Paper Title:

The consequences of Al 7129 Alloy Reinforced with B 4 C & TiC Wear

Behavior of Hybrid Composite Using Taguchi and Multi Linear
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Regression.

Paper ID : 7109
Authors Details Presented by
Mr. Madri. Rajesh , Mr. Madri. Rajesh
Dr. G Naga Malleswara Rao, Research Scholar,

Dr. B. Chandra Mohana Reddy Department of Mechanical Engineering, JNTUA,

Anantapur, Andhra Pradesh, India
Contents
• Composite Material
• Abstract
• Objectives of the Present Research Work
• Materials & Methods
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• Fabrication of AMCs
• Mechanical Properties
• Wear Behaviour
• Results and conclusion
 COMPOSITE MATERIAL

A Composite is a structural material, which combines two or

more constituents.
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The constituents are combines in macroscopic level are not soluble in

each other.

One constituent is called reinforcing phase which is embedded in

soft in ductile phase is called matrix.

 Classification of Composite Materials
Composites

Based on Matrix Based on Reinforcement

Polymer Ceramic Metal Matrix

Composites Matrix Composites
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Composites

Particle Fiber Structural

Reinforced Reinforced

Large Particle Dispersion Continuous Dis -

Strengthened Continuous

Laminated Sandwich
Aligned Randomly
Oriented
 Metal Matrix Composites

Metal matrix composite (MMCs) is composite material with one of two

constituent parts should be a metal and the other material is usually non-
metallic or organic compound.

Generally this material processes high mechanical, tribological, thermal and

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physical properties, high strength to weight ratio, stiffness, fracture

toughness, thermal resistance and wear resistance etc.

The fallowing characteristic of MMCs over Polymer based composites.

• Damp proof
• Good thermal and electrical conductivity
• Resistance to fire
• Radiation resistance
• Operate at high temperatures
• The major challenge against on MMCs is machining such as
milling, drilling, grinding, turning etc.

• During the machining of MMCs, the reinforced particles are

fractured and pulled out of the matrix which lead to the
deterioration of the product surface quality, rapid tool wear, and
increased machining cost, specific energy consumption.

• Now the research is under progress to overcome these problems.

• The major challenge against on MMCs is machining such as
milling, drilling, grinding, turning etc.

• During the machining of MMCs, the reinforced particles are

fractured and pulled out of the matrix which lead to the
deterioration of the product surface quality, rapid tool wear, and
increased machining cost, specific energy consumption.

• Now the research is under progress to overcome these problems.

 In this investigation, Aluminium Alloy
7129 are chosen as a matrix material and
B4C & TiC as a reinforcement material.
The advantages of AMCs over other materials are given below:
• Excellent tribological properties with damage tolerance
• Can be worked at high temperatures
• Can be controlled at high stress and high cycle steel components
• Stronger than other conventional materials with half the weight
• Having low thermal coefficient of expansion
• Better impact resistance
• Good electrical performance
• More abrasion resistance
• High Corrosion resistance
• Better control of mass
• Good Thermal, wear and Physical properties
 Major Applications of Aluminium Alloy
7129
• Valve Body (Aerospace and Automotive)
• Connecting rods
• Medical devices (Prosthetic limbs)
• Mountain – Climbing Equipment
• Recreational Products (Bicycles)
• Hydraulic Valve Components
• sabot
Sabot Rocker Arms In Racing Car Engines

Auto Spot Gearbox Actuators

 Connecting Rods

Snow Mobile Engine Shaft

Applications
• Defense, missiles, aircraft, space vehicles
• Auto sport gearbox actuators and wheel components
• Prosthetic limbs
• Load cells
• Hydraulic valve components
• High pressure solenoids
• Flexible shaft coupling
• Snowmobile engine shafts
• Automobile shock absorbers
• Fuel pumps for racing engines
• Motorcycle gears
• Recreational products such as tents, ski and backpack rods,
bicycles and mountain climbing equipment
• Automotive valve body and connecting rod
 ABSTRACT
•To enhance the wear-resistant assets of the aluminum 7129 as base metal and boron
carbide, and titanium carbide as reinforcement. To fabricate the pins for the test with
even and equal distribution of the titanium carbide reinforcement particles varying
in order of 1%, 3%, and 5%, boron carbide is kept constant that is 2% into
aluminum 7129 base metal by using stir casting technique.
•In this research, an attempt was made to study the influence of wear parameters. To
discover the most reliable values of different parameters like load, sliding distance,
reinforcement, and temperature and to acquire a mathematical version with the
Taguchi technique and Multilinear regression.
•A Pin-on-disc system became accustomed to sliding wear tests. The Taguchi
approach was utilized to accumulate knowledge in a controlled way to analyze the
wear behavior of the composites.
•An orthogonal array, signal/noise, and analysis of variance were used to research the
wear behavior of the composite. The mathematical model was obtained to see the
wear of the composite and confirmation tests were conducted to verify the
experimental results
 Literature Survey
• Gopalakrishna et al. developed AA6061/ TiC MMCs using
stir casing technique and observed that, specific strength and
wear resistance of composite has been increased with increase
of wt. % of TiC.
• Baskaran et al. worked on AA 7075 / TiC (4% and 8% wt. %
of TiC) MMCs, they observed the wear behaviour under dry
sliding condition. The experimental results reveal that the
applied load has the highest influence followed by sliding
velocity.
• Pragnesh and Patel studied the effect of cutting parameters such as spindle
speed, feed and depth of cut on power consumption and surface roughness in
machining of Al6063/TiC MMC. Results shown that feed rate is most
affected parameter on surface roughness followed by spindle speed and
depth of cut. Cutting speed is significant parameter on power consumption
followed by depth of cut and feed rate.
• Sai chaitanya kishore et al. have done experiments on in-situ Al6061-TiC
MMC and investigate on cutting force, surface roughness and flank wear in
machining for different weight percentages of TiC viz., 0, 2 and 4%. The
results given that responses were increases with respect to TiC reinforcement
and as cutting speed increases cutting force and flank wear also increases. By
increasing the feed rate and depth of cut cutting force flank wear and surface
roughness also increases.
• Nityanatham and suresh evaluate surface roughness after machining such as

shaping, milling and grinding by machine vision system. A linear equation has been

developed between optical surface roughness parameter (G a) and conventional

average surface roughness (Ra). It is concluded that Ga is excellent correlation with

Ra in almost all readings.

• Aswathy et al. developed a response surface model to evaluate the machining

responses in surface roughness, material removal rate, roundness error in turning of

Ti-6A-Al-4V with the CVD coated carbide tool

• Sarah et al. used PSO technique in the pulp industry to get optimal solution to direct

the input parameters to diminish the resources utilization and wastage of the finished

paper. The experimental results were compared with both genetic algorithm (GA) and

PSO. PSO gave the better computational efficiency with less time than GA.
 OBJECTIVES OF THE PRESENT RESEARCH

• To develop the samples of Aluminium Alloy 7129 / TiC / B4C HMMCs

using the stir casting technique.

• To study the Microstructures of developed samples of AA7129 / TiC /

B4C HMMCs using SEM analysis and the percentage of various

elements present in all the samples.

• To study the mechanical properties viz., Tensile strength, Flexural

strength, Compression strength, Impact strength, and harness of

AA7129 / TiC / B4C HMMCs by conducting the experiments as per

ASTM standards.
• To conduct the experiments on Pin-on-disc apparatus as per
the central composite design in DOE to observe the wear
responses of AA7129 / TiC / B4C
• To study the responses in wear behavior of AA7129 / TiC /
B4C HMMCs such as wear, wear rate and wear resistance.
• To model the wear and machining parameters of AA7129 / TiC
/ B4C HMMCs using response surface methodology.
• To optimize the results in the machining of AA7129 / TiC /
B4C HMMC by using Taguchi and Multi Linear Regression.
 Materials & Methods
In this investigation, two materials are employed
such as AA7129 used as a matrix supplied by
Parshwamani metals, Mumbai and B4C (Boran
Carbide) and TiC (Titanium Carbide) as
reinforcement with a size of 4 µm supplied by Triveni
Interchem Pvt. Ltd, Mumbai, used as a reinforced
agent.
 Element Weight Percentage (%) Element Identification

Chemical formula TiC

Molar mass 59.89 g/mol

Aluminum(Al) 90.9 – 94
Appearance black powder

Zinc (Zn) 4.2 - 5.2 Density 4.93 g/cm3

Melting point 3160 °C

Magnesium(Mg) 1.3 – 2
Boiling point 4820 °C

Copper (Cu) 0.50 - 0.90 Solubility in water insoluble in water

Aluminum 7129 chemical composition Titanium carbide properties

Property Value

Chemical formula B4C

Density 2.52 g/cm3

Melting Point 2445 °C

Hardness 2900 - 3580Kg / mm2

Fracture Toughness 2.9 - 3.7 MPa.m-½

Young's Modulus 450 – 470 GPa

Electrical Conductivity (at 25 °C) 140 S

Boron carbide properties

 Fabrication of AMMCs
Stir casting technique is employed to produce AHMMCs, the
2wt.% of reinforcing particles of B4C is kept has a constant in
AHMMCs and varying the TiC particles is added to the molten
aluminium and the entire mixture was stirred for 15min at 300
rpm to facilitate uniform distribution of the reinforcing phase
throughout molten aluminium alloy before solidification.
During the process magnesium is also added to the molten metal
for better wettability and to removes the dust particles from the
molten metal
Figure 1. Stir Casting Setup
Figure 2. Fabricated Specimens of AA7129 / TiC / B4C
HMMCs
SEM Analysis for AA7129 / TiC / B4C HMMCs
A scanning electron microscopy test is used to evaluate the microstructure of
specimen materials.
This work aimed to evaluate i.e.,

• Mechanical Characterization

• Wear Behaviour
Fabricated Specimens for Mechanical Characterization
Hardness Testing
(a) Tensile testing (b) Compression Testing

The tensile, compression, flexural strength values were determined by universal

testing machine.
(a) Flexural testing (b) Impact Testing
 Wear Behaviour
•The wear response of AA7129 / TiC /B4C AHMMCs have been determined
using pin on-disc test apparatus. The abrasive wear is observed in dry sliding
wear test for fabricated samples to evaluate wear, wear rate.
•The test samples were prepared as per ASTM(American Society for Testing &
material) standard, conducted according to central composite design.
•The control parameters chosen are wt.% of TiC, applied load, sliding velocity
and Rotational speed, the each control parameter is kept at three levels.
•Each experimental run was repeated three times and average value is
recorded.
Experimental Setup of Computerized Pin on Disc tester
ASTM –G-99

Wear Test Specimens

Process parameters and levels used for dry sliding wear

Level Sliding Load Sliding  

  Velocity (N) Time %of
(m/s)   (min) Reinforcement
1 1.5 10 5 1
2 2 20 10 3
3 2.5 30 15 5
Calculated Responses of wear rate
Experimental results for AA7129 / TiC / B4C HMMCs for sliding wear on pin-on-disc

Ex. Speed Load Time Reinforcement Wear Rate S/N Ratio for Coefficient S/N Ratio for
No (m/s)S (N)L (min)   (mm3/m) Wear (db) of friction Coefficient of
    t (%) R Wr Cf friction (db)
   
1 1.5 10 5 1 0.00105 48.554 0.374 8.575
2 1.5 10 10 3 0.00170 51.368 0.329 9.582
3 1.5 10 15 5 0.0003 52.686 0.313 10.227
4 1.5 20 5 3 0.00159 58.202 0.339 9.354
5 1.5 20 10 5 0.00148 53.975 0.341 9.485
6 1.5 20 15 1 0.00162 57.223 0.315 10.192
7 1.5 30 5 5 0.00209 49.845 0.352 8.985
8 1.5 30 10 1 0.00419 52.248 0.322 9.880
9 1.5 30 15 3 0.00851 50.895 0.310 10.265
10 2 10 5 3 0.00149 55.799 0.390 8.269
11 2 10 10 5 0.00321 51.258 0.355 8.981
12 2 10 15 1 0.00232 53.070 0.332 9.750
13 2 20 5 5 0.00312 52.195 0.369 8.690
14 2 20 10 1 0.00235 54.069 0.352 9.293
15 2 20 15 3 0.00208 52.195 0.324 9.798
16 2 30 5 1 0.00285 53.556 0.344 9.942
17 2 30 10 3 0.00242 55.199 0.335 9.653
18 2 30 15 5 0.00179 55.020 0.340 9.961
19 2.5 10 5 5 0.00048 62.3142 0.132 13.434
20 2.5 10 10 1 0.00387 52.736 0.374 8.661
21 2.5 10 15 3 0.00345 56.054 0.355 8.942
22 2.5 20 5 1 0.00435 60.267 0.410 7.372
23 2.5 20 10 3 0.00342 54.499 0.333 8.781
24 2.5 20 15 5 0.00255 52.495 0345 9.10
25 2.5 30 5 3 0.04521 55.908 0.389 8.210
26 2.5 30 10 5 0.00312 58.652 0.353 9.193

27 2.5 30 1.5 1 0.00054 51.399 0.347 9.190

 Speed(m/s) Load (N)
9.75
9.75

9.5

Means of SN ratios
9.5

Means of SN ratios
9.25
9.25

9 9

8.75 8.75

8.5 8.5
1.5 2 2.5 10 20 30

Time(m/s) Reinforcement(%)
9.75
9.75

9.5
9.5

Means of SN ratios

Means of SN ratios
9.25
9.25

9
9

8.75 8.75

8.5 8.5
5 10 15 1 3 5
Axis Title
• In present research, the wear behaviour of AA7068 / TiC
MMCs is carried out to study the effect of various viz., wt. %
of TiC on wear and wear rate with influence of rotational
speed, sliding velocity, applied load for various wt. % of TiC.

• For analyzing the affect of process parameters on wear

response of AA7068/TiC MMCs graphs have been drawn
using response surface model.

• In these plots keeping only one parameter is in variation in

nature and other parameters kept constant at the middle level.
 CONCLUSIONS
The following conclusions are derived from the present
investigation on Mechanical, Tribological behaviour of AA7129 /
TiC /B4C HMMCs.
• A new composite material has been developed with different wt.
% of reinforcement (TiC) in aluminium matrix by stir casting
technique.
• The Tensile strength of the composite gradually increases with
increase of TiC particles
• Compression strength increases linearly with increase of TiC
particles
•Flexural strength of the composite material is increases with increasing of TiC particles into a matrix
•Impact strength of the composite material increases with increasing the weight percentage of TiC
particles
•Hardness of the composite material is gradually increases with increase of TiC particles in matrix.

•The low wear is observed for wt.% of TiC MMC at low applied loads 9.81N and high wear is
observed for 3 wt.% of TiC at higher applied load of 49.05N.
•For maximum sliding velocity the wear is gradually decreases for all composites of AA7129 / TiC
/B4C HMMCs considered in this investigation.
 SCOPE FOR FUTURE WORK

• Similar work can be replicated by

changing the matrix and reinforcing
materials.
• More machining parameters can be
included and hence, the database can be
improved by extensive experimentation.
• Extend the experimental work to another
machining process on the same material.
Thank You