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VSRD-MAP, Vol. 1 (3), 2011, 96-103

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1,2
Associate Professor, Department of Mechanical Engineering, ABES Engineering College, Ghaziabad, Uttar Pradesh,
INDIA. *Correspondence : ravi.raman21@gmail.com
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Mechanical Properties of Stirr Cast
Hypoeutectic Al-Si Alloys
1
Ravi Shankar Raman* and
2
K. V. Ojha
ABSTRACT
The manufacturing process through stirr casting leads to give near-net-shape and fine grain microstructure. In
this process Si particles, which are not distributed uniformly in conventional casting process, are distributed
uniformly throughout the casting. In the present study stirr castings were made of Al-7Si, Al-10Si and Al-12Si
alloys and then their Mechanical properties and casting properties were studied. Microstructure of stirr casted
formed alloys showed equiaxed grains morphology in contrast to as cast alloys. The mechanical properties of
Al12 Si alloy were found to be better than that of the Al-7Si and Al-10Si.
Keywords : Stirr Casting; Mechanical Properties; Microstructure.
1. INTRODUCTION
Aluminium- Silicon alloys are widely used in aerospace, automobile and electronic industries due to their light
weight, high strength to weight ratio, excellent wear and corrosion resistance, good casting ability and low
coefficient of thermal expansion [1]. The Silicon phase in aluminium- Silicon alloy provides it all
aforementioned properties. But in conventional casting process coerse Silicon phase is formed which leads to
poor mechanical properties. Therefore, Stirr Casting is required to enhance the mechanical properties [1,2]
Stirr casting, which is a rapid solidification process increases the solubility of Silicon in Aluminium and also
modifies the morphology of Silicon Phase. Mechanical properties of Aluminium Silicon Stirr casting alloy
produced at various compositions were studied [3, 4].
In the present work, hypoeutectic Aluminium- Silicon alloys with compositions Al-7Si, Al-10Si and Al-12Si
were stirr casted for the study of various mechanical properties.
Ravi Shankar Raman et al / VSRD International Journal of Mechanical, Auto. & Prod. Engg. Vol. 1 (3), 2011
Page 97 of 103
2. RESEARCH METHODOLOGY
2.1. Alloy Preparation
For the experimental set up of Al-Si percentages are maintain with weight as per the given set and alloys are
prepare on the basis of weight ratio
(a) Al-93%, Si-7%
(b) Al-90%, Si-10%
(c) Al-88%, Si-12 %
2.2. Procedure
2.2.1. Setup
027064 - Al 7424-905 grade Laboratory aluminium powder and 030066- Si 7440-21-3 MW-28.09 grade
Laboratory silicon powder are mixed in dry state. After proper mixing of Al-Si powder in a single crucible as
per the given weight ratio. The molten metal is properly mixed with steel rod due to that temperature losses are
occurred so for maintaining the fluidity and viscosity of mixture crucible is reheated up to 1370
o
C and moulded
in crucible with nitrogen sealded head upto 1430
o
C and casted on three different stages ( sand , ferrous and non
ferrous casting ). 12 to 24 hours used for solidifying for the casting material then sample is used for the
investigation of mechanical Properties [1,3].
Three sets of mould were prepared for the casting which is mentioned below:
Sand
Ferrous
Non ferrous
Table 1: Percentages of Al- Si mixture and Casting Code
Sl.No. Percentages of Al Si mixture Type of Casting Casting code
1. Al-93%, Si-7% Sand Casting 1 / 1
Al-93%, Si-7% Ferrous Casting 1 / 2
Al-93%, Si-7% Non ferrous casting 1 / 3
2. Al-90%, Si-10% Sand Casting 2 / 1
Al-90%, Si-10% Ferrous Casting 2 / 2
Al-90%, Si-10% Non ferrous casting 2 / 3
3. Al-88%, Si-12 % Sand Casting 3 / 1
Al-88%, Si-12 % Ferrous Casting 3 / 2
Al-88%, Si-12 % Non ferrous casting 3 / 3
Once casting work is over then we go for investigation of casting defects. For verify the visual inspection of all
the above casting then we analyse that the outer structural of the ferrous casting is comparatively smoother than
the others castings like sand and non ferrous casting. To know about the casting defects we use for Non-
destructive testing like ultrasonic testing for all the casted materials.
Ravi Shankar Raman et al / VSRD International Journal of Mechanical, Auto. & Prod. Engg. Vol. 1 (3), 2011
Page 98 of 103
2.2.2. Hardness Testing of the Specimens
For hardness testing of the specimen same test piece is used, since aluminium is a ductile material so britnell
hardness, B grade of scale is used for testing. For this use the 1.5mm diameter Indentor and 100 kgf load is used,
after applying the load the hardness is calibrated for each and every specimen.
2.2.3. Ultimate Tensile Strength of the Specimens
Ultimate tensile strength is the maximum stress that a material can withstand while being stretched or pulled
before necking, which is when the specimen's cross-section starts to significantly contract. The Ultimate tensile
strength is usually found by performing a tensile test and recording the stress versus strain; the highest point of
the stress-strain curve is the UTS. It is an intensive property; therefore its value does not depend on the size of
the test specimen. However, it is dependent on other factors, such as the preparation of the specimen, the
presence or otherwise of surface defects, and the temperature of the test environment and material.
3. RESULTS
3.1. Specimen Nomenclature
The Silicon based aluminium was casted. For recognition of specimen easily a code was self generated which is
illustrated in Table 2.
Table 2 : Specimen Code
Sl. No. Heat No. / Sample No. Process of Mould
1. 1/1 Sand
2 1/2 Ferrous
3 1/3 Non ferrous
4. 2/1 Sand
5 2/2 Ferrous
6 2/3 Non ferrous
7. 3/1 Sand
8 3/2 Ferrous
9 3/3 Non ferrous
3.2. Non Destructive Testing
Six inch long and 1.5 inch diameter specimen are tested for to knowing about the casting defect and primary
stage of grain structure of the alloys. The following results are absorbed.
Table 3 : Performance of Specimens Tested through Non Destructive Testing
Sample no. Performance
1/1 Poor
1/2 Good
1/3 Good
2/1 Appreciable
2/2 Good
2/3 Very good
3/1 Good
3/2 Very good
3/3 Excellent
Ravi Shankar Raman et al / VSRD International Journal of Mechanical, Auto. & Prod. Engg. Vol. 1 (3), 2011
Page 99 of 103
From the NDT test sample, sample no 3/3, 3/2, 2/3, 3/2, 2/1 has good backwell so that above sample are
assumed to free from casting defect and have good grain structure
3.3. Spectrometer Testing Of The Specimens
Weight % of element ingredients of the test specimens are as follows
Table : Weight % of element ingredients
ELEMENT
NAME
SAMPLE NUMBER
3/3 2/3 1/3
Al 86.64 88.48 92.12
Si 12.23 10.20 6.80
Fe 0.273 0.255 0.212
Cu 0.150 0.160 0.124
Mn 0.009 0.012 0.019
Mg 0.029 0.038 0.046
Zn 0.062 0.008 0.019
Ti 0.010 0.000 0.014
3.4. Hardness of the Specimens
From the hardness testing of all specimens the following data of hardness are recorded as shown in Table 4. It
was found that when the % Si is increased the hardness of the specimen is increased and it is independent of the
variation of % Al content.
Table 4 : Hardness Testing
Sample
No.
Aluminium
%
Silicon
%
Rockwell Hardness No.
(HRB)
1/1 93 6.8 46
1/2 93 6.8 50
1/3 93 6.8 52
2/1 90 10.2 57
2/2 90 10.2 58
2/3 90 10.2 61
3/1 88 12.23 63
3/2 88 12.23 67
3/3 88 12.23 70

Fig. 1 : Variation of Hardness Curve
0
20
40
60
80
(1/1) (1/2) (1/3) (2/1) (2/2) (2/3) (3/1) (3/2) (3/3)
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Sample
Variation of Hardness with Silicon %
SILICON %
HARDNESS( HRB)
Ravi Shankar Raman et al / VSRD International Journal of Mechanical, Auto. & Prod. Engg. Vol. 1 (3), 2011
Page 100 of 103
3.5. Variation of Ultimate Load with % Si
From the Ultimate load testing of all specimens the following data are recorded as shown in Table 5. It was
found that when the silicon % is improved the then ultimate load of the specimen is increase and it is free from
the % of aluminium constituents.
Table 5 : Ultimate Load Variation with % Si
Sample no. ALUMINIUM % SILICON % Ultimate Load(kN)
1/3 93 6.8 8.36
2/3 90 10.2 12.25
3/3 88 12.23 14.65

Fig. 2 : Variation of Ultimate Load Curve
3.6. Yield Load Variation with % Si
From the testing of the entire specimen the following data are recorded as shown in Table 6. It was found that
when the silicon % is improved then yield load of the specimen is increase and it is independent from the % Al
constituents.
Table 6 : Yield Load Variation with % Si
Sample
No.
Aluminium
%
Silicon
%
Yield Load
(kN)
1/3 93 6.8 5.68
2/3 90 10.2 7.62
3/3 88 12.23 10.2
0
5
10
15
20
(1/3) (2/3) (3/3)
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Sample
Variation of Ultimate Load with Silicon %
SILICON %
ULTIMATE LOAD (kN)
Ravi Shankar Raman et al / VSRD International Journal of Mechanical, Auto. & Prod. Engg. Vol. 1 (3), 2011
Page 101 of 103

Fig. 3 : Variation of Yield Load Curve
3.7. Ultimate Tensile Strength (UTS)
From the tensile testing of all the specimens the UTS values were calculated as shown in Table It was found that
when the silicon % is improved the then Ultimate load of the specimen is increased.
Table : Ultimate Tensile Strength (UTS)
Sample no. Silicon % Ultimate strength (MPa)
1/3 6.8 72.08
2/3 10.2 105.62
3/3 12.23 126.31

Fig. 4 : Variation of Ultimate Strength Curve
3.8. Yield Strength
From the testing of the entire specimen the following data are recorded as shown in Table. It was found that
when the silicon % is improved then yield strength of the specimen is increased.

0
2
4
6
8
10
12
14
(1/3) (2/3) (3/3)
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Variation of Yield Load with Silicon %
SILICON %
YIELD LOAD (kN)
0
50
100
150
(1/3) (2/3) (3/3)
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Variation of Ultimate Strength with Silicon %
SILICON %
Ravi Shankar Raman et al / VSRD International Journal of Mechanical, Auto. & Prod. Engg. Vol. 1 (3), 2011
Page 102 of 103
Table : Variation of Yield Strength
Sample
No.
Silicon
%
Yield Strength
(MPa)
1/3 6.8 48.97
2/3 10.2 65.70
3/3 12.23 87.94

Fig. 5 : Variation of Yield Strength Curve
4. CONCLUSION
In the present study the grains of alloys are refined which is studied through the microscope and mechanical
properties are determined from hardness testing machine and universal testing machine in such a way that the
following conclusion can be drawn.
Hardness of Al-Si alloy in non-ferrous mould is better than the Sand mould casting and ferrous mould
casting.
Grains are refined much better in non ferrous mould casting than the Sand mould casting and ferrous mould
casting.
Workability of alloys is improved in hot and cold working.
Machinability of alloy in non-ferrous mould is improved and ultimate as compare to other two moulds.
Hardness of Al-Si alloys is increased as % of silicon is increases.
5. REFERENCES
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[3] Zhang Wei-wen, Chen Wei-ping, Fei jin a Microstructure and mechanical property of 2024/3003 Gredient
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100
(1/3) (2/3) (3/3)
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%
Sample
Variation of Yield Strength with Silicon %
SILICON %
YIELD STRENGTH
(MPa)
Ravi Shankar Raman et al / VSRD International Journal of Mechanical, Auto. & Prod. Engg. Vol. 1 (3), 2011
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