ISSN: XXXX-XXXX Vol.

1 (1),
pp. 001-005, March, 2014.
Global Science Research Journals

International Journal of Mechanical

Engineering

Full Length Research Paper

Effects on Microstructure and Hardness of Al-B4C Metal

Matrix Composite Fabricated through Powder
Metallurgy
Raja T.1 and *Sahu O.P.2
1

Department of Mechanical Engineering, KIOT Wollo University, Kombolcha (SW), Ethiopia

2
Department of Chemical Engineering, KIOT Wollo University, Kombolcha (SW), Ethiopia
th

Accepted 17 March, 2014

The experiment was conducted for the evaluation of cold compaction behavior and hardness of Al-B4C
composites for varying percentage of reinforcement. The reinforcement percentage of boron carbide
as varied in the range of 5, 10, 15 & 20%. The particle reinforced composite was prepared by a powder
metallurgy route with the particle size of Boron carbide as 150 m. The matrix and the reinforcement
powders were blended to produce homogeneous distribution by using pot mill. The compacts were
prepared by suitable punch and die set assembly. The density values were evaluated from the effect of
cold compaction behavior and the hardness values of each samples varying according to the
percentage of reinforcement. From the experimental studies 20% reinforced B4C sample yielded a
higher hardness value. The Micro structural behaviors were studied by using scanning electron
microscope.
Keywords: Metal Matrix Composites, powder metallurgy, density, hardness, microstructure

INTRODUCTION
Aluminum metal matrix composites (Al MMCs) are being
considered as a group of new advanced materials for its
light weight, high strength, high specific modulus, low coefficient of thermal expansion and good wear resistance
properties. Combinations of these properties are not
available in a conventional material (Abouelmagd, 2004).
The use of Al MMC has been limited to specific
applications such as aerospace and military weapon due
to high processing cost. Recently, Al matrix composites
have been used for the automobile products such as
engine piston, cylinder liner, brake disc/drum etc.

Correspondence author Email:ops0121@gmail.com;

Tel: +251933520653

Discontinuously reinforced metal-matrix composites

(MMCs) have attracted attention because of their high
specific stiffness and strength, ease of fabrication and
relatively low cost. These MMC components can be made
by different fabrication routes and may be subjected to
impacts (Lahaie, 2004). Due to the higher cost of Boron
carbide (B4C) powder relative to more common abrasive
powders (E.g. SiC and Al2O3), limited research has been
conducted on B4C reinforced MMCs. B4C is lower in
density and has higher hardness than SiC and Al2O3, thus
a better reinforcement type for high performance MMCs
(Zhang, 2004). Powder forging is particularly attractive
because it blends the cost and material saving advantages
compared to the conventional castings and forgings
through
better
dimension
and
weight
control
(Narayanasamya, 2009). Powder forged parts can even

Int'l J. Mech. Eng.

002

Fig.1: Scanning
aluminium powder

electron

micrographs

of

Table1: Characteristics of powders used

S.N

Powder

Size(m

Purit

Densit

y (%)

y
(g/cm3)

Al

75

99.8

2.7

B4C

150

99.7

2.51

as well as their light weight, high stiffness, and hardness

(Narayanasamya, 2009). Generally, processes for the
manufacture of aluminum-based metalmatrix composites
(MMCs) include: (1) the liquid mixing process, and (2) the
powder metallurgy process. Isostatic pressing of metallic
and ceramic powders is one of the important
achievements in high technology material processing. In
isostatic compaction, a uniform pressure is applied
simultaneously to all the external surfaces of a powder
(Zhou, 1999). Consequently, CIP provides increased and
more uniform density at a given compaction pressure, and
relatively defect-free compacts when applied to brittle or
fine powders. Another characteristic of the process is the
elimination of lubricant additives. Their absence eliminates
problems associated with lubricant removal prior to or
during final sintering; Densification of a powder body is
dependent upon a number of powder characteristics. The
first group is the material features, e.g., hardness, workhardening and cold-welding responses. The second group
are the geometrical features, e.g., particle shape, particle
size and distribution, and the effect of lubricant additives
that govern their inter particle movement and interlocking
during pressing. This paper deals with the effect of cold
compaction behavior and density by powder metallurgy
route. The hardness values of each sample were
evaluated according to the percentage of reinforcement.
The Micro structural behavior on AlB4C composite was
studied.
MATERIALS AND METHODS
Experimental process

Table 2: Apparent and tap density of powders

S.No.

Properties

Aluminium

(g/cm3)

Apparent

Boron
carbide

0.96

1.23

1.11

1.31

density
2

Tap density

outperform parts machined from a forged blank, probably

as a consequence of fully dense, absolutely uniform and
very fine grained microstructure. Particle reinforced
aluminum alloy matrix composite is one of the best
materials to substitute the conventional structural alloys.
AlB4C metalmatrix composites are considered as new
advanced materials due to their ability to capture neutrons,

The atomized aluminum powder particle size in the range

of 75 m and boron carbide 150 m were purchased from
Sdfine chem ltd, Mumbai, India. The powder was 99.8%
purity and insoluble impurities in the range of 0.2%. The
powder characterization was studied by determining the
apparent density and Tap density of the powder details
were provided in Table 2. To investigate the particle size
and shape by using microscopic study was made with the
scanning electron microscope and the same image is
provided in Fig. 1. The density Dp of the pressed powder
may be calculated.

Where W is the weight of the powder, Vp is the volume of

the powder in die setup
Preparation of Powder Blend
Blending is an operation of thoroughly intermingling of
different powders of the same composition or various
compositions. The main purpose of mixing is to produce
uniform distribution of powder. Various types of blenders

Raja and Sahu 003

Fig.2: Punch and die set assembly

and mills are employed for mixing. Here Pot mill is used
for blending operation. A powder mix corresponding to the
composition Al-95%+B4C-5%, Al-90%+B4C-10%, Al85%+B4C-15% & Al- 80% + B4C-20% respectively here in
referred to as sample-1, 2, 3, & 4. The blending operation
was carried out for 5 hours, it was found to be sufficient
time to attain homogeneity in the powder
Cold Compaction

Fig.3: Hydraulic press

The hydraulic press with suitable punch and die set

assembly as shown in fig (2&3). The blended powder
mixtures mentioned above were cold compacted using
0.60 MN Capacity universal testing machine by Suitable
punch and die set assembly. A known amount of powder
blend was taken and poured into the die setup. After filling
the die setup the load which has been gradually applied
over it. The compacting pressure applied was 15010
MPa, which was maintained for all composite samples.
During compaction, specially prepared zinc sterate was
used as lubricant to avoid powder sticking and for easy
ejection so as to obtain damage free compacts. The
ejection of the compacts was by placing the die on a
hollow cylindrical block and applying pressure. Then finally
the green compact specimen was carefully removed.
Sintering

Fig 4: Density value with respect to applied pressure for various

samples

The cold green compacts were sintered in an electric

muffle furnace at 550100C for a period of 120 minutes.
Normally metals are sintered at 70-80% of the melting
point temperature; certain refractory material may be
sintered at 90% of the melting point. Its time varies from
30 min to several hours. Sintering of powder sequentially
involves the establishment and growth of bonds between
the particles of powder at their areas of contact and
migration of the grain boundaries formed at the bonds.
This has resulted in spheroidization of the pores between
the particles, and the elimination of small pores (and
possibly the growth of larger pores). As the sintering
temperature increases, porosity decreases and shrinkage
increases. Bonds form between the particles during
sintering, and the number of particle bonds increases as
the temperature increases. After the 120 minutes sintering,
it was allowed to cool to room temperature in the furnace
itself.
RESULT AND DISCUSSION
Compressibility Data for various samples
The compressibility data for various samples were drawn
between the density variations with respect to applied load
in fig (1). The applying load value increases in addition

Int'l J. Mech. Eng.

004

Table 3: Properties of various samples

S.No

Samples

Density(g/cm3)

Hardness

Fig.5: SEM micrographs of sample-4 Sintered Al-80%+B4C-20%

value
1

Sample-

2.394

15

2.355

17.4

2.338

19.6

2.318

21

1
2

Sample2

Sample3

Sample4

Fig.4: Hardness values with respect to volume percentage of

B4C

increases with respect to the increment in the volume

fraction of B4C content.
Microstructure and properties

with corresponding density values were increased. The

density of the various samples reduces with increasing the
reinforcement volume.

Microstructure of sintered has been studied for Al matrix

material with 10% & 20% of B4C reinforcement, which is
shown in Fig 5 . The SEM micrograph represents the
presence of B4C reinforcement (Bright contrast particle) in
the Aluminium matrix
composite. The uniform particle
distribution was achieved in both the samples as shown in
Fig. 5 (a) & (d). The pore defects were created in some
areas of the microstructure. The good bonding was
achieved in between the matrix and reinforced materials
as shown inFig.(e)-(f).
CONCLUSION

Hardness value
The hardness values were determined for various samples
by using Rockwell hardness test as shown in figure (3).
The indentation was achieved by using 1/16" ball tip on
the samples for the aluminium alloys. The 100 kgf load
was applied on sample for every indentation. The average
hardness values were determined from the number of
indentations. The Fig.4 shows hardness values were

The experiment was successfully carried out for the cold

compaction of aluminium as matrix and boron carbide
content as reinforcement by using powder metallurgy
route. The volume fraction of reinforcement in the
microstructure as low as 5% and as high as 20% plays a
Major role in the powder consolidated Al-B4C MMCs. The
density of the every sample reduces in a small variation
with respect to the increment percentage of reinforcement
due to the low density value of reinforcement. The

Raja and Sahu 005

hardness values were gradually increasing according to

the percentage of increment in the reinforcement. The
hardness value is very high for the 20% reinforced B4C
sample. Microstructure observations in general revealed a
good distribution & bonding of reinforcement particles
through this method of fabrication.
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