Tribological study of aluminium 6063-B4C/Gr

composite-An experimental study

NAME =JASHIM AHAMED

ROLL NO =23MP33
 abstract
Being one of the lightweight material and easily available materials aluminium has
a lot of applications in various fields of automobile, electronics, and aircraft. In
this study, the tribological study of aluminium-based composite is being done for
the wear characteristics. A comparison is being made for the wear study of the Al
6063-based composite with the base alloy. Stir casting is used to form the
composite. Microscopic images confirm the presence of Boron Carbide (B4C) and
Graphite (Gr.) particles in the composite. Tribological experiments are being
performed to check for the outcome of B4C and Gr.reinforcement particles on the
composite wear rate and SEM images of the worn surfaces depict that the insite
presence of Gr. particles reduces the wear characteristics and improves the surface
quality for the word composite as compared to the base alloy.
introduction

6063 is an aluminium alloy, with magnesium and silicon as the alloying elements. The standard controlling its composition is maintained by The Aluminum Association. It has
generally good mechanical properties and is heat treatable and weldable. It is similar to the British aluminium alloy HE9.
6063 is the most common alloy used for aluminium extrusion. It allows complex shapes to be formed with very smooth surfaces fit for anodizing and so is popular for visible
architectural applications such as window frames, door frames, roofs, and sign frames. [3] Applications requiring higher strength typically use 6061 or 6082 instead.

Aluminiu
Compare al 6061 and 6063
● Aluminum Alloy 6061: It is a commonly used aluminum alloy with good strength,
excellent machinability, and weldability. It is often used in structural applications and
is widely used for manufacturing aircraft, marine, and automotive components.
● Aluminum Alloy 6063: This alloy is often used for extrusion purposes. It has
generally good mechanical properties and is heat treatable and weldable. 6063 is
commonly used in architectural applications.
Common Uses:
● Aerospace Components: 6061 is used in aircraft wings and fuselages because of its
lightweight properties and strength.
● Marine Applications: Boat components, such as masts and other structures, often use 6061
due to its corrosion resistance.
● Automotive Parts: Various automotive parts, including frames and panels, utilize 6061
alloy.
● Bicycle Frames: High-quality bicycle frames are often made from 6061 due to its strength-
to-weight ratio.
● Structural Components: Beams, columns, and other structural applications often use 6061
aluminum.
Proposed of methodology
⮚ First the combination of alloys are being taken and mixed well for certain period
of time.

⮚ Then , using the tool insert these mixture are being compressed and a pin is
being formed and then heated to form as a metal.

⮚ By using pin on disc, the metal is treated and the wear and tear of the
aluminium metal is found.
 parameters

Sliding 0.5 =500mm 0.8= 800mm 1 =1000mm

condition

Sliding velocity 2 m/s 3m/s 4m/s

Load condition 1 kg =9.81 n 2kg =19.62n 3kg=29.43n

Track radius 50 mm 50mm 50mm

rpm 381.97 rpm 572.95 rpm 763.9 rpm

time 250 s 266 s 250 s

 LIST OF FIGURE
Creating a list of figures for a wear test on aluminum alloy 6063 involves identifying and numbering each figure that is
included in the report or documentation. Figures typically include graphs, charts, diagrams, and images that visually
represent data, findings, or key aspects of the wear test. Below is an example list of figures:
1. Figure 1: Wear Test Setup
○ Schematic or photograph illustrating the experimental setup for the wear test on aluminum alloy 6063.
2. Figure 2: Pin-on-Disc Configuration
○ Diagram depicting the configuration of the pin-on-disc wear testing apparatus used for the experiment.
3. Figure 3: Aluminum Alloy 6063 Samples
○ Image or illustration showing the prepared samples of aluminum alloy 6063 before the wear test.
4. Figure 4: Load vs. Time Graph
○ Graph depicting the variation in load over time during the wear test.
5. Figure 5: Friction Coefficient vs. Sliding Distance
○ Graph showing the relationship between friction coefficient and sliding distance for aluminum alloy 6063.
6. Figure 6: Wear Rate Analysis
○ Comparative chart illustrating the wear rates of aluminum alloy 6063 under different test conditions.
 METODOLOGY

The methodology for conducting a wear test on aluminum alloy 6063 involves several steps, and the specific details can vary
depending on the type of wear test, testing conditions, and the desired outcome. Below is a general outline of the methodology
for a wear test:
1. Define Objectives:
○ Clearly define the objectives of the wear test. Identify the specific wear mechanism (e.g., abrasive, adhesive,
erosive) and the conditions under which the material will be tested.
2. Select Test Parameters:
○ Determine the key parameters for the wear test, such as the type of wear test (e.g., pin-on-disc, abrasion, sliding
wear), contact load, sliding speed, and duration of the test.
3. Sample Preparation:
○ Prepare the aluminum alloy 6063 samples in the desired shape and size. Ensure that the samples are
representative of the actual application conditions.
4. Surface Preparation:
○ Prepare the sample surfaces by cleaning and ensuring they are free from contaminants. This may involve polishing
or other surface treatments to achieve the desired surface finish.
5. Test Apparatus Setup:
○ Set up the wear test apparatus according to the selected test parameters. This may involve using specialized
equipment such as pin-on-disc machines, abrasion testers, or other wear testing devices.
 1. Calibration:
○ Calibrate the testing equipment to ensure accurate measurements of parameters such as load, speed,
and displacement.
2. Conduct the Wear Test:
○ Initiate the wear test under the defined conditions. Monitor and record relevant parameters throughout
the test, including wear rate, frictional force, and temperature.
3. Post-Test Examination:
○ After completing the wear test, examine the samples for wear patterns, surface damage, and any other
relevant features. This may involve optical microscopy, scanning electron microscopy (SEM), or other
characterization techniques.
4. Data Analysis:
○ Analyze the data collected during the wear test. Calculate wear rates, coefficients of friction, and other
relevant metrics. Compare the results with the defined objectives and any applicable standards.
5. Reporting and Documentation:

Prepare a detailed report that includes the methodology, test parameters, results, and conclusions. Document any
issues or observations during the test
 PROBLEM STATEMENT

The wear resistance of aluminum alloy 6063 is a critical factor in determining its suitability for various
applications, particularly those involving friction and sliding contact. The need for a comprehensive wear test
arises from the demand for reliable performance data under different wear conditions. The objective is to
assess and quantify the wear behavior of aluminum alloy 6063 to enhance its applicability in diverse
environments. This includes understanding its response to abrasive, adhesive, or erosive wear and
establishing correlations between wear parameters, such as load, speed, and surface finish. The outcome of
the wear test will provide valuable insights into the material's durability and aid in optimizing its use in
applications where wear resistance is a crucial performance criterion.
The wear test will involve a systematic examination of aluminum alloy 6063 using [specific wear testing
method, e.g., pin-on-disc apparatus, abrasion tester, etc.]. The study will consider variations in load, sliding
speed, and surface conditions to simulate diverse operating environments. Post-test analysis will include
surface characterization using [relevant techniques, e.g., microscopy, SEM] to identify wear patterns and
surface changes. The results will be analyzed to draw conclusions regarding the alloy's wear resistance and to
make recommendations for its application in real-world scenarios.
Problem Statement: The wear resistance of aluminum alloy 6063 in architectural applications, particularly in sliding components, requires
improvement to ensure long-term durability. The objective is to assess the alloy's wear behavior under conditions simulating real-world usage,
identify contributing factors to wear, and propose modifications to enhance wear resistance.
ADVANTAGE AND DISADVANTAGE

1. Good Extrudability:
○ One of the primary advantages of aluminum alloy 6063 is its excellent extrudability. This
makes it easy to form complex shapes for various applications, particularly in the
production of extruded profiles for architectural components.
2. Corrosion Resistance:
○ Aluminum alloy 6063 exhibits good corrosion resistance, making it suitable for use in
outdoor and marine environments. This property contributes to its longevity and low
maintenance requirements.
3. Versatility:
○ The alloy is versatile and finds applications in a wide range of industries, including
construction, automotive, and electrical, due to its balanced combination of mechanical
properties.
4. Aesthetic Appeal:
○ Aluminum alloy 6063 can be easily anodized or coated, providing a customizable
and aesthetically pleasing finish. This makes it popular in architectural applications
where appearance is a significant consideration.
5. High Thermal Conductivity:
○ The alloy has good thermal conductivity, which makes it suitable for heat sinks and
other applications where efficient heat dissipation is essential.
6. Recyclability:
○ Aluminum is highly recyclable, and aluminum alloy 6063 is no exception. Recycling
aluminum requires significantly less energy compared to producing it from raw
materials, making it an environmentally friendly choice.
Disadvantages:
1. Lower Strength Compared to Some Alloys:

○ While aluminum alloy 6063 has good strength, it may not be as strong as some other aluminum alloys.
This can be a limiting factor in applications where higher strength is a critical requirement.

2. Limited Hardness:

○ The alloy has limitations in achieving high levels of hardness compared to certain other alloys. This may
impact its suitability for wear resistance in certain applications.

3. Limited Weldability:

○ While generally weldable, aluminum alloy 6063 may have limitations in welding compared to some other
alloys. Special care and techniques may be required to avoid welding-related issues.

4. Cost Considerations:

○ Aluminum alloys, including 6063, can be more expensive than some alternative materials. Depending
on the application and budget constraints, the cost may be a limiting factor.
Literature review
:

Recent progress in aluminum metal matrix composites:

Priyaranjan Samal *, Pandu R. Vundavilli, Arabinda Meher, Manas M. Mahapatra

Among the available metals Al, Mg, Ti, Cu, Ni, Fe
AMMCs are used to manufacture a wide range of aerospace components that need enhanced wear, frictional
resistance, and some promising mechanical propertie
spark plasma sintering (SPS) process. During heating, the SPS process increases the pressure and temperature rapidly
which breaks the aluminum particles, which causes the local metal to metal contact. The hardness and tensile strength
of the fabricated 6 wt% SiC composites were seen to be increased by 34 % and 26 %, respectively
The optimum sintering temperature was reported as 600 ℃ for 60 min in a conventional furnace. In schematic This
route is also found to be effective due to the rapid heat transfer and low energy consumption criteria. Bhatt et al. [61]
performed ball milling and sintering of Al-Mg alloy with SiO2 particles. Higher hardness was observed for nano-
composites as compared to the micro-composites.
spark plasma sintering microwave sintering. Casting method Squeeze casting
process. Centrifugal casting processAccumulative roll bonding process. specimen
mechanical properties and wear behavior of aluminum based metal matrix composites
Aluminum matrix composites have been used as structural members in automotive,
aerospace, defense and marine applications because of its light weight, high strength to
weight ratio, excellent resistance to wear and corrosion.
Aluminum matrix composites have been fabricated using solid state processes
Samson Jerold Samuel Chelladurai a, S. Senthil Kumar b, Narasimharaj Venugopal c, Abhra Pratip Ray d, T.C.
Manjunath e, S. Gnanasekaran f
solid state processes viz., powder blending and consolidation, physical vapor deposition, diffusion bonding
and liquid state process viz., casting process, spray deposition and in-situ processing. Selection of the
manufacturing process depends on the geometry of reinforcement, volume percentage of reinforcement added to
the matrix and desirable properties viz., mechanical and wear resistance of composites. Among all these
manufacturing processes, casting is the most economical and viable method to produce components by pouring the
molten metal into a fixed die to produce the components with required shape and size [6], [7], [8], [9], [10].
An overview of production technologies and its application of metal matrix composites

Nikhil Bharat and P.S.C Bose

Metal matrix composites are very useful in the field of aerospace, automobile as well as naval
industries. In the recent past varieties of metals and alloys are used to obtain the desired properties of
better quality but metals having low quality are not preferred. Aluminum, Magnesium and Titanium
are some of the metal matrices that are used in the industries. However, the strength of the metal
matrix composites mainly relies on the type of reinforcing material used. The most commonly used
reinforcing materials are SiC, B4C, Al2O3, Si3N4, TiC, TiB2, TiO2. Liquid state fabrication
technique Stir casting method Compocasting
200° C a 700° C a
Effects of alumina-rich waste (valoxy) as an alternative sustainable material to alumina on the morphology,
mechanical and wear behavior of Al-6063 alloy by stir casting

Sunday Gbenga Borisade a , Seun Samuel Owoeye b,* , Solomon Akindutire a , Howard Epstein c
In recent years, the quest to improve sustainability and cut costs has shifted focus to the use of waste materials as reinforcement in metal
matrix composites. The current study aimed to evaluate the effects of valoxy as an alternative material to alumina on Al-6063 based
composites for the first time. Al-composites containing 10 wt-. % Al2O3: Valoxy in the steps of 0, 10:0, 7.5:2.5, 5:5, 2.5:7.5, and 0:10 were
fabricated using a double stir casting approach, while representative samples from each composition were studied for microstructure,
mechanical, and wear properties, respectively. The results of the chemical composition showed that valoxy contains 70 wt-.% Al2O3
alongside other oxides like SiO2 and MgO, making it a potential sustainable alternative to traditional alumina. The density of the
composites decreases with an increase in valoxy content, which is attributed to the density of valoxy (1.4 g/cm3 ) compared to alumina
(3.89 g/cm3 ), which it replaces. There is also a general improvement in all the properties tested across the composites containing valoxy
compared with the base alloy and Al-6063/Al2O3 samples. Composite samples 7.5:2.5 and 5:5 (Al2O3:Valoxy) showed consistent results
with better hardness of 46.45 and 46.21 HB, tensile strength
500 wear papameter
500 frictional force
Coeff of friction