mohameda, The influence of SiC
particles on the corrosion resistance of electroless, Cu composite coating in 1 M HCl
(Hydrocloric acid)
10. Poovazhagan.La, and Kalaichelvan.Ka, Department of Production Technology, Madras
Institute of Technology, Characterization of Hybrid Silicon Carbide and Boron Carbide
Nan particles-Reinforced Aluminum Alloy Composites.
11. Bhakthavathsala R.B. , Raghavendra Bhat R, and Chandrashekar R., comparative
evaluation of effects of generalcorrosion on the mechanical properties of aa2014, aa6061
and aa7075 alloys, AMMMT-2010
12. Kenneth Kanayo Alaneme a,∗, Tolulope Moyosore Adewale b, Peter Apata Olubambi,
Corrosion and wear behaviour of Al–Mg–Si alloy matrix hybrid composites reinforced
with rice husk ash and silicon carbide, j mater res technol . 2014;3(1):9–16.

13. Yu-Mei Han a,b, Danick Gallant b, X.-Grant Chen, Corrosion inhibition of AleB4C metal
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Composites in NaCl Solution, 21 September 2015
16. R. Arrabal, B. Mingo, A. Pardo, M. Mohedano, E. Matykina, I. Rodríguez, Pitting
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VISVESVARAYA TECHNOLOGICAL UNIVERSITY

Jnana Sangama, Belgaum-590018

“CORROSION BEHAVIOUR OF Al (0.4Mg,0.3Si) ALLOY REINFORCED

Under the Guidance of

DEPARTMENT OF MECHANICAL ENGINEERING

Department of Mechanical Engineering

Certified that the project work entitled “CORROSION BEHAVIOUR OF Al (0.4Mg,0.3Si)

DILEEP KUMAR H S 1KS18ME411

Mr Rajesh G L Prof. Umashankar M

We, the students of final semester of Mechanical Engineering, K S Institute of Technology,

We take this opportunity to thank Dr. Dilip kumar K, Principal/Director, K S Institute of

We thank Prof. Umashankar M, HOD, Department of Mechanical Engineering, K S Institute

We thank Rajesh G L, Assistant Professor, Department of Mechanical Engineering, K S

Figure 1 The usage volume of different matrix materials in MMCs ............................................................2

1.1 BACKGROUND OF THE PROJECT

Department of Mechanical Engineering, KSIT Page 1

1.2 METAL MATRIX COMPOSITES

1.2.1 Classification of MMCs based on the matrix material

e. Super alloy-based composites

Figure 1 the usage volume of different matrix materials in MMCs

Department of Mechanical Engineering, KSIT Page 2

Figure 2 Aluminum based MMC's

Department of Mechanical Engineering, KSIT Page 3

1.3.1 The most important MMC systems are:

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1.4 TYPES OF MARINE CORROSION

1.4.1 Crevice corrosion

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Figure 3 Crevice corrosion

1.4.2 Uniform corrosion

Figure 4 Uniform corrosion

1.4.3 Pitting corrosion

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Figure 5 Pitting corrosion

1.4.4 Erosion corrosion

Figure 6 Erosion Corrosion

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1.4.5 Galvanic corrosion

Figure 7 Galvanic corrosion

1.4.6 Electrolytic Corrosion

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Figure 8 Electrolytic corrosion

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2.1 Analyzing the Mechanical Properties and Corrosion Phenomenon of

2.2 Corrosion Behavior of Alumina Reinforced Aluminum (6063) Metal

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2.3 Corrosion Behavior of Alumina-Aluminum and Silicon Carbide-

• Particle-reinforced, aluminum-based metal-matrix composites (MMCs) are being

2.4 Corrosion Behavior of SiC/AI Metal Matrix Composites by P. P.

• Recent advances in the fabrication and characterization of SiC/A1 composites have

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variety of structural, defense, and aerospace applications. Composite materials have

2.5 Silicon Carbide Reinforced Aluminum Metal Matrix Composites for

2.6 Properties and Applications of Silicon Carbide by Rosario Gerhardt

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3.1 ALUMINIUM 6061 ALLOY

➢ Good Machinability and weld ability.