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CHAPTER 2
LITERATURE SURVEY
2.1
INTRODUCTION
Extensive survey of available literature was carried. A summary of
2.
3.
Fabrication techniques
4.
Microstructural investigations
5.
Design of experiments
6.
7.
Wear testing
8.
Property evaluation
9.
Investigators
Matrix
Dispersoids
Remarks
Mahagundappa
Benal and
Shivanand (2007)
Al 6061
9wt.% SiC
particulates
and 0, 1, 3,
5wt.% E6glass
fibre
Wear rate
increased with
increase in the
sliding distance
and decrease with
increasing the
weight percentage
of reinforcing
materials.
Basavarajappa et al
(2007)
Al 2219
15wt.%SiCp
and
3wt.%graphite
particles
The graphitic
composite
exhibited less
degree of
subsurface
deformation.
10
Matrix
Al 8090
Dispersoids
15vol.%SiCp
Du Jun et al (2007)
SAE321
alloy
Al2O3 and
carbon short
fibre
Ramachandra and
Radhakrishna
(2007)
Al (12wt.%
Si) alloy
15wt.% of
flyash
particulates
Al 6061
SiC, Al2O3
Olivier Beffort et al
(2007)
Pure
aluminium
SiC particles
Uyyuru et al (2006)
Al6Si alloy
SiC particles
Remarks
Composite
exhibited higher
wear resistance.
Friction coefficient
is always higher in
the composite.
Heat6treatment was
beneficial to the
improvement of
dry sliding friction
and wear property
of the composites.
Wear resistance of
composite
increased with
increase in flyash
content, but
decreases with
increase in normal
load, and track
velocity.
Composites
possess higher
microhardness and
lower wear rates.
Hardness of
composite was
increased. Addition
of the elements
Mg, Zn and Cu
does not
significantly
improve the
bending strength of
as6cast composite.
Applied load is
most important
parameter on wear
performance.
11
Matrix
Al 6061
Dispersoids
20wt.% Al2O3
particles
10
Kilickap et al
(2005)
Pure
Aluminium
20wt.% SiC
particles with
an average
size of 24 Hm
11
Ramesh et al
(2005)
Al 6061
TiO2
12
Mandal et al (2004)
Pure
aluminium
Short steel
fiber
13
Narender Singh et
al (2004)
Pure
aluminium
10% SiCp
14
Cambronero et al
(2003)
AA 7015
15
Korkut (2003)
Al 2024
Al2O3
particulates
(15 vol.%)
16
AlSiCu
Mg(Ni)
alloy
SiCp
Remarks
Improvement in
ductility as well as
strength of
composite.
Higher cutting
speeds and lower
feed rates produced
better surface
quality of
composite.
Wear coefficient
decreased at higher
loads and larger
sliding distances.
Wear resistance
and coefficient of
friction of
composites
improved.
For larger current
settings in EDM
MRR and TWR
found to be higher.
Hardness is
increased by the
ceramic addition
and better wear
behaviour of
composite.
Under severe wear
condition Al2O3
particulates were
broken and
particulates
affected wear
behavior badly.
Wear decreased
with increase of the
sliding speed.
12
Matrix
Al 2024
Dispersoids
SiC particles
Remarks
The presence of
SiC particles
refined the
structure of the
matrix. The peak
hardness of
composites is
slightly higher than
that for Al 2024
alloy.
18
Sharma (2001)
Al 6061
Garnet
particles (90
150 Hm)
Wear resistance
was superior to that
of unreinforced
matrix alloy. It
increases with
increasing wt.% of
garnet. The average
coefficient of
friction of the
composite is lesser
than that of matrix
alloy.
19
Tiancheng Zhang
and Li (2001)
Pure
aluminium
1wt.%Y2O3
powder
Improved dry
sliding wear
properties of
composites.
20
Rong Chen et al
(2000)
A356
aluminum
alloy
15 vol.%
Silicon
carbide
particles
21
Lin et al (1998a)
Al 6061
22
Szu Ying Yu et al
(1997)
Al 6061
SiC particles
Wear resistance of
the composite was
increased.
13
Matrix
A16Li alloys
Dispersoids
10620 wt.% of
SiC
particulates
Remarks
Tool wear was
reduced during
machining.
24
A356 alloy
Graphite
particles
Wear of the
composite reduced.
25
Al 2024
Molybdenum
powder (15
vol.%)
With increasing
load, the wear rate
increases quickly
and the wear
mechanism is
ploughing with
delamination.
26
Al 2014, Al
6061
SiC particles
(3 20Hm)
Maximum wear
resistance was
achieved when the
composites were in
the peak6aged
condition.
27
Hall Jody et al
(1994)
Al 2124
SiC particles
Increased particle
fracture with
increased SiCp size
and volume
fraction.
28
Doel et al (1993)
Al 7075
SiC particles
As particle size is
increased from 13
to 60Hm toughness
of composites was
increased.
29
A356 alloy
10620 vol.%
of SiC
particles
Sliding wear
resistance of
aluminium6silicon
alloys varies with
the applied
pressure.
30
Prasad and Mc
Connell (1991)
Al6Si alloy
20 vol.% of
SiC particles.
Wear resistance
was improved.
14
2.3
15
FABRICATION TECHNIQUES
The most widely applied methods for the production of composites
16
17
18
until the alloy reached a semi solid state. At this temperature, the
reinforcement particles were added and stirring were continued until particle
and matrix wetting occurred. The size of the garnet particles was varied
between 30650m.
2.5
MICROSTRUCTURAL INVESTIGATIONS
The main objective of the microstructure study is to find the
19
DESIGN OF EXPERIMENTS
Design of experiments (DOE) is a technique for studying any
20
21
They also stated that the tensile strength of the composite decreased with
higher extrusion ratio (25:1) due to the reduced aspect ratio of SiC whiskers.
Huda et al (1994) developed a model for estimating the hardness of
aluminum alloy reinforced with alumina particles. A design consisting of
twelve experiments was used to develop the model. They also applied
response surface methodology to study the effect of manufacturing
parameters on the hardness of the composite. They found that higher hardness
was obtained with a combination of high temperature and high volume
fraction of reinforcement.
2.7
22
23
using a L27orthogonal array with three levels for each factor. The network
was trained using Error Back6Propagation Training Algorithm (EBPTA).
They reported that, the performance of ANN prediction model though
adequate, can be improved by defining more number of levels for input
process parameters.
Mohammed Hayajneh et al (2009) predicted the wear loss of
aluminium composites using Artificial Neural Network. They coded the
experimental results prior to training in a feed forward back propagation
artificial neural network. A satisfactory agreement between the experimental
and ANN was obtained when the model was tested.
Hafizpour et al (2009) developed neural network model to predict
the densification of composite powders. They used back propagation (BP)
learning algorithm with two hidden layers to train the experimental data. The
neural network model gave better values when tested.
Abdullah Kurt (2009) developed a neural network model to predict
the cutting tool stresses. A back propagation algorithm was developed for
training the network. The best fitting set was obtained with ten neurons in the
hidden layer in the model.
Rapetto et al (2009) developed neural network model to determine
the relationship between the roughness parameter. They found that, the neural
network was able to prove the correlation between the roughness parameters.
Raghuprased et al (2009) predicted compressive strength using
neural network. They found that the proposed neural network model gave
good prediction of the values.
24
WEAR TESTING
Wear is a material removal from a component by mechanical attack
of solids. Adhesive wear occurs when two solid surfaces slide over one
another under pressure. Abrasive wear occurs when material is removed from
a surface during contact with hard particles. The particles either may be
present at the surface of a second material or may exist as loose particles
25
26
27
28
29
PROPERTY EVALUATION
Various mechanical properties such as hardness, tensile strength,
30
31
32
33
that, the strength of the composites increased with decreasing size of the SiC
particulates.
Stone and Tsakiropoulos (1994) reported the heat treatment of
aluminium composites reinforced with SiC particles. The heat treatment cycle
comprised of solution treatment for 1h at 803K followed by a cold water
quench and subsequent ageing at 463K for varying times between 30min to
8h followed by a cold water quench. The results revealed that when the
reinforcement becomes more uniformly distributed throughout the matrix, the
cracking tendency at the edges became less severe during heat treatment. The
wear rate decreased with increase in ageing duration.
Slipenyuk et al (2004) investigated the effect of heat treatment on
the mechanical properties of Al6SiCp composites. The specimens were
solution treated for 1h at 803K followed by water quenching to room
temperature. It was observed ultimate strength was increased as a result of
heat treatment.
Rong Chen et al (2000a) investigated the fretting wear behaviour of
A356 aluminium alloy reinforced by 15vol.%,10m SiC particles under T6
conditions. They found that the composites with heat treatment showed a low
coefficient of friction during the initial fretting stages. The hardness and yield
strength of composites showed an increase after heat treatment.
Sug Won Kim et al (2003a) investigated the effect of heat treatment
on the wear resistance of Al/SiCp composites. The specimens were treated in
a solution for 10h at 773K and then aged at 430K for various periods of time.
They found that the composites exhibited higher hardness. Aluminium
composites reinforced with 10m SiCp was found to have the lowest wear
loss.
34
Sawla and Das (2004) investigated the two body abrasive wear of
aluminium composites with heat treatment. The hardness of the composites
was improved by as much as 33% due to combined effect of heat treatment
and reinforcement of 15wt. % SiC particles. The wear constant decreased
with load. Heat treated alloy and composite showed increased hardness.
Olivier Beffort et al (2007a) studied the mechanical properties of
heat treated composites. The composite specimens were subjected to solution
treatment and artificial ageing. They found that, the dominant failure
mechanism in silicon carbide reinforced composite was SiC intra6particulate
fracture.
2.11
35
of composites caused extremely rapid flank wear in the drilling tools. Among
the drilling tools studied, Polycrystalline diamond (PCD) drills possessed the
highest resistance to abrasion. High speed steel (HSS) drills were unsuitable
for drilling MMCs because of very high tool wear, poor drilled hole quality
and higher drilling forces induced. PCD drills induced lowest drilling forces.
Yusuf Keskin et al (2006) investigated the effects of machining
parameters on surface roughness in EDM. Surface roughness showed an
increasing trend with increase in the discharge duration. The interaction
between spark time and power to surface roughness was found to be
statistically significant.
Narcls Pellicer et al (2009) studied the influence of process
parameters on surface quality in EDM of AISIH13 steel. They found that,
metal removal rate and surface roughness increased with discharge current.
Pulse6off variation affects metal removal rate, but its behaviour is not linear
due to the interactions with other parameters like voltage, current.
El6Taweel (2009) investigated the relationship between process
parameters in electro discharge machining of CK45 steel with Al6Cu6Si6TiC
composite electrode tool. They used titanium carbide percent, peak current,
dielectric flushing pressure and pulse6on time as input process parameters.
The optimal process parameter settings obtained were TiC percent of 18%,
peak current 6A, flushing pressure 1.2 MPa, and pulse6on6time 182 s, for
achieving maximum metal removal rate and minimum tool wear rate.
Ponappa et al (2009) investigated the effect of process parameters
such as pulse on time, pulse6off time, voltage gap and servo speed on surface
finish and reduced taper during EDM of magnesium nano alumina
composites. They found that the pulse6on6time and the servo speed are the
most influencing factors on surface finish and reduced taper.
36