www.mejournal.

orgJournalofMetallurgicalEngineering(ME)Volume4,2015
doi:10.14355/me.2015.04.004

PotentialofRecycledAluminiumCansand
215mSizedEggshellPowderforLowCost
MetalMatrixComposites
J. O. Agunsoye*1, S. A.Bello1,2, A. A. Yekinni3, I. A. Raheem1, M. M. Idehenre1, T. E. Idegbekwu1 A. D.
Oderinde1

1Department

of Metallurgical and Materials Engineering, Faculty of Engineering, University of Lagos, Lagos, Nigeria

2Department

of Materials Science and Engineering, College of Engineering, Kwara State, University, Malete, Nigeria

3DepartmentofMechanicalEngineering,LagosStatePolytechnic,IkoroduLagos,Nigeria
*1

jagunsoye@unilag.edu.ng;2sefiu.bellokwasu.edu.ng;3kunleyk2003@yahoo.com

Abstract
The potentials of recycled aluminium cans with 215 m sized eggshell powders to produce a useful engineering composite
material were investigated. the stir cast method was used to enhance proper mixing of the composite melt prior to pouring
exercise.theprocessinvolvesgradualincreaseoftheeggshellpowderadditionstothealuminiumcanmeltfrom2to12%.the
composite melt was pouredinto a preheated steel die mould to produce 250 x 120 x 120 mm rectangular bars. thebars were
machined to standard samples for mechanical and physical property investigations. morphology of eggshell powders
wasexamined with the aids of scanning electron microscope. the results showed a considerable increase in tensile strength,
youngsmodulusofelasticityandhardnessvalues.theincreaseisattributabletoformationofdislocationloopandpileupdue
toimpingement/hindrancetodislocationmovementbyeggshellpowderswithinthealuminiumcanmatrix.however,therewas
anoticeabledecreaseintensilestrainandimpactenergyrespectively.furthermore,thedevelopedcompositesarelighter(lower
density)thanthecontrolsamplewithouteggshellpowderadditions.
Keywords
StirCast;Potentials;Investigation;MechanicalAnalysis;Density

Introduction
Increaseinrefusegenerationplaceshighburdenonwastemanagementwhichaffectshumanssocialandeconomic
activities. Harnessing waste materials (discarded aluminium cans and eggshells) to make new and useful
engineering materials is means of wealth creation from waste. This research work ultimately contributes to
knowledge in thearea ofrecycling particularly in Lagos citywhere therearehuge wastemanagementproblems
andchallenges.ThereisnobetterplacetocultivatethecultureofrecyclingthanUniversityofLagos;immediate
institutiontoLagoscity.
Materialdevelopmentbeingaformoftechnologicaladvancementisaresultofhumansthoughtandperception.
This is the main distinguishing factor that differentiates human beings from other mammals since evolution of
mankind.Today,manymaterialsinuseareproducedindifferentwaystosatisfyhumanneedforhousing,heating,
furniture, clothes, transportation, entertainment, medical care, defense and all the other trappings of a modern,
civilizedsociety[13].
Metalshavebeenthemostimportantengineeringmaterials;ferrousmetalshavebeenthemostsignificant.Their
applicationsarefoundinmanyengineeringstructures.Amongthenonferrousmetals,aluminiumanditsalloysare
themostproducedfordifferentapplicationsincludingtransport,packaging,buildingandconstructionbecauseof
itslightness,corrosionresistance,damagetolerance,andeaseofformability[4].Thisisnowbeingchallengedby
other important engineering materials such as polymer, ceramics and composites because of their high specific
mechanical properties. Composites are mixtures of at least two components, the matrix (continuous phase) and
reinforcement (discontinuous phase), having better properties than when each component is used alone. In

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JournalofMetallurgicalEngineering(ME)Volume4,2015www.mejournal.org

accordance with matrix, they are classified as metal, ceramic and polymer matrix composites. Aluminium and
magnesiumarecommonlyusedmetalsasmatricesformetalmatrixcomposite(MMCs)productions.Aluminiumis
producedfrombauxiteswhoseworldbiggestproducersin2008areAustralia,BrazilandChinain30,13and10%
respectively [7]. However, production of aluminium from bauxites not only consumes a great amount of energy
butalsoemitshazardousgasessuchascarbondioxide(CO2)andsomeflorocarbons(FC)whichimpactnegatively
on environment. CO2 because of its ability to retain heat, has been rated as one of gases that cause the global
warming, thereby causing the melting of global ice, exposing us to dangerous cosmic rays. Aluminium industry
alone accounts for 1% of global greenhouse gas emissions [5]. Vast use of aluminium and its alloys in many
engineeringstructureshascalledforincreasingsupplyofbauxite.Thereforethemenacesassociatedwithprimary
productionofaluminiumfrombauxiteincrease.Bauxitemininghassignificantnegativeenvironmentalandsocial
impacts in Jamaica, Australia, India and Brazil including the contamination of water and fishing supplies, the
destructionoflandanddisplacementoflocalcommunities.Moreover,menacesassociatedwithaluminiumdonot
endinbauxiteminingalone.
In Nigeria, the use of aluminium cans in packaging has almost replaced the traditional glass bottle packaging
systems.Highconsumptionsofdrinkspackagedwithaluminiumcanshaveincreasedthenumberofaluminium
canslitteringtheenvironments.Indiscriminatedumpingofaluminiumcanandotherproductsaftertheirservice
life has contributed to other forms of environmental issues (seeFigure1). In order to reduce/eliminate problems
associatedwithwastealuminiumproducts,thereisaneedforrecyclingofwastealuminiummaterials.Critically,
thealuminiumrecyclingprocessusesonly5%oftheenergyrequiredforitsinitialextractionandprocessingand
10%oftheinitialcapitalequipmentcosts.Recyclingalsosaves97%ofthegreenhousegasemissionsgeneratedin
theprimaryproductionprocess[5].Eggshellisthenonediblebyproductsofeggswithlittleornosaleablevalues
[6].PreviousstudybyHusseinetal,(2011)[7]revealedthattheeggshellcontains95%weightofcalciumcarbonate
in the form of calcites and 5% by weight of organic materials. Indiscriminate dumping of eggshell has been
reported as one of the causes of the worst environmental problems, most especially in countries having highly
developedeggproductindustries.Shuhadahetal,(2008)[8]reportedthatmorethan150,000tonsofeggshellsare
disposedinlandfillsintheUnitedStateofAmerica.InNigeria,eggshellsfromhatcheriesandfastfoodindustries
aredumpedincanals,gutters,riversandevenonopengrounds.Thesepreventnormalflowofwater,becoming
cloggedandreleasingbadodour.Benefitsofactivecompoundssuchascalcite,uronicandsalicacidsineggshells
canberealizedviaconversionoftheeggshellsintousefulmaterialssuchasfertilizerforimprovingcropgrowth;
humanandanimalnutrition;buildingmaterialsandparticulatepowderformetalandpolymerreinforcementin
compositedevelopment.

FIG.1DISCARDEDWASTESINCANAL

Agunsoyeetal,(2014)[9]havestudiedeffectsofcocosnucifera(coconutshell)onthemechanicalandtribological
propertiesofrecycledwastealuminiumcancomposites.Theirexperimentalresultsrevealedthattensilestrength
and wear resistance of the composites increased as volume fractions of coconut shell increased whereas there is
light reduction in impact energy absorbed by the composites. Also aluminium cansreinforced with 10%volume
fractionofcoconutshellparticlesatfinestsizeused(215m)displayedthehighesttensilestrengthandoptimum
wearresistance.Hassanetal,(2012)[10]developedpolyester/eggshellparticulatecomposites.Theirexperimental
resultsshowed that carbonised eggshells enhanced the mechanical properties of the polyester matrix composites

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www.mejournal.orgJournalofMetallurgicalEngineering(ME)Volume4,2015

morethanuncarbonisedeggshells.Effectsofcastingmethodsandcoolingmediawerestudiedonaluminiumalloy
(AlMgSi)andtheresultrevealedthatinadditiontodependenceofhardnessvaluesoftheproducedsampleson
cooling media, samples produced from air cooled dies have the best mechanical properties whereas those
producedbysandcastinghavecomparablehardnessvaluesbutlowertensilestrength[11].Theeffectsofparticle
size and volume fractions of Al2O3 on the thermal conductivities properties of Al2O3 particulate reinforced
aluminium composites (Al/ Al2O3MMC) were investigated and the citations revealed that the thermal
conductivitiesofthecompositesarehigherwithanAl2O3particlesizeof15mthanwithaparticlesizeof30m
[12].
Inthispresentwork,aluminiumcan/eggshellparticlecompositeshavebeenproduced.Effectsof%weightofthe
eggshell particle addition to the aluminium cans on physical and mechanical properties of the produced metal
matrix composites have been investigated. This research work was aimed at providing solution to problems of
poormanagementofdiscardedaluminiumcansandeggshellswithinNigeria.
Materials and Methods
Materials
Waste aluminium cans were obtained from the Waste Management Centre of University of Lagos and eggshells
werecollectedfromFastFoodCentre,JajaHallofUniversityofLagos.
ProcessingofEggshells
10kgeggshellswererinsedinwatertoremovethemembraneanddriedinthesunfor6hours.Thedriedeggshells
were crushed manually using mortar and pestle (see Figure 2) and finally pulverized using a grinding machine.
Theeggshellpowdersobtainedweresievedintodifferentmeshsizesusingsievesofdifferentsizes:75,150,212,
300 and 600 m. Eggshell powders retained in each sieve were packed in sample bottles and labelled
accordingly.%powderretainsineachsievewerecalculated(seeTable1)usingequation1.
% Sample retain

mass retain
100 (1)
total mass

215 m sized eggshell powders of highest % retain in the sieve were used as reinforcement for development of
metal matrix aluminium can composites. Morphology of the eggshell particles was examined with the use of
scanning electron microscope (SEM): ASPEX 3020. The sample was placed in a sample cavity of a standard
aluminiumplateinasamplestandandscannedinavacuumat34.0kVandbeamenergyof63.4%.Thescanning
electronmicrograph(SEMg)oftheeggshellwaspresentedinFigure3.

FIG.3SEMGOFTHE215mEGGSHELLPOWDERS

FIG.2GRINDINGOFEGGSHELLS

TABLE1%RETAINOFEGGSHELLPOWDERSINEACHSIEVE

26

Meshsizes(m)

75

150

212

300

600

%retain

8.0

10.4

44.3

32.3

5.0

JournalofMetallurgicalEngineering(ME)Volume4,2015www.mejournal.org

DevelopmentofComposites
5kgaluminiumcanswereheatedinacrucibleusinganoilfiredpitfurnaceto850 0C.Slag(duetodecorativecoat
onthecans)floatingonthemeltofthealuminiumcanwasscreamedoffafterwhichthemeltwascastintosmall
diameterballsthroughatomizationprocess(inaccordancewithBelloetal,2014[13]).Ballswereweighedandthe
percentage mass loss due to slag formation was calculated using equation 2. The elemental analysis of the
representativesampleoftheballwascarriedoutusingHilgerPolyvacSpectrometer,ModelE980C.
%mass loss=

mass of Al cans mass of Al can balls

100 (2)
mass of Al cans

Ballsweredividedinto7differentpartseachofmass500g.Thefirstpackoftheballswasreheatedto67050 0C
andthenpouredintoametallicmould.Themeltwasleftinthemoulduntilitcooledtoroomtemperature.This
givesacontrolaluminiumcansample.
Another pack of aluminium balls was heated to 850 0C. 10 g of 215 m eggshell powders (equivalent 2 %) was
addedtothemelt.Thecompositemeltwasstirreduntiltemperaturehadfallento67050 0C.Then,thecomposite
melt was poured into the mould and then left to cool to the room temperature. The process was repeated with
increasing%weightofeggshellpowderadditions(upto12%)tothealuminiumcanmelt.Samplesobtainedfrom
differentbatchesofproductionswerelabelledforidentificationpurpose(seeFigure4).
Masses of the 60 x 10 x 10 mm samples of control and the composites were measured with the aids of a digital
Pioneerbalance(byOhausCorporation,USA),havingamaximumcapacityandreadabilityof210and0.0001g.
Thedensityofeachsamplewasdeterminedusingequation3.
Density

mass
(3)
volume

Representativesamplesfromeachbatchofproductionweremachinedintostandardsizesformechanicalanalysis.
Standard tensile samples as shown on Figure 5 were subjected to tensile loading at a strain rate of 103 s1 until
fracturesoccurredafternecking.Theimpactenergiesofthecontrolandtheproducedcompositesweremeasured
withtheaidsofAveryDenisonUniversalImpactTestingMachine.Thenotched60x10x10samplesofthecontrol
and produced composites were subjected to a striking energy of 300 J by a pendulum released from the upper
positionequivalenttocharpyimpacttest.Theimpactenergyabsorbedbyeachsampleisnotedandrecorded.The
hardness values of the produced materials were determined through Vickers approach using square based
pyramid indenter. A right pyramid indenter was pressed on the surface of each sample by a load of 30 kgf for
dwelltimeof15seconds.Thetwodiagonalsoftheindentationleftonthesurfaceofthematerialafterremovalof
the load are measured by the machine. The Vickers hardness is automatically measured by the machine by
dividingthekgfloadbythesquaremmareaofindentation.

FIG.4ALUMINIUMCAN/EGGSHELLCOMPOSITESFIG.5TENSILESAMPLES

Results and Discussion

The%compositionofthealuminiumcanballsispresentedonTable2.

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www.mejournal.orgJournalofMetallurgicalEngineering(ME)Volume4,2015

TABLE2%COMPOSITIONOFALUMINIUMCANBALLS

Element

Al

Si

Fe

Cu

Mn

Mg

Ti

%comp

98.10

0.53

0.51

0.03

0.77

0.02

0.04

%MassLoss
Themasslossduringremeltingofaluminiumcanswas1.5kg,equivalentto30%oftheoriginalmass(5kg)ofthe
aluminium cans. The loss was attributable to the formation of slag floating on the surface of the melt of the
aluminiumcans.Theslagwasformedfromthedecorativecoatingsontheoutersurfaceofthecans.
Densities
Figure6showsthedecreaseindensitiesofthecontrolandthealuminiumcan/eggshellcompositesasthe%weight
ofeggshelladditionsincreased.Thisisattributabletolighterweightofeggshellpowdersthanthatofaluminium
cans.

FIG.6VARIATIONOFDENSITIESWITH%EGGSHELLPOWDERADDITIONS

TensileProperties
Figures79showthevariationoftensilepropertieswith%weightofeggshellpowderadditions.Figure7revealsan
increaseintensilestrengthatbreakfrom5MPaofthecastaluminiumcanwith0%eggshellpowderadditionstoa
maximum of 37.42 MPa of aluminium can/12% eggshell composites. Figure 8 indicates a minimum value of
Youngsmodulus(3158.2MPa)ofthecastofaluminiumcanwith0%weightofeggshelladditiontoamaximumof
4697.6MPaat12%eggshellpowderadditions.Thisisanindicationofincreaseinthestrengthsorresistanceswhich
thealuminiumcan/eggshellcompositesofferedtothedeformationduringtensiletest.Figure9declaresadecrease
intensilestrainasthe%weightofeggshellpowderadditionstothemeltofaluminiumcanincreases.Thisimplies
alowerductilityofthealuminiumcan/eggshellcompositesthanthecastofaluminiumcan(control).

FIG.7TENSILESTRESSATBREAKWITH%WEIGHTOFEGGSHELLPOWDERS

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www.mejournal.orgJournalofMetallurgicalEngineering(ME)Volume4,2015
doi:10.14355/me.2015.04.004

FIG.8YOUNGSMODULUSOFELASTICITYWITH%WEIGHTOF
EGGSHELLPOWDERS

FIG.9TENSILESTRAINWITH%WEIGHTOFEGGSHELL
POWDERS

ImpactEnergy
Figure10showsavariationbetweenimpactenergyabsorbedduringcharpyimpacttestand%weightofeggshell
additions. It revealed a decrease in the energy absorbed by the tested samples as the eggshell powder additions
increased. This is an indication of the lower fracture toughness of the produced aluminium/eggshell composites
thanthecastaluminiumcan.ThisagreesperfectlywithFigure9.ThedecreasingtrendrevealedbothinFigures9
10areattributabletobrittlenessoftheeggshellpowders.

FIG.10IMPACTENERGYWITH%WEIGHTOFEGGSHELL
POWDERS

FIG.11HARDNESSVALUESWITH%WEIGHTOFEGGSHELL
POWDERS

HardnessValues
Figure 11 describes the resistance of tested samples to surface indentation during hardness value measurement
through Vickers approach. It revealed an increase in the hardness values as % weight of eggshell powders
additions increased. The slope of the curve at 6% weight eggshell powders addition is steeper than others. This
implieshigherincreaseinhardnessvaluesat6%weighteggshellpowdersaddition.Figure11agreesperfectlywith
Figures 67. The increase in Youngs modulus of elasticity, tensile strength at break and hardness values is
attributable to formation of dislocation loop. During deformation of the examined samples, eggshell powders
impinge/block dislocation movement. This leads to dislocation pileup or loop. The dislocation pileup/loop
increases as the number of grain boundaries or % weight of eggshell powders increases. Therefore, for further
dislocation movement to occur, higher external pressure must be furnished. This is an indication of increase in
strength, rigidity and hardness values. Hence, the aluminium can/eggshell powders produced can be used in a
relatively high strength applications where the excessively high ductilityand fracture toughness are nota prime
consideration.
Conclusions
Fromresultsanddiscussionofthisresearchwork,thefollowingconclusioncanbeinferred:
1.

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Lighterengineeringmaterialshavebeenproducedfromrecycledaluminiumcanand215msizedeggshell
powders.

www.mejournal.orgJournalofMetallurgicalEngineering(ME)Volume4,2015

2.

The produced aluminium can/eggshell metal matrix composites can be used in relatively high strength
applicationwhereexcessivelyhighductilityandfracturetoughnessarenotaprerequisite.

3.

Thetensilestrength,modulusofelasticityandhardnessincreasewithhigher%weightofeggshellpowder
additions.

4.

The increase in Youngs modulus of elasticity is an indication of enhancement in the rigidity of the
aluminiumcan/eggshellcomposites.

5.

The reduction in tensile strain and impact energy absorbed with an increment in % weight of eggshell
powder additions is an indication of decrease in ductility and fracture toughness of the aluminium
can/eggshellcomposites.Hence,suchadecreaseisattributabletobrittlenessofeggshellpowders.

6.

Eggshellpowdersarepotentialmaterialsforreinforcement.However,itimpactsnegativelyontheductility
andimpacttoughnessofthematerials.

7.

Discarded aluminium cans are potential matrix materials which can be harnessed into development of
usefulengineeringmaterials.

ACKNOWLEDGMENT

Authors wish to appreciate Prof. S. B. Hassan of Department of Metallurgical and Materials Engineering for his
assistanceinmakingthisworkareality.
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