International Journal of Mechanical and Production

Engineering Research and Development (IJMPERD)

ISSN(P): 2249–6890; ISSN(E): 2249–8001
Vol. 10, Special Issue, Jun 2020, 23–30
© TJPRC Pvt. Ltd.

MECHANICAL AND WEAR CHARACTERISTICS OF MWCNTs/LM25

NANOCOMPOSITES FABRICATED THROUGH POWDER METALLURGY – AN
INVESTIGATION

SHIVARAMU. H. T1*, PRASHANTHA. D. A2, VIGNESH NAYAK. U3 & UMASHANKAR. K. S4

1
Research Scholar, K V G College of Engineering, Sullia and Department of Mechanical Engineering, Mangalore Institute of
Technology and Engineering, Moodbidri, Affiliated to VTU Belagavi, Karnataka, India
2
Department of Mechanical Engineering, A J I E T Mangalore, Affiliated to VTU Belagavi, Karnataka, India
3
Department of Mechanical Engineering, M I T E, Moodbidri, Affiliated to VTU Belagavi, Karnataka, India
4
Department of Mechanical Engineering, K V G College of Engineering, Sullia, Affiliated to V T U Belagavi, Karnataka, India
ABSTRACT

In the current investigation, Aluminum Silicon LM25 alloy was taken as matrix material to which multi walled carbon
nano tube nanoparticles with 0.0, 0.25, 0.5, 0.75, 1.0 and 1.5 wt.% concentrations were added as reinforcements to obtain
composite material. The powder metallurgy technique process was adopted to fabricate nanocomposites. The fabricated
nanocomposites were characterized using X-Ray Diffractometry and Energy Dispersion Spectroscopy. X-Ray

Original Article
Diffractometry was used to obtain the chemical compounds formed in the material while EDS was used to obtain the
chemical composition and to ascertain the presence of MWCNT in the wear tested samples. Mechanical properties like
density, hardness and elongation were obtained. Fracture mechanisms were identified using Scanning Electron
Microscope. The better hardness and Young's modulus were obtained for 0.5 wt.% of MWCNTs reinforced
nanocomposites in compare to other MWCNTs wt.% concentrations. The wear experiment was conducted in accordance
with the G99-95a ASTM standard on a pin on disk wear testing apparatus. Wear nature was investigated for the applied
loads of 10, 15 and 20N at disc speed of 750 rpm and traversing distance of 1500m. It was found that 0.75 wt.% MWCNT
reinforcement showed enhanced mechanical properties and reduced wear rate due to increased hardness and lubrication
properties of reinforcement.

KEYWORDS: Aluminium-Silicon alloy (LM25), Multi Walled Carbon Nano Tube (MWCNT), Wear, & Powder
Metallurgy (PM)

1.0 INTRODUCTION

Naturally available materials include wood and stone. From the engineering perspective, these materials find limited
applications. Man Made materials such as steel and Aluminium (Al) have significantly improved the scope of the
application of engineering from simple utensils to aircrafts. However, they have also met with challenges,
particularly from the standpoint of weight of the designed components particularly for aerospace and automobile
applications. In addition to this requirement, the material used must be stronger, durable and reliable to perform its
intended function efficiently [1].

Al has been traditionally used owing to its availability, better specific strength compared to steel,
formability and lower energy per ton of production comparison with steel. However, automotive, aerospace and
several other engineering sectors opposed to utilize of Al and Al-Si alloys due to its narrow rigidity, strength and
reduced friction and wear resistance [2-7].

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24 Shivaramu. H. T, Prashantha. D. A, Vignesh Nayak. U & Umashankar. K. S

Wear resistance is a key factor in design and selection of the structural component that undergone relative
rotational/sliding motion during functioning. The reduction in a rate of wear is important to the constantly performing of
modern machines [8]. The most important problems encountered in engineering and automotive components are seizures,
wear and tear. The nature of wear study is an important consideration that aids in developing solutions to increase the viability
of materials for applications involving relative motion [9]. Among Al-Si alloys, wear resistance of the eutectic alloy was
found to be better than other alloys and was reported to vary linearly with increasing load [10]. Powder Metallurgy (PM)
production method was found to overcome this limitation, and it was reported that the material obtained by PM had improved
the mechanical properties [11].

The material losses observed during wear testing published in the literature is not an absolute property of the
material, but was due to the characteristics of the manufacturing process. The route of production directly influences the
wear is speed, load, temperature, hardness and ambient conditions [12]. The applied load is a very important parameter in
finding the wear rate and wear increases linearly to the increment of the load irrespective to the dry sliding situation of an
Al/Al-Si alloys. In Al–Si alloy, eutectic alloys wear resistance is superior to other Al/Al-Si alloys and linearly rate of wear
increased with the applied load [10]. The Si effect in Al-Si alloy proved lower density and coefficient of thermal expansion,
improved wear resistance, stiffness and specific strength compared to Al [6, 13].

In eutectic alloys, the Si element enriches the mechanical properties, the mechanical ball milling process improves
grain refinement, lengthen the limits of solid solubility and good homogeneous distribution of Carbon Nanotubes (CNTs) in
the alloy, therefore strength increased in alloys. The rolling and milling dissolved Si substance efficiently into Al alloy.
Presently, CNTs as reinforcement showed best results to beaten the engineering restrictions and proved outstanding stiffness
and strength property. The cumulative techniques of grain refinement, alloying and Multi Walled Nanotubes (MWNTs)
reinforcement achieved strength in composites with ductility [14].The effective dispersion and surface attachment of CNT
in the Al matrix is obtained through the mechanical high energy ball mill production route for the composite preparation, but
it has limitation of length reduction and harming of CNTs [15]. To obtain homogeneous dispersion of CNT reinforcement in
matrix, the most effective fabrication method is a PM process and it has shown improved strength, hardness and stiffness,
resistance to oxidation and wear, lower coefficient of friction and thermal coefficient for expansion, excellent dimensional
precision properties with the lower density of the material. Therefore, atribological and structural system in auto, aircraft and
in other engineering sectors much inclined towards the usage of nanocomposites [4].

The present investigation aims to develop the Al-Si alloys reinforced with varying weight % of MWCNTs by
powder metallurgy technique and investigating the mechanical properties and wear characteristics of nanocomposites.

2.0 METHODOLOGY
Specimens Preparation:

The concentrated nitric acid was used to purify the purchased reinforcement MWCNTs material. After purification, the
residual content of acid on MWCNTs was removed by washing with the deionized water. Later, the washed MWCNTs were
heated for 230oC to remove moisture content. The purchased material LM25 Al-Si alloy was used as the matrix. A 35 grams
of LM25 matrix material was weighed accurately and the required amount of MWCNTs in wt.% was added to prepare the
nanocomposites. Initially, particles of the LM25-MWCNTs was poured into a porcelain container and then mixed manually.
To avoid chemical reaction among the matrix and reinforcement, the ethanol was used during the blending process. Further
to get uniform distribution of MWCNTs in the matrix material, ultrasonicated the mixture to about 30 minutes. The blend

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Mechanical and Wear Characteristics of MWCNTS/Lm25 Nanocomposites Fabricated 25
through Powder Metallurgy – An Investigation

received from the sonicator was heated in a vacuum atmosphere at 120oC to remove any moisture before feeding the blend
into ball milling. The high energy ball milling set up was rotated at 250 rpm for 10 minutes to split the agglomerations of
composition and to achieve a uniform dispersion of MWCNTs reinforcement in LM25 matrix material.

The compaction die set was fabricated using EN31 steel material; it is used to produce the composite material with
a ASTM B-925-03 standard. The die, plunger and base plate contacting surfaces were coated with zinc stearate and acetone
to avoid friction during the extrusion of the compacted billet.

The homogeneously blended constituents filled in to the die and it is placed on UTM. For the extrusion of compacted
material carried out on UTM, a load rate of 10kN/min is applied. The density variation of LM25 for the different compaction
load is shown in Figure1.The compaction load varied from 60 to 160kN to obtain optimum density. The compaction load of
140 kN was established as the optimum compaction load to obtain the good density in material.

Figure 1: Compaction Density for LM25 Material. Figure 2: XRD pattern for Al-Si (LM25) Alloy and
Produced Composites.

The sintering of compacted specimens was carried out using a vacuum furnace at 515oCin inert atmospheric
condition. During the sintering process,a10oC/min was considered as heating rate. After reaching the temperature of 515oC,
specimens were placed for about 60minutes in the furnace. Later, the specimens were cooled in the nitrogen atmosphere.
The sintered billets were extruded to the 10mm diameter with the help of hot extrusion die setup. The hydraulic pressure of
21 MPa is applied on the extrusion die and the composite extrusion rate of 1.2 mm/sec was maintained [16,17].

(a) (b)

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26 Shivaramu. H. T, Prashantha. D. A, Vignesh Nayak. U & Umashankar. K. S

Figure 3: Energy Dispersions Spectroscopy of (a) LM25 (b) LM25+0.5wt.% MWCNT.

X-Ray Diffractometer (JEOL -JDX-8P diffractometer) was used to analyze the purchased LM25 alloys and
developed composite materials. The scanning rate of 0.25/minute was adopted for the spot range of 20-80 degree. Figure 2
shows the XRD pattern of LM25 alloy and fabricated composites used in current investigation. There is no carbon peak in
the XRD pattern; it confirms there is no reaction taken place between the matrix and reinforcement. To confirm the existence
of MWCNT in anano composite, Energy Dispersion Spectroscopy (EDS) examination was conducted with Scanning
Electron Microscopy (SEM) (JEOL 6380 LV). The EDS images of the LM25and LM25+0.5wt.% MWCNTs composite
shown inFigure 3 (a) and (b),respectively. The presence of carbon element and the constituents of LM25alloy were clearly
indicated in the EDS images.

Experimentation

Investigation of rate of wear was carried out in accordance with ASTM G99-95a standard using pin on disk wear tester.
Figure 4 shows computerized wear test apparatus. The fabricated composites machined to diameter of 8 mm and length of
20 mm, these pins were used for wear examination. The specimen was positioned against to the EN31 steel, 60HRC revolving
disk, which is having diameter of 165mm and 1.6Ra surface roughness. The wear study conducted in the ambient
circumstance at room temperature. The dry sliding wear examination carried for the load of 10, 15 and 20N, 750 rpm of disc
speed and traversing distance of 1500 m. After completing the test for the specific parameter, specimen was removed from
the fixture and acetone used to eliminate debris. The specimen weight was recorded before and after the test with the aid of
electronic weighing apparatus, it is having an accuracy of 0.0001grams. Pin on disc instrument measures the length of pin
wear in micrometer and friction force in Newton. The rate of wear (mm3/m) computed by consideration of volume losses to
the total traversed sliding distance.

Figure 4: Ducom Pin on Disc Apparatus.

3.0 RESULT AND DISCUSSIONS

3.1 Rockwell Hardness Study:

Hardness measurement conducted by Rockwell hardness instrument, the hardness was measured in accordance to ASTM
E18-02 standard. To obtain hardness value, hardened steel indenter with 1/16th inch diameter was used. For each specimen,
five tests were conducted by taking the minimum 5mm gap among indentations.

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Mechanical and Wear Characteristics of MWCNTS/Lm25 Nanocomposites Fabricated 27
through Powder Metallurgy – An Investigation

Figure 5: Rockwell Hardness number (HRB) for Figure 6: Young’s Modulus of the Specimens.
varying wt.% of MWCNT in LM25 Alloy.

The average hardness found for every fabricated composite material is shown in Figure 5. Hardness number
increased with the addition in reinforcement concentration up to 0.5 wt.% MWCNT. This was due to the uniform diffusion
of MWCNT in the LM25matrix. With a further addition of reinforcements, composites hardness was shown decrement trend.
In the current investigation, the minimum hardness was found with 1.5wt.% MWCNT nanocomposite. The clustering of
MWCNT enlarged beyond 0.5wt.% of reinforcements, due to which agglomeration taken place. This direct to the reduced
interfaces bond among MWCNT and LM25 matrix material, which in-turn minimized the resistance to the scratch causing
smooth slip inside the composite material.

3.2 Tensile Study

To investigate the tensile properties of the LM25-MWCNT reinforced composites, three specimens in every concentration
of composite were prepared as per ASTM E-8 standard. The variation of Young’s modulus with different wt.% addition of
MWCNT of composites is shown in Figure 6. The maximum Young's modulus was obtained with LM25 + 0.5 wt.%
MWCNTs nanocomposites.

(a) (b)
Figure 7: SEM of Fractured Surface of (a) LM25 (b) LM25 + 1.0 wt.% MWCNTs Composite.

A dimple shape is observed in SEM image Figure 7(a) of the LM25, indicating a ductile nature of the fractured
surface. At the higher wt.% of MWNT, agglomeration occurred. This creates a stress concentration due to weak adhesion
between matrix and reinforcement. At these points of MWCNT, carbon cluster requiring lesser energy are pulled out, and
the specimen fails at lower loads. The pullout was observed as holes in the SEM picture of LM25 + 1.0 wt.% MWCNTs
composite fractured surface as shown in Figure7 (b).

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28 Shivaramu. H. T, Prashantha. D. A, Vignesh Nayak. U & Umashankar. K. S

3.3 WEAR STUDY

The dry sliding wear behavior for prepared nanocomposites was carried out at 750rpm, by varying load applied to traverse
the 1500m distance. The rate of wear increases with increases in load applied due to the linear increment in the temperature
of the pin with respect to the applied load. The resistance of the composites to wear with the applied load is shown in Figure
8, and is compared with that obtained during testing with pure LM25 material. The 0.75wt.%+LM25 showed higher
resistance to wear in comparison to other weight fractions of MWCNT reinforcements. The applied load on the pin was
transferred to the reinforcement and observed good bonding among the MWCNTs with the matrix. The thermal expansion
of MWCNTs was low in compare to matrix material, so the rate of wear was found less in compare to Al-Si alloy [18].

Figure 8: Wear Rate for Varying Applied Load.

The uniform dispersion of MWCNTs shown resistance to wear, this was achieved through PM processes. The
reinforcement acts as barrier for the crack initiation by holding the matrix particles. The development of tribo film between
the counteracting faces minimize the coefficient of friction and in turn, the wear rate also decreased [19, 20].

4.0 CONCLUSIONS

Following inference is drawn from the Al-Si – MWCNT nano-reinforced wear and mechanical behavior study:

 The optimum compaction load was found to be 140kN for the preparation of LM25 nanocomposites through powder
metallurgy technique.

 XRD and EDS validate the presence of MWCNT in the prepared nanocomposites implying inertness of MWCNT
in the aluminum matrix

 LM25 + 0.5 wt.% MWCNT composites were found to be having higher hardness and Young's modulus in
comparison to other composites.

 Aluminum Silicon alloy metal matrix with 0.75 wt.% MWCNT showed thehighest wear resistance compared to
other nanocomposites.

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Mechanical and Wear Characteristics of MWCNTS/Lm25 Nanocomposites Fabricated 29
through Powder Metallurgy – An Investigation
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