International Journal of Manufacturing and Materials Processing
Preparation and Characterization of Double Step StirCusted Aluminum Hybrid Composite Reinforced with RHA and Si3N4 Micron Particles
Abstract
Abstract: The improvement of the mechanical and tribological characteristics of composites is always a crucial area of research for materials scientists. Nowadays, particulate aluminum matrix hybrid composites, known as particle-reinforced hybrid aluminum matrix composites (PHAMCs), are becoming more popular due to their desirable properties, cost-effectiveness, ease of processing, and compatibility with
traditional processing techniques. In this current study, a two-step stir casting method was utilized to
create aluminum hybrid composites using Al6061 alloy and submicron-sized particles (0.5-1 μm) of
Rice Husk Ash (RHA)-Silicon Nitride (Si3N4) reinforcements. A total of six compositions, including one
base alloy, two single reinforced composites with 2wt% reinforcement, and three hybrid composites
with different weight percentages (RHA- Si3N4, 1:1, 0.5:1.5, and 1.5:0.5), were prepared for
investigation. The physical, mechanical, and wear properties of the fabricated composites were
measured according to ASTM Standards and compared with each other. The specific wear rate was
determined under various loads (5 N, 10 N, and 15 N), different grit sizes of abrasive wear papers (180
and 320 grit SiC), and different sliding distances (125 m and 250 m) at a constant sliding velocity of
1.25 m/s. It was observed that Al6061/1wt%RHA/1wt% Si3N4 and Al6061/0.5wt%RHA/1.5wt% Si3N4
exhibited superior wear properties and lower coefficients of friction, which can be attributed to the
cushioning effect of RHA and the hardness of Si3N4 particles. The highest achieved tensile strength was
25% greater than that of the base alloy. Furthermore, the highest hardness was approximately 30%
greater than that of the base alloy, while the minimum density was reduced by 1.1%.
References (44)
- Yashpal, Sumankant, Jawalkar CS, Verma AS, Suri NM (2017) Fabrication of Aluminium Metal Matrix Composites with Particulate Reinforcement A Review. Mater Today Proc 4:2927–2936
- Alaneme KK, Aluko AO (2012) Fracture toughness (K1C) and tensile properties of as-cast and age-hardened aluminium (6063) –silicon carbide particulate composites. Sci Iran 19(4):992–996
- Alaneme KK, Bodunrin MO (2013) Mechanical behaviour of alumina reinforced AA 6063 metal matrix composites developed by two step stir casting process. Acta Tech Corvininesis – Bull Eng 6(3):105–110
- Singh J, Chauhan A (2016) Characterization of hybrid aluminum matrix composites for advanced applications - A review. J Mater Res Technol 5:159–169
- Alaneme KK, Aluko AO (2012) Production and age-hardening behaviour of borax premixed SiC reinforced Al-Mg-Si alloy composites developed by double stir casting technique. West Indian J Eng 34(1–2):80–5
- Reddy PV, Prasad PR, Krishnudu DM, Goud EV (2019) J Bio Tribo-Corrosion 5:1–10. https:// doi. org/ 10. 1007/s40735- 019- 0282-0
- Taha MA (2001) Industrialization of cast aluminum matrix composites (AMCCs). Mater Manuf Process 16(5):619–641
- Surappa MK (1997) Microstructure evolution during solidification of DRMMCs (Discontinuously reinforced metal matrix composites):State of art. J Mater Process Technol 63(1–3):325–333
- Arunachalam R, Kumar P, Muraliraja RA (2019) Review on the production of metal matrix composites through stir casting – furnace design, properties, challenges, and research opportunities. J Manuf Process 42:213–245. https:// doi. org/ 10. 1016/j. jmapro. 2019. 04. 017
- Samal P, Vundavilli PR, Meher A, Mahapatra MM (2019) Fabrication and mechanical properties of titanium carbide reinforced aluminium composites. Mater Today Proc 18(7):2649–2655. https:// doi. org/ 10. 1016/j. matpr. 2019. 07. 125
- Samal P, Vundavilli PR, Meher A, Mahapatra MM (2020) Recent progress in aluminum metal matrix composites: A review on processing, mechanical and wear properties. J Manuf Processes 59:131–152. https:// doi. org/ 10. 1016/j. jmapro. 2020. 09. 010
- Samal P, Vundavilli PR, Meher A, Mahapatra MM (2022) Reinforcing effect of multi-walled carbon nanotubes on microstructure and mechanical behavior of AA5052 composites assisted by insitu TiC particles. Ceram Int 48(6):8245–8257.
- [13]Hashim J, Looney L, Hashmi MSJ (1999) Metal matrix composites: production by the stir casting method. Journal of materials processing technology Elsevier BV Netherlands. Volume 92- 93:1-7
- Zhou W, Xu ZM (1997) Casting of SiC reinforced metal matrix composites. Journal of material processing technology Elsevier BV Netherlands Volume63:358-363
- Michael J, Kumar JS (2018) Fabrication and Characterization of hybrid aluminium metal matrix composite. Int Res J Eng Technol 05(06)
- Sharma P, Khanduja D, Sharma (2015) 4th International Conference on Material Processing and Characterization. 14–15 March GRIET Hyderabad India Mater Today Proc Elsevier (in press)
- Arya RK, Telang A (2021) Processing, Characterization and Fractography of Dual Step Stir Casted Al6061/( Si3N4+SiC) Composites. Int J Eng Trends Technol 69(7):270–277
- Arya RK, Kumar R, Telang A (2023) Influence of Microstructure on Tribological Behaviors of Al6061 Metal Matrix Composite Reinforced with Silicon Nitride (Si3N4) and Silicon Carbide (SiC) Micro Particles. Silicon. https:// doi. org/ 10. 1007/s12633- 023- 02309-6
- Subramaniam B, Natarajan B, Kaliyaperumal B, Jerold S (2018)Investigation on mechanical properties of aluminium 6061–boron carbide–coconut shell fly ash reinforced hybrid metal matrix composites. China Found 15(6):449–456
- Arya R, Telang A (2020) Silicon nitride as a reinforcement for aluminium metal matrix composites to enhance microstructural, mechanical and tribological behavior. Int J Eng Adv Technol9(3):3366–3374
- Shalaby EAM, Churyumov AY, Solonin AN, Lotfy A (2016) Preparation and characterization of hybrid A359/(SiC+Si3N4) composites synthesized by stir/squeeze casting techniques. Mater Sci Eng A 674:18–24
- Han IS, Seo DW, Kim SY, Hong KS, Guahk KH, Lee KS (2008) J Eur Ceram Soc 28:1057–1063
- Xiu ZY, Chen GQ, Liu YM, Yang WS, Wu GH (2009) Trans Non ferr Met Soc China 19:373–377
- Zhu X, Zhou Y, Hirao K (2004) Effect of sintering additive composition on the processing and thermal conductivity of sintered reaction-bonded Si3N4. J Am Ceram Soc 87(7):1398–1400
- Lange FF (1973) Relation between strength, fracture energy, and microstructure of hot-Pressed (Si3N4). J Am Ceram Soc 56:518–522
- Kishore Kumar PR, Manikandan VN, Deepak Raj P, Sridharan M(2016) Characterization of magnetron sputtered Si3N4 thin films deposited on Aluminum alloy substrates. Mater Today Proc 3:1536–1540
- Tuchinskiy L, Veksler E, Loutfy R, Williams M (2000) Tribological characteristics of Si3N4- based self-lubricating materials. Tribol Trans 43:603–610
- Bocanegra-Bernal MH, Matovic B (2010) Mechanical properties of silicon nitride-based ceramics and its use in structural applications at high temperatures. Mater Sci Eng A 527:1314–1338
- Carrasquero E, Bellosi A, Staia MH(2005) Characterization and wear behavior of modified silicon nitride. Int J Refract Met Hard Mater 23:391–397
- Mohan A, Narendra K, Rakesh K, Mohan S (2017) High-temperature tribology of AA5052/ZrB2 PAMCs. J Tribol 139(1):011601-12
- Verma N, Vettivel SC (2018) Characterization and experimentalanalysis of boron carbide and rice husk ash reinforced AA6061aluminium alloy hybrid composite. J Alloys Compd 741:981–998
- Ravikumar K, Kiran K, Sreebalaji VS (2017) Micro structural characteristics and mechanical behaviour of aluminium matrix composite reinforced with titanium carbide. J Alloys Compd 723:795–801
- Shoba C, Prasad DS, Prathipati R (2019) Investigations on the machinability of Al/SiC/RHA hybrid metal matrix composites.Silicon 11(47):1–12
- Prasad DS (2012) Production and mechanical properties of A356.2/RHA composites. J Mater Sci Technol 28(4):367–372
- Veeravalli RR, Ramanaiah N, Sarcar MM (2016) Mechanical and tribology properties of AA7075–TiC metal matrix composites under heat treated (T6) and cast conditions. J Mater Res Technol 5(4):377–383
- Hossain MR, Ali MH, Amin MA, Kibria MG, Ferdous MS (2017) Fabrication and performance test of aluminium alloy–rice husk ash hybrid metal matrix composite as industrial and construction material. Int J Eng Mater Manuf 2:94–102
- Sano T, Srivatsan TS (eds) (2015). John Wiley & Sons, Inc., Hoboken, NJ
- Chawla KK, Chawla N. Metal-Matrix Composites. Mater Sci Technol 2004:1–25. https:// doi. org/ 10. 1016/ B978-0- 08- 050073-7. 50011-7
- Scudino S, Liu G, Sakaliyska M, Surreddi KB, Eckert J (2009) Acta Mater. 57:4529
- Aigbodion VS, Hassan SB and Oghenevweta JE. Microstructural analysis and properties of Al–Cu–Mg/bagasse ash particulate composites. J Alloys Compd 2010; 497: 188–194.
- Reddy PS, Kesavan R and Ramnath BV. Investigation of mechanical properties of aluminum 6061-silicon carbide,boron carbide metal matrix composite. Silicon 2018; 10: 495–502.
- Gracio JJ, Barlat F, Rauch EE, Jones PT (2004) Int J Plast 20:427
- Amigo V, Ortiz JL, Salvador MD (2000) Microstructure and mechanical behavior of 6061Al reinforced with silicon nitride particles, processed by powder metallurgy. Scr Mater 42:383–388
- Rao RN, Das S (2010) Effect of matrix alloy and influence of SiC particle on the sliding wear characteristics of aluminum alloy composites. Mater Des 31:1200–1207