WEAR BEHAVIOUR OF ALUMINIUM ALLOY

7075 METAL MATRIX COMPOSITES

PROJECT MEMBER

G.MAHENDRAN
(911220408009)

Under The Guidance Of

Mr.C.Gopikrishnan M.E.,(Ph.D).
AP/Mechanical Engineering
Mahatma Institute of Engineering &
Technology, Pudukkottai.
 ABSTRACT
Aluminium metal matrix composites (AMMCs) is an aluminium alloy. It is
strong, with strength comparable to many steels, and has good fatigue strength and
average machinability. It has lower resistance to wear than many other aluminium
alloys, but it has significantly better wear resistance than the 2000 aluminium alloys.
AMMCs are potential materials for various applications due to their good physical
and mechanical properties.This work aluminum metal matrix composite (AA7075)
reinforced with Zirconium di oxide (ZrO2) by using the stir casting techniques. This
serves as an additive to aluminum metal matrix composites, wear resistant alloy. To
fabricate the (AA7075) aluminum metal matrix composites reinforced with
Zirconium di oxide (ZrO2) . To determine the mechanical properties such as tensile
strength and hardness.

Keywords: AA7075, ZrO2, Stir Casting, Mechanical Properties,

Wear.
OBJECTIVES

The main purpose of this project is to develop the

strong light weight metal matrix AA7075 reinforced
with ZrO2.

To identify the mechanical properties( Hardness

Test, Tensile Test) of the material matrix composite.
Literature review

1.Meshram, S.D., Mohandas, T. and Reddy, G.M., “Friction welding of

dissimilar pure metals”, Journal of Material Processing Technology, Vol.
184, pp. 330–337, 2007.
2 Cam, G. and Kocak, M., “Microstructural and mechanical characterization
of electron beam welded Al-alloy 7020”, Journal of Materials Science, Vol.
42, pp. 7154–7161.
3. Çam, G., Ventzke, V., Dos Santos, J.F., Koçak, M., Jennequin, G. and
Gonthier-Maurin, P., “Characterisation of electron beam welded aluminium
alloys”, Science and Technology of Welding and Joining, Vol.
4, No. 5, pp. 317–323, 1999. 4. Çam, G., Ventzke, V., Dos Santos, J.F. and
Koçak, M., “Characterization of laser and electron beam welded Al alloys”,
Practical Metallography, Vol. 37, No. 2, pp. 59–89, 2000.
5. Pakdil M., Çam G, Koçak M. and Erim S. “Microstructural and
mechanical characterization of laser beam welded AA6056 Al-alloy”, Mater
Sci Eng A, Vol. 528, No. 24, pp. 7350–7356, 2011
11. Fuwana, H., Katoh, K. and Tokisue, H., “Effects of friction welding conditions on
the mechanical properties of friction welded joints in AA7075 aluminum alloy”,
Welding International, Vol. 11, No. 9, pp. 682–687, 2010.
12. Çam, G., Dos Santos, J.F. and Koçak, M., Laser and Electron Beam Weldability
of Al-Alloys: Literature Review, GKSS Report 97/E/25, IIW Document IX-1896-98,
GKSS Research Centre, Geesthacht, 1997.
13. Squillace, A., Fenzo, A.D., Giorleo, G. and Bellucci, F., “A comparison between
FSW and TIG welding techniques: modifications of microstructure and pitting
corrosion resistance in AA2024-T3 butt joints”, Journal of Materials Processing and
Technology, Vol. 152, pp. 97–105, 2004.
14. Khalid R.H., Janikiraman, G.D., Phanikumar, G. and Prasad R.K.,
“Microstructure and tensile properties were studied by selecting the process
parameters”, Material and Design, Vol. 31, pp. 2375–2380, 2010. Transactions of the
Canadian Society for Mechanical Engineering, Vol. 39, No. 4, 2015 853
15. Avinash, S., Pachal and Amol B., “Taguchi optimization of process parameters in
friction welding of 6061 aluminium alloy and 304 steel: A review”, International
Journal of Emerging Technology and Advanced Engineering, Vol. 3, No. 4, pp. 229–
233, April 2013.
 Process Chart
Selection of Material(AA7075)

Selection of reinforcement(ZrO2 )

Stir casting Process

Mechanical Testing :
1.Hardness(Brinell) Test
2.Tensile Test
3. Wear

Comparison of Mechanical Properties

Conclusion
DEFINITION OF COMPOSITE

 Composites remult ifunctional material systems that provide

Characteristics not obtainable from any discrete material.

 They are cohesive structures made by physically combining two

or more compatible materials, different in composition and characteristics
and sometimes in form”.
Types of Matrix Material

1. Metal Matrix Composite

2. Polymer Matrix Composite

3. Ceramic Matrix Composite

Material Used In Composite
Aluminium Alloy 7075

Zirconium di oxide (ZrO2)

 Aluminium Alloy 7075
7075 aluminium alloy is an aluminium alloy. It is strong, with a strength comparable
to many steels, and has good fatigue strength and average machinability.

It has significantly better corrosion resistance than the 2000 alloys. Its relatively high
cost limits its use.

AA7075
Properties of AA7075
Physical Properties

The physical properties of aluminum 7075 alloy are tabulated below.

Properties Metric Imperial

Density 2.8 g/cm3 0.101 lb/in3

Melting point 483°C 900°F

CHEMICAL PROPERTIES:

The following table shows the chemical composition of the

aluminum 7075 alloy.

Element Content (%)

Aluminum, Al 90

Zinc, Zn 5.6

Magnesium, Mg 2.5

Copper, Cu 1.6

Chromium, Cr 0.23
THERMAL PROPERTIES
The thermal properties of aluminum 7075 alloy are given in the
following table.

Properties Conditions

T (ºC) Treatment

Thermal 23.2 (10-

-
20-100
expansion 6
/ºC)

Thermal 130 25 T6
conductivity W/mK
Mechanical Properties:
The mechanical properties of aluminum 7075 alloy are outlined in the
following table.

Properties Metric Imperial

Tensile strength 220 MPa 31909 psi
Yield strength 95 MPa 13779 psi
Shear strength 150 MPa 21756 psi

Fatigue strength 160 MPa 23206 psi

Elastic modulus 70-80 GPa 10153-11603 ksi
Poisson's ratio 0.33 0.33
Elongation at break 17% 17%
Hardness 60 60
Applications of AA7075

To used in transport applications.

Military weapons specified from M16 rifles.

It is used in RC models in the chassis plate.

It is used in marine.

Zirconium di Oxide(ZrO2)

Zirconium di Oxide is chemical compound with the formula ZrO 2. This

compound is produced on the largest scale of any molybdenum compound.

ZrO2
 Chemical Properties Of ZrO2
Properties of ZrO2
Chemical Properties
The chemical properties of molybdenum oxide nanoparticles are
outlined in the following table.

Chemical Composition

Content
Properties

Std molarentropy (So298) 50.3 J K−1 mol−1

SoluleinHF,and hot H2SO4
Solubility
Physical properties
The physical properties of molybdenum oxide nanoparticles
are given in the following table.

Properties Metric Imperial

Density 4.70 g/cm3 0.170 lb/in3

123.28 g/mol
Molar mass -
Thermal Properties

The thermal properties of molybdenum oxide nanoparticles are

provided in the table below.

Properties Metric Imperial

Melting point 2715°C 4919°F

Boiling point 4300°C 7772°F

Applications

Zirconia’s high mechanical propertis.

 high-temperature stability.

corrosion resistance, and high quality .

oxygen sensors, membranes in fuel cells, deep well valve seats,

and marine pump seals.
Composition of Material

1. AA7075
2. AA7075 + 5wt.% of ZrO2
3. AA7075 + 10wt.% of ZrO2
Stir Casting

 Stir Casting is a liquid state method of composite materials

fabrication, in which a dispersed phase (ceramic particles, short
fibers) is mixed with a molten matrix metal by means of mechanical
stirring.

 The liquid composite material is then cast by conventional

casting methods and may also be processed by conventional Metal
forming technologies.
Figure of Stir Casting
 Mechanical properties

1. Tensile test
2. Hardness test
 Tensile test
The engineering Tensile Test is also known as
tension test which vary widely used for
providing the base of the design information
on the strength of material and as an
acceptance test for the specification of the
materials.

As the machine continues to pull on the

material until it breaks, a good, complete
tensile profile is obtained. The curve shows
how it reacted to the forces being applied.

Universal tensile Machine

 RESULT AND DISCUSSION
4.1 BRINELL HARDNESS TEST
 Brinell Hardness Test
85

75
Brinell Hardness (BHN)

65

55

45

35

25

15

1 2 3
Series1 68 74 83

From the above hardness graph values of the Al7075 + 10% of ZrO 2 is better
hardness than the Al7075 + 5% of ZrO2.
•AA7075 + 10% of ZrO2 have hardness is 83 BHN.
•AA7075 + 5% of ZrO2 have hardness is 74BHN.
•AA7075 have hardness is 68 BHN.
TENSILE TEST
 Ultimate Tensile Strength Percentage Elongation
315 7.5

305 6.5

% Elongation
UTS (MPa)

295 5.5
285
4.5
275
3.5
265
255 2.5

245 1.5
235
0.5
1 2 3
1 2 3
Series1 263 296 310
Series1 7.35 6.25 5.6

From the above Tensile Test graph values of the Al7075 + 10% of ZrO2 is
better Ultimate tensile strength than the Al7075 + 5% of ZrO2.
AA7075 + 10% of ZrO2 have hardness is 310 MPa.
• AA7075 + 5% of ZrO2 have hardness is 296 MPa.
• AA7075 have hardness is 263 MPa.
 WEAR ANALYSIS

SN Ratio analysis for WR

The below table shows the calculated SN ratio for all the experiments.
Table shows the response table for the WR along with the rank. From this
next table, the highly influenced factor is identified based on the rank. From
Table, it is identified that, the 'P" is the largely important parameter affecting
the WR of AA7075-ZrO2 composites followed by 'V', 'D'.
• Figure shows the main effect plot for the WR in mm 3/m. From the
main effect plot is observed that, 'P" is the most dominating factor
affecting the wear rate. Also the low 'P", high 'V' and the low 'D' are
the conditions for obtain low WR of the composite.
• It has been observed that, the WR increases with the increase of the
applied 'P" and 'D', which shows further subtraction of materials from
the surface. Also, the WR decreases with an increase in the 'V' due to
the development of a mechanically mixed layer, thus decreasing the
wear by casing more area of contact.
 CONCLUSION

• AA7075 and (5&10) wt% of ZrO2 reinforcement particles

were mixed successfully by stir casting method.

• The mechanical properties were increased with the

reinforcements of 10wt% of ZrO2 confirmed by hardness test
such as Brinell Hardness test and Tensile test.

• From SN ratio analysis the dominant parameters were ranked

for minimum WR as follow; 'P", 'V', 'D' and weight
percentage of reinforcement.

• From the main effect plot it was observed that, the 'P" is the
most dominating factor affecting the wear rate.
THANK YOU