Final 4d Project 1

Tribological Analysis of Hypereutectic Al-Si Alloys With and Without Addition of Titanium
Chapter 1
INTRODUCTION
A composite material is a material made from two or more constituent materials with
significantly different physical or chemical properties that, when combined, produce a
material with characteristics different from the individual components.
1.1 Alloy
An alloy is a material that has metallic properties and is formed by combination of two
or more chemical elements of which at least one is a metal.
The metallic atoms must dominate in its chemical composition and the metallic bond in
its crystal structure. Commonly, alloys have different properties from those of the
component elements. An alloy of a metal is made by combining it with one or more other
metals or non-metals that often enhances its properties. For example, steel is stronger
than iron which its primary element. The physical properties, such as density and
conductivity, of an alloy may not differ greatly from those of its component elements, but
engineering properties such as tensile strength and shear strength may be considerably
different from those of the constituent materials.
1.2 Classification of Composites

The First Level of classification is usually made with respect to the matrix constituent.
The major composite classes include
1. Polymer Matrix Composites (PMC’s)

2. Metal Matrix Composites (MMC’s)
3. Ceramic Matrix Composite (CMC’s).
The Second Level of classification refers to the reinforcement form
1. Fiber Reinforced Composites

2. Laminar Composites
3. Particulate Composites.
1.2.1 Classification Based on Matrix
The First level of Classification is usually made with respect to the matrix constituent.
The Fig. 1.1 indicates classification of MMC’s based on matrices.
Dept. of Mechanical Engg., RIT, Hassan 1

Composite materials
Matrices
Metal matrix Ceramic

Polymer
composites Matrix
Matrix
(MMC) Composites
Composites
(CMC)
1. Thermoset
es (PMC)
2. Thermoplastic
3. Rubber
Fig. 1.1 Classification based on matrices
 Metal Matrix Composite (MMC)

A Metal Matrix Composite (MMC) is composite material with at least two
constituent parts, one being a metal necessarily, the other material may be a
different metal or another material, such as a ceramic or organic compound.
1.2.2 Classification Based on Reinforcement
 Particulate Composites
Particle reinforced composite are cost effective in automotive and aerospace industries
because of their ease of fabrication and mechanical properties that offers during working
condition. Particle reinforced composites although having a hard reinforcing dispersed
phase differ from the dispersion harden materials in the sense that they have higher
volume fraction of dispersed, smaller size of particles and inter particle spacing. With
particle based reinforced composites such as tungsten-carbide-cobalt, the reinforcing
space is the principal load-bearing phase and the matrix is used for transferring the load.
 Fibrous Composites
Short-fiber reinforced composites: Short-fiber reinforced composites consist of a matrix
reinforced by a dispersed phase in form of discontinuous fibers .
 Composites with random orientation of fibers.
 Composites with preferred orientation of fibers.

Long-fiber reinforced composites: Long-fiber reinforced composites consist of a matrix

reinforced by a dispersed phase in form of continuous fibers.
 Unidirectional orientation of fibers.

 Bidirectional orientation of fibers (woven).
 Laminate Composites
Laminate Composites are found is as many combinations as the number of materials.

They can be describing as materials comprising of layers of materials bonded together.
These may be of several layers of two more metal materials occurring alternatively or in a
determined order more than once, and in as many numbers as required for a specific
purpose.
1.3 Aluminium
Aluminium is one of the most abundant metals available in the earth's crust as bauxite
with wide range of applications in the modem world. There are many reasons for
aluminium's continued expansion into newer and wider fields of application. Light
weight, excellent specific strength, high thermal and electrical conductivities, high
reflectivity, good corrosion resistance, excellent workability, and attractive appearance
are some of aluminium's most appealing properties. However, its relatively low strength
and poor cast ability limit its use largely to the production of rotor castings for electrical
motors and other applications in which high electrical conductivity is required. The costs
involved in producing aluminium are high compared to steel production, as the energy
requirements to reduce the metal from the oxide is much higher. However, due to the
higher specific strength of aluminium alloys, a comparative higher corrosion resistance
due to the formation of a stable oxide layer and ease of working results in aluminium
alloys being competitive with ferrous alloys in engineering applications . The Aluminium
Association’s Designations and Chemical Composition Limits for Aluminium Alloys in
the Form of Castings and Ingot lists for each alloy 10 specific alloying elements and also
have a column for “others”. Not all of the listed elements are major alloying ingredients
in terms of an alloys intended uses; and some major elements in one alloy are not major
elements in another. Also, some elements, like Sr for example, can be very important to
microstructure control and mechanical properties but are not specifically identified in the
Aluminium Association document and are instead are merely included in the category
“others”. For the purposes of understanding their effects and importance, alloying

elements for the majority of alloys are probably best classified as major, minor,
microstructure modifiers or impurities; understanding, however, that impurity elements in
some alloys might be major elements in others.
➢ Major elements typically include silicon (Si), copper (Cu) and magnesium (Mg).
➢ Minor elements include nickel (Ni) and tin (Sn) -- found largely in alloys that
likely would not be used in high integrity die castings.
➢ Microstructure modifying elements include titanium (Ti), boron (B), strontium
(Sr), phosphorus (P), beryllium (Be), manganese (Mn) and chromium (Cr).
➢ Impurity elements would typically include iron (Fe), chromium (Cr) and zinc
(Zn).
1.4 Aluminium Alloys

In recent years aluminium alloys are widely used in automotive industries. This is
particularly due to the real need to weight saving for more reduction of fuel
consumption. The wide popularity of Al–Si alloys in the automobile industry stems from
their high strength to weight ratio, excellent casting characteristics, good mechanical
properties, low coefficient of thermal expansion, high thermal conductivity and high
corrosion resistance, high wear resistance, high strength-to-weight ratio, excellent
castability, hot tearing resistance, good weld ability etc which makes them attractive
candidate material in many Tribological applications, aerospace and other engineering
sectors where they can successfully replace ferrous components in heavy wear
applications. These applications demand the study of techniques to improve the wear
properties of these alloys. For this purpose, many researches had been done to enhance
their wear properties. Most common applications of aluminium silicon alloys are
components like connecting rods, pistons, air conditioner compressors, engine blocks,
cylinder liners, brake drums etc. The improvement in the Tribological properties
depends on number of material-related properties like shape, size and size distribution
of the second-phase particles. With the development of automobile industry, the need of
hypereutectic Al-Si alloys is increasing greatly. modern development in the field of
science and technology demands the developments of advanced engineering materials for
various engineering applications, especially in the field of transportation, aerospace and
military engineering related areas. These area demands light weight high strength having
good tribological properties. Such demands can only be met by development and
processing of aluminum metal matrix composite materials. The main challenge in the

development and processing of engineering materials is to control the microstructure,

mechanical properties and cost of the product through optimizing the chemical
composition , processing method and heat treatment. This requires the sound theoretical
and practical knowledge of the materials engineers.
1.5 Designation of Aluminium alloys

particularly due to the real need to weight saving for more reduction of fuel consumption.
The typical alloying elements are copper, magnesium, manganese, silicon, and zinc.
Surfaces of aluminium alloys have a brilliant lustre in dry environment due to the
formation of a shielding layer of aluminium oxide. Aluminium alloys of the 4xxx, 5xxx
and 6xxx series, containing major elemental additives of Mg and Si, are now being used
to replace steel panels if various automobile industries. Due to such reasons, these alloys
were subject of several scientific studies in the past few years
On the basis of the major alloying element, the aluminium alloys are designated
according to the Aluminium Association Wrought Alloy Designation System which
consists of four numerical digits.
Table 1.1 Designation of aluminium alloys and their applications
Alloy Main alloying element Applications

1xxx Mostly pure aluminium, no major Electrical and chemical
alloying additions industries
2xxx Copper Aircraft components
3xxx Manganese Architectural applications
4xxx Silicon Welding rods, automobile
parts
5xxx Magnesium Boat hulls, marine
industries
6xxx Magnesium and silicon Architectural extrusions
7xxx Zinc Aircraft components
8xxx Other elements (e.g., Fe, Ni or Ti)
9xxx Unassigned

1.6 Properties of Aluminium Alloys

A wide range of physical and mechanical properties can be obtained from very pure
aluminium. The different properties are:
1) Aluminium has a density of about 2.7g/cc which is one third (approximately) the
value of steel.
2) Unlike steel, aluminium prevents progressive oxidation by formation of a protective
oxide layer on its surface on exposure to air.
3) Aluminium alloys exhibit excellent electrical and thermal conductivities. The thermal
conductivity of aluminium is twice that of copper.
1.7 Aluminium-Silicon Alloy

Aluminium-Silicon alloys are of greater importance to engineering industries as they
exhibit high strength to weight ratio, high wear resistance, low density, low coefficient of
thermal expansion etc. Silicon imparts high fluidity and low shrinkage, which result in
good castability and weldability. Al-Si alloys are designated 4xxx alloys according to the
Aluminium Association Wrought Alloy Designation System. The major features of the
4xxx series are:
a. Heat treatable
b. Good flow characteristics, medium strength
c. Easily joined, especially by brazing and soldering
There are two major uses of the 4xxx series – for forging and weld filler alloy. These
both applications are due to the excellent flow characteristics provided by relatively high
silicon content.
Effects of silicon in the Al-Si alloys are as follows:
i. Thermal expansion is reduced substantially by silicon.
ii. Magnetic susceptibility is only slightly decreased by silicon.
iii. The lattice parameter is decreased slightly by silicon.
iv. Machinability is poor because of the hardness of the silicon.
Although many investigations exist in literature and based on the above discussion, it is
evident that there is enough scope for further research of Al-Si alloys especially their
mechanical properties.
1.8 Problem Identification

particularly due to the real need to weight saving for more reduction of fuel

consumption. The wide popularity of Al–Si alloys in the automobile industry stems from
their high strength to weight ratio, excellent casting characteristics, good mechanical
properties, low coefficient of thermal expansion, high thermal conductivity and high
corrosion resistance, high wear resistance, high strength-to-weight ratio, excellent
castability, hot tearing resistance, good weld ability etc which makes them attractive
candidate material in many Tribological applications, aerospace and other engineering
sectors where they can successfully replace ferrous components in heavy wear
applications. These applications demand the study of techniques to improve the wear
properties of these alloys. For this purpose, many researches had been done to enhance
their wear properties. Most common applications of aluminium silicon alloys are
components like connecting rods, pistons, air conditioner compressors, engine blocks,
cylinder liners, brake drums etc. The improvement in the Tribological properties
depends on number of material-related properties like shape, size and size distribution
of the second-phase particles. With the development of automobile industry, the need of
hypereutectic Al-Si alloys is increasing greatly.
Modern development in the field of science and technology demands the developments of
advanced engineering materials for various engineering applications, especially in the
field of transportation, aerospace and military engineering related areas. These area
demands light weight high strength having good tribological properties.
Such demands can only be met by development and processing of aluminium metal
matrix composite materials. The main challenge in the development and processing of
engineering materials is to control the microstructure, mechanical properties and cost of
the product through optimizing the chemical composition , processing method and heat
treatment. This requires the sound theoretical and practical knowledge of the materials
engineers.

Chapter 2
LITERATURE SURVEY
Metal matrix composites are a combination of two phases, matrix and the reinforcement.
Matrices can be selected from a number of Aluminium alloys example AA 2000, 6000,
7000, A356 and many reinforcement types SiC, B4C, Al2O3 etc. are available in different
sizes, morphologies (particulates, short fibers, long fibers and platelets) and volume
fractions. These reinforcements can be combined with the different matrices, resulting in
large composite systems. Furthermore, several different processing routes, such as
powder metallurgy, stir casting, squeeze casting, hot extrusion etc.
A brief survey on the literature has been carried out to know the current status in the field
of metal matrix composition.
Tsushima-Naka, [2015], says Aluminium casting alloys with silicon as the major
alloying elements are the most important commercial casting alloys because of their
superior casting characteristics. This study aimed to investigate solidification and
mechanical behaviour of Al- Si alloy against both the moulding conditions and silicon
content (3%- 15% Si). However, an increase of both the ultimate tensile strength and the
hardness is obtained by the increase of the silicon content. With the increase of silicon
content the wear rate decrease and coefficient of friction increase.
Dheerendra Kumar Dwivedi, [2015], says that the influence of sliding interface
temperature on friction and wear behavior of cast Al–(4–20%) Si–0.3% Mg has been
reported. Wear and friction tests were performed under dry sliding conditions using pin
on disc type of friction and wear monitor with the data acquisition system conforming to
ASTM G99 standard. It was found that sliding interface temperature has close relation
with wear and friction response of these alloys. Initial rise in interface temperature
reduces the wear rate and as soon as a critical temperature (CT) is crossed, wear rate
abruptly increases in case of all the compositions used in this investigation. Friction
coefficient during the sliding of all aluminium alloys (irrespective of silicon content) first
decreases with the rise in interface temperature and then abruptly increases beyond
certain critical temperature. Critical temperature was found to be a function of alloy
composition, i.e. silicon content. Hypoeutectic alloys showed lower critical temperature
than the hypereutectic alloys

Milind G. Kalhapure, [2015], says that Mechanical testing plays an important role in
evaluating fundamental properties of engineering materials as well as in developing new
materials and in controlling the quality of materials for use in design and construction. If
a material is to be used as part of an engineering structure that will be subjected to a load,
it is important to know that the material is strong enough and rigid enough to withstand
the loads that it will experience in service. As a result engineers have developed a number
of experimental techniques for mechanical testing of engineering materials subjected to
tension, compression, bending or torsion loading. The influence of silicon on mechanical
properties such as ductility, hardness, toughness, yields strength of Aluminum alloy. The
silicon content is varied from 5, 7, 9, 12.5 and 14% in five different aluminum alloys. The
mechanical properties were measured using the tension test. It was found that the
ductility has been increased after increase in silicon percentage. Also there is a significant
change in ultimate tensile strength and hardness due to silicon.
Hesham Elzanaty, [2015], The aim of his work was to determine the effect of Si content
on the mechanical properties of near eutectic and hypereutectic Al–Si alloys with high Si
content. The alloys of different content of Si–namely, 2, 4, 6, 8, 11.6, 12.5, 15, 17 and 20
wt.% are produced by stir casting route in an induction heating furnace. The mechanical
properties namely Tensile strength and Hardness were investigated according to standard
procedure. Tensile tests were carried out with universal testing machine. Yield strength
and ultimate tensile strength has increased with increase in silicon content. But, percent
elongation decreases with the increase of silicon content
M. Gupta, [2015], says that three aluminum–silicon alloys containing 7, 10 and 19 wt %

silicon were synthesized using a novel technique commonly known as disintegrated melt
deposition technique. The results following processing revealed that a yield of at least
80% can be achieved after defacing the shrinkage cavity from the as-processed ingots.
Microstructural characterization studies conducted on the as-processed samples revealed
an increase in the volume fraction of porosity with an increase in silicon content. Porosity
levels of 1.07, 1.51 and 2.65% attained in the case of Al–7Si, Al–10Si, and Al–19Si
alloys indicates the near-net shape forming capability of the disintegrated melt deposition
technique. The results of aging studies conducted on the aluminum–silicon alloys
revealed similar aging kinetics irrespective of different silicon content. Results of
ambient temperature mechanical tests demonstrate an increase in matrix microhardness

and 0.2% yield stress and decrease in ductility with an increase in silicon content in
aluminum.
Ravichandran M. et.al., [2014], carried out the research work by fabricating aluminium
metal matrix composites through liquid powder metallurgy route. The aluminium matrix
composite containing TiO2 reinforcement particle was produced to study the mechanical
properties such as tensile strength and hardness. The characterization studies are also
carried out to evident the phase presence in the composite and the results are discussed
for the reinforcement addition with the mechanical properties. Results show that, the
addition of 5 weight percentage of TiO2 to the pure aluminium improves the mechanical
properties.
Uvaraja et .al., [2015] observed that Hybridization is commonly used for improving the
properties and for lowering the cost of conventional composites. Hybrid MMCs are made
by dispersing two or more reinforcing materials into a metal matrix. They have received
considerable research and trials by Toyota Motor Inc., in the early 1980s. Hybrid metal
matrix composites are a relatively new class of materials characterized by lighter weight,
greater strength, high wear resistance, good fatigue properties and dimensional stability at
elevated temperatures than those of conventional composites. Due to such attractive
properties coupled with the ability to operate at high temperatures, the Al matrix
composite reinforced with SiC particulate are a new range of advanced materials. It was
found that applications of hybrid composites in aerospace industries and automobile
engine parts like drive shafts, cylinders, pistons and brake rotors, consequently interests
in studying structural components wear behaviour.
Himanshu Kala et.al., [ 2014], In the past few years the global need for low cost, high
performance and good quality materials has caused a shift in research from monolithic to
composite materials. In case of MMC's, aluminium matrix composite due their high
strength to weight ratio, low cost and high wear resistance are widely manufactured and
used in structural applications along with aerospace and automobile industry. Also a
simple and cost effective method for manufacturing of the composites is very essential
for expanding their application. Reinforcements like particulate alumina, silicon carbide,
graphite, fly ash etc can easily be incorporated in the melt using cheap and widely
available stir casting method. This paper presents a review on the mechanical and
tribological properties of stir cast aluminium matrix composites containing single and
multiple reinforcement. Addition of alumina to aluminium has shown an increase in its

mechanical and tribological properties. Organic reinforcement like fly ash, coconut ash
also improved the tensile and yield strength. Self-lubricating property of graphite
improved the machine ability of aluminium. Many authors have also reported about
modified stir casting route.
Anand Kumar et.al., [2014] research work carried out by Addition of reinforcement
such as Ti, Si, Al2O3, TiO2, TiN, etc. to Aluminium matrix for enhancing the mechanical
properties has been a well–established fact. In-situ method of reinforcement of the
Aluminium matrix with ceramic phase like Titanium Carbide (TiC) is well preferred over
the Ex–situ method. In the present investigation, Al-Cu alloy (series of 2014 Aluminium
alloy) was used as matrix and reinforced with TiC using In-situ process. The Metal
Matrix Composite (MMC) material, Al-.5%Cu/10%TiC developed exhibits higher yield
strength, ultimate strength and hardness as compared to Al-4.5%Cu alloy. Percentage
increase in yield and ultimate tensile strengths were reported to be about 15% and 24%
respectively whereas Vickers hardness increased by about 35%. The higher values in
hardness indicated that the TiC particles contributed to the increase of hardness of matrix.
Gowri Shankar M. C. et.al., [2013], The unique thermal properties of aluminium

composites such as metallic conductivity with coefficient of expansion that can be
tailored down to zero, add to their prospects in aerospace and avionics. The reason for
aluminium being a success over magnesium is said to be mainly due to the design
flexibility, good corrosion resistance, low density, good wettability and strong bonding at
the interface. Titanium has been used in aero engines mainly for compressor blades and
discs due to its higher elevated temperature resistance properly. Magnesium is the
potential material to fabricate composite for making reciprocating components in motors
and for pistons, gudgeon pins and spring caps. It is also used in aerospace due to its low
coefficient of thermal expansion and high stiffness properties combined with low density.
Magnesium and magnesium alloys are among the lightest candidate materials for
practical use as the matrix phase in metal matrix composites. When compared to other
currently available structural materials. Magnesium is very attractive because of its
unique combination of low density and excellent machinability. However, it has been
reported by several authors that though their low density (35% lower than that of Al)
makes them competitive in terms of strength/density values. Magnesium alloys do not
compare favorably with aluminium alloys in terms of absolute strength.

Chapter 3
OBJECTIVES AND METHODOLOGY

3.1 Objectives
The main objectives of this study are;
i) Preparation of hyper eutectic Al-Si alloys compositions with 13, 14, 15% of Silicon.
ii) Preparation of hyper eutectic Al-Si alloys compositions with 13, 14, 15% of Silicon
With addition of 3% of Titanium.
iii) To study of their mechanical properties.
iv) To carry out various tests on the specimens.
v) To evaluate their wear behaviour.
3.2 Methodology
The methodology was explained in a flowchart below
Casting
Machining
Preparation of specimen
according to ASTM standard
Conducting tests
Result and discussion

Fig. 3.1 Process flowchart

The manufacturing methods available for Al-Si MMC can be broadly classified into three
types. They are solid phase processes such as powder metallurgy and diffusion bonding,
liquid phase processes such as stir casting, infiltration of liquid matrix into the
reinforcements and in situ processes, and semi-solid method such as spray and rheo
casting and compo casting. These manufacturing methods determine the microstructure
and interfacial bond condition between reinforcement and matrix. The difficulty in
fabrication of fiber reinforced plastics has made the use of metal matrix composite widely
acceptable. Solid phase process such as powder metallurgy, diffusion bonding, are
expensive because it needs expensive starting materials such as powder or foil matrix etc.
Liquid phase process (casting process) is generally less expensive than solid phase
process. In the casting process, high temperature melt is used. High temperature often
promotes the chemical reaction between the melt and the reinforcements. The reaction
leads to the degradation or disappearance of the reinforcements. The expected properties
of the composite would not be obtained if this reaction occurs. So in order to obtain metal
matrix composite with good characteristics special techniques are required. Among
various manufacturing methods stir casting is generally accepted as a promising route
because of low cost, little damage to reinforcement and stir cast components are not
restricted by its size and shape. It also possesses advantages like simplicity, flexibility
and applicability to large quantity production.
Manufacturing methods used for production of MMCs should ensure uniform distribution
of reinforcement in matrix. The non uniform distribution is due to density differences
between the reinforcement particles and the matrix alloy melt. The distribution of
reinforcement is influenced during several stages including
(i) Distribution in the liquid as a result of mixing,
(ii) Distribution in the liquid after mixing,
But before solidification, Manufacturing methods should also ensure proper wettability of
reinforcement in matrix. Wettability can be defined as the ability of a liquid to spread on
a solid surface. It also describes the extent of intimate contact between a liquid and a
solid.

Chapter 4
MATERIALS AND COMPOSITE FABRICATION

4.1 Introduction
This chapter describes the details of the materials used for processing of composites and
experimental procedure followed for their characterization. The materials used in present
investigations are,
4.2 Materials
4.2.1 Matrix Material
The basic matrix selected for this study is Al4032 alloy. Fig. 4.1 shows the matrix
Aluminium alloy 4032.
4032 Aluminium is a 4000 series aluminium alloy. The main alloying addition is silicon.
It is typically furnished in the T6 temper. To achieve this temper, the metal is solution
heat treated and artificially aged until it meets standard mechanical property
requirements. 4032 is the Aluminium Association (AA) designation for this material.
Fig. 4.1 Al 4032 alloy
Table 4.1 Chemical composition of aluminium alloy 4032
Chemical Al Si Mg Cu Ni
composition
Wt % 85 12.2 1 0.9 0.9

The properties of Aluminium 4032 are outlined in following table
Table 4.2 Properties of Al4032
Properties Metric Unit
Density 2.68 g/cm3
Poisonn’s Ratio 0.33
Hardness 120 HB
Thermal Conductivity 154 W/moC
Young’s Modulus 82 GPa
Tensile Strength 379 MPa
4.2.2 Reinforcement
The role of the reinforcement in a composite material is fundamentally one of increasing
the mechanical properties of the neat resin system. All of the different particulates/ fibres
used in composites have different properties and so affect the properties of the composite
in different ways. The desirable properties of the reinforcements include:
1. High strength
2. Ease of fabrication and low cost
3. Good chemical stability
4. Density and distribution
 Silicon Powder as Reinforcement
The reinforcement we used for preparing composite is silicon.
Silicon is a hard and brittle crystalline solid with a blue-grey metallic lustre, it
a tetravalent metalloid and semiconductor. Silicon is the eighth most common element in
the universe by mass, but very rarely occurs as the pure element in the Earth's crust. It is
most widely distributed in dusts, sands, planetoids, and planets as various forms
of silicon dioxide (silica) or silicates. Over 90% of the Earth's crust is composed
of silicate minerals, making silicon the second most abundant element in the Earth's crust
(about 28% by mass) after oxygen.

Fig. 4.2 Silicon powder
Most silicon is used commercially without being separated, and often with little
processing of the natural minerals. Such use includes industrial construction
with clays, silica sand, and stone.
Silicates are used in Portland cement for mortar and stucco, and mixed with silica sand
and gravel to make concrete for walkways, foundations, and roads. They are also used in
whiteware ceramics such as porcelain, and in traditional quartz-based soda-lime glass and
many other specialty glasses. Silicon compounds such as silicon carbide are used as
abrasives and components of high-strength ceramics.
Properties of Silicon are
 High Thermal Conductivity
 Low Thermal Expansion
 High Hardness
 Corossion Resistance and Stiffness
 Titanium as reinforcement
Titanium is resistant to corrosion in sea water, aqua regia, and chlorine. The element
occurs within a number of mineral deposits, principally rutile and ilmenite, which are
widely distributed in the Earth's crust and lithosphere, and it is found in almost all living
things, water bodies, rocks, and soils. The metal is extracted from its principal mineral
ores by the Kroll and Hunter processes.
Titanium can be alloyed with iron, aluminium, vanadium, and molybdenum, among
other elements, to produce strong, lightweight alloys for aerospace (jet engines, missiles,

and spacecraft), military, industrial processes (chemicals and petrochemicals, desalination

plants, pulp, and paper), automotive, agri-food, medical prostheses, orthopedic implants,
dental and endodontic instruments and files, dental implants, sporting goods,
jewellery, mobile phones, and other applications.
Fig. 4.3 Titanium powder
The properties of Titanium are
 High strength to Weight ratio
 Corrosion Resistance
 High Boiling and Melting properties
 Light Weight
4.3 Fabrication of Composites

Al4032 based composites were prepared using stir casting process shown in Fig. 4.4. A
coke feed melting furnace with graphite crucible was used for melting, Al4032 alloy was
melted in crucible by heating in a melting furnace.
Fig. 4.4 Stir casting set-up

Composite is prepared by stir casting technique. Stir-casting technique is currently the

simplest and most commercial method of production of MMCs. This approach involves
mechanical mixing of the reinforcement particulate into a molten metal bath and
transferred the mixture directly to a shaped mould prior to complete solidification. In this
technique aluminium alloy 4032 pieces will be heated in the furnace to its molten state.
When the temperature is maintained between 700-750oC, a vortex will be created using a
mechanical stirrer. Reinforcement particles will be preheated in the furnace. The
temperature of the furnace is maintained between 700-750oC. Preheated particles are
added to the melt when the stirring is in progress. Stirring is continued for about 15 min
after addition of particles for uniform distribution in the melt. Castings are prepared by
pouring the melt into preheated moulds of cylindrical shapes.
4.4 Steps in Stir Casting

Stir casting is the cheapest and easily available method among all the available methods
in fabricating metal matrix composite, and even conventional are not feasible in
manufacturing composites as they are of different density materials, therefore a stirrer is
employed to assure mixing along with regular casting process.
 First of all the aluminium 4032 is melted in a furnace and casted.

 The initial temperature of 750oC is been fixed in the furnace, in which the
aluminium is added till the molten state is obtained.
 Then obtained molten metal is degassed by purging hexa-chloroethane tablets.
 Cover all is added to reduce oxidation and to remove slag
 Magnesium is added to improve wettabilty
 Then the Silicon and Titanium were preheated in order to reduce the effect of
chilling during solidification.
 After degassing, the preheated reinforcement particles were added slowly into the
crucible.
 Then the molten metal is stirred using a stirrer.
 The magnesium added should be less than 2% to avoid porosity
 Now this molten metal is poured into the mould having a cylindrical shape.
 Now obtained solid cylinder is been shaped according to ASTM standards and it
is tested, tests such as SEM, hardness and wear.

Steps involved in Preparation of MMC’s
1. Preheating of mould 2. Melting of Alloy
4. Adding reinforcement 3. Adding of degasser
5. Adding magnesium 6. Pouring of molten 7. Casted Specimen

metal into the mould
Fig. 4.5 Steps involved in preparation of MMC’s

4.5 Parameter Affecting Stir Casting Process

 The distribution of reinforcement materials.
 Wet ability between reinforcement material and matrix alloy.
 Porosity in the cast metal matrix composites.
 Chemical reaction between reinforcement material and matrix alloy.
4.5.1 The Distribution of Reinforcement Materials
One of the problems encountered in the metal matrix composite processing is the setting
of the reinforcement particles during melt holding or during casting. This arises as a
result of the density differences between the reinforcement particles and the matrix alloy
melt.
The reinforcement distribution is influenced during several stages including distribution

in the liquid as a result of mixing, distribution in the liquid after mixing, but before
solidification and redistribution as a result of solidification. Mechanical stirrer used, melt
temperature, pouring temperature, type, nature and amount of reinforcement used are the
some of the main factors.
4.5.2 Wettablity between Reinforcement Material and Matrix Alloy
Wettability is another significant problem when producing cast matrix composites.

Wettability can be defined as the ability of a liquid to spread on a solid surface. It also
describes the extent of the intimate contact between a liquid and a solid. Successful
incorporation of the solid ceramic particles into casting requires that the melt should wet
the solid ceramic phase. The problem of the wetting of the ceramic by molten metal is
one of the surface chemistry and surface tension. The chemistry of the particle surface,
including any contaminating or oxidation, the melt surface and oxide layer must be
considered.
4.5.3 Porosity in the Cast Metal Matrix Composites
The volume fraction of porosity and its size and distribution in a cast metal matrix
composite play an important role in controlling the materials mechanical properties. This
kind of a composite defect can be detrimental also to the corrosion resistance of the
casting. Porosity levels must, therefore, be kept to a minimum. Porosity cannot be fully
avoided during the casting process, but it can, however be controlled. In general, porosity

arises from three causes (a) gas entrapment during mixing, (b) hydrogen evolution and (c)
shrinkage during solidification.
4.5.4 Chemical Reactions between Reinforcement Material and the

Matrix Alloy
This is also the important factor which contributes to the poor quality of cast AMC. The
reaction can be prevented by preheating of the both matrix and reinforcement before
mechanical stirring. The surface of the both must be properly cleaned in order to
minimize the reaction between these two.
4.6 Process Parameters

The following variable parameters are to be considered, while preparing the MMC by stir
casting.
4.6.1 Stirring Speed
Stirring speed is the important process parameter because of the following reasons.
 Mechanical stirring is necessary to help in promoting wet ability.

 Stirring in a fully liquid condition does not help to incorporate particles into the
matrix.
4.6.2 Stirring Temperature

The viscosity of Al matrix is influenced by the processing temperature. The particle
distribution in the matrix is subjective to the change of viscosity. When processing
temperature is increased along with increasing holding time of stirring, there is a decrease
in the viscosity of liquid. There is also acceleration in the chemical reaction between
matrix and reinforcement.
4.6.3 Reinforcement Preheat Temperature
In order to remove moisture present within reinforcement, the reinforcement was

preheated at a specified 5000C temperature for 30 minutes. The wettability of
reinforcement with matrix is promoted by preheating.
4.6.4 Stirring Time
Uniform distribution of the particles in the liquid and perfect interface bond between
reinforcement and matrix is promoted by stirring. In the processing of composite, the
stirring time between matrix and reinforcement is considered as important factor. The
better stirring time was chosen for best result.
4.7 Preparation of Specimens

A number of samples will be prepared from Al4032 matrix alloy, Silicon and Titanium
composites. The samples prepared for hardness test, tensile test and microstructure are
according to ASTM standards.
4.7.1 Hardness Test Specimen

Hardness test specimens are prepared according to the ASTM standard of E10 having
diameter 10 mm and length 10 mm. Hardness test specimen and its geometry are shown
in Fig. 4.7. When processing temperature is increased along with increasing holding time
of stirring.
All dimensions are in mm
Fig. 4.6 Hardness test specimen
4.7.2 Wear test specimen
All dimensions are in mm
Fig. 4.7 Wear test specimen
The specimens are machined according to E90 standard and it is as shown in figure. Pin
on disc apparatus is employed to measure the wear rate it is as shown in fig. 4.7.

Chapter 5
EXPERIMENTAL WORK
Aluminium-silicon alloys were prepared with different weight percentage of silicon by
stir casting route in an induction heating furnace. Samples of different dimensions were
cut for different tests. Wear behaviour of different composition samples were studied by
conducting wear tests on computerized wear monitor pin on-disc wear test machine. The
microstructures of the samples and of the worn surfaces were observed under a scanning
electron microscope. The hardness was measured with the leeb hardness testing machine.
Mechanical characterization means identification of composite’s mechanical properties

which provide the basis for preventing failure of materials in service. The critical
mechanical properties of composites are strength related properties, elastic properties,
fracture toughness etc. These properties are influenced by the dispersion of
reinforcements in the composite and also by the wettability between matrix and
reinforcement particles. The dispersion of reinforcement in the composite are analyzed by
optical micrographs. Reaction between the reinforcements and the matrix is sometimes
too minor to be detected by the optical microscopy. Scanning electron microscopy (SEM)
and transmission electron microscopy (TEM) or electron probe X-ray microanalysis
(EPMA) would be effective in that case. Research work on MMC showed that Al-Si
composites are having clusters of particles and some places are identified without Si
inclusions. This is due to variation in contact time between the Si particles and molten Al
during processing, high surface tension and poor wetting behaviour. The reinforcement
particles are found to distribute. Magnesium (Mg) is added during manufacturing of
composites to ensure proper wettability of reinforcement in matrix. This will improve the
wettability between Al and Si particles by reducing the formation of SiO2 layer on the
surface of the Si. If the surface area of the particles is higher, its wettability is more and
hence by using fine sized reinforcement the level of wettability can be enhanced. Also by
decreasing the surface tension of the alloy by heating at higher temperature wettability
can be improved.
By increasing the weight fraction of reinforcement composites hardness, elastic modulus,

creep resistance, fatigue behaviour, tensile strength, density, impact strength and wear
resistance are increased but its cooling rate, ductility and forge ability are decreased. By
increasing the volume fraction of reinforcement the ultimate strength of composite is

increased. This is due to fact that more load is transferred to the reinforcement which
results in higher ultimate strength. The addition of breadfruit seed hull (husk) or ash
particles of size 500 nm to aluminium alloy matrix using a double stir-casting method
shows that with the increase in reinforcement weight fraction, the matrix grain size
decreases. Also the mechanical properties of the composites are improved over the matrix
material, except for the slight decrease in impact energy.
MMC elastic properties are strongly influenced by micro structural parameters of the
reinforcement like shape, size, orientation, distribution. Particle shape and size play an
important role since angular particles can act as stress raisers, whereas rounded particles
are favoured for better impact properties. Spherical particles are found to give better
ductility than angular shapes.
The major failure mechanism of particle reinforced metal matrix composites are
(i) Particle fracture
(ii) Interfaced cohesion and
(iii) Matrix yielding.
Particle fracture failure of composites indicates both ductile and brittle modes of failure.
Even though composite possess high modulus of elasticity, specific strength, and
excellent heat resistance it has low fracture toughness and low tensile ductility. This is
mainly due to differential elastic and thermal properties of matrix and reinforcement that
degrade the matrix alloy near the interface and also by stress intensification introduced by
the Si particle geometry Fracture toughness studies on MMC show that composites
reinforced with fine grain particles possess good fracture toughness compared to coarse
grain.
The Al-Si system is a simple binary eutectic in which Si has limited solubility in
aluminium. The solubility of Si in Al reaches a maximum of 1.65% wt. Si at the eutectic
temperature of 577°C. As the Al-Si alloy solidifies, the primary aluminium forms and
grows into dendrites or in the case of hypereutectic Si compositions, the silicon phase
forms and grows into angular primary particles. At room temperature, hypoeutectic Al-Si
alloys comprise a soft and ductile primary aluminium phase and a hard and brittle silicon
phase. Hypereutectic cast Al-Si alloys usually contain coarse, angular primary silicon
particles as well as an Al-Si eutectic containing eutectic silicon and eutectic Al phases.
Commercial aluminium alloys have different levels of other alloying elements which are
added to enhance their microstructure for the recommended applications.

Chapter 6
TESTING
The various tests carried out on the specimens are:
6.1 Wear Test

When friction is the predominant factor causing deterioration of your materials, abrasion
and wear testing will give you data to compare materials or coatings and can help you
predict the lifetime of a material or coating. Abrasion testing is used to test the abrasive
resistance of solid materials. Three types of wear are abrasion, adhesion, and corrosion.
Each type has inherent problems and benefits that can be affected by materials,
lubrication, and surface finish.
Fig. 6.1 Wear testing machine
6.2 Leeb Hardness Test

The Leeb Rebound Hardness Test is one of the four most used methods for testing metal
hardness. This portable method is mainly used for testing sufficiently large work pieces.
The traditional methods are based on well-defined physical indendation hardness tests.
Very hard indenters of defined geometries and sizes are continuously pressed into the
material under a particular force. Deformation parameters, such as the indentation depth
in the Rockwell method, are recorded to give measures of hardness.

Fig. 6.2 Leeb hardness testing machine
6.3 Scanning Electron Microscope

A scanning electron microscope (SEM) is a type of electron microscope that produces
images of a sample by scanning the surface with a focused beam of electrons. The
electrons interact with atoms in the sample, producing various signals that contain
information about the sample's surface topography and composition. The electron beam is
scanned in a raster scan pattern, and the beam's position is combined with the detected
signal to produce an image. SEM can achieve resolution better than 1 nanometer.
Specimens can be observed in high vacuum in conventional SEM, or in low vacuum or
wet conditions in variable pressure or environmental SEM, and at a wide range of
cryogenic or elevated temperatures with specialized instruments.
Fig. 6.3 SEM equipment

Chapter 7
RESULTS AND DISCUSSION

Wear Test Results
Table 7.1 Wear test experimental details
Disc material EN36 steel with hardness of 65HRC

Material AL4032, TITANIUM, SILICON
Pin dimension Cylinder with diameter 10mm and height 30mm
Sliding speed(m/s) 0.83, 1.67, 2.51, 3.35, 4.18
Sliding distance(mm) 750mm
Diameter of the disc 160mm
Results obtained from Wear Test
Technical specifications of the wear test apparatus:
· Pin size : 3-12mm

· Diagonal disc size : 160mm dia x 8mm thick
· Wear track dia (mean) : 8mm-125mm
· Sliding speed range : 6m/s-26m/s
· Disc rotating speed : 100-1000 RPM
· Maximum normal load : 200N
· Frictional force : 0-200N
· Wear measurement range : 4mm digital read out
· Input power : 230V, 5A, Single Phase, 50HZ.
Weight Loss Recorded Values

Wear test is conducted and the results obtained are tabulated in the tables given below.
The results are obtained by testing the wear specimens employed with constant load and
with varying velocity (speed) & for the constant load and time of 20N & 3min for
different percents of Silicon. Wear test were carried out as per ASTM G-99 standard.

Table 7.2 Values of weight loss for Al4032.
Sl. No. Speed in RPM Velocity in m/s Wear Loss in mg

1 100 0.83 1.5
2 200 1.67 2.0
3 300 2.51 2.6
4 400 3.35 4.1
5 500 4.18 5.3
Wear loss
6
5
Wear loss (mg)
3
Wear loss
2
0
100 200 300 400 500
Speed (rpm)
Fig. 7.1 Variation of wear loss of Al4032
The graph shows the wear loss of Al4032 with the varying speed from 100-500 rpm and
with a wear loss of 1mg-5.3mg. The wear loss increases with the increasing speed.
Table 7.3 Values of weight loss for 13% silicon

1 100 0.83 1.8
2 200 1.67 1.9
3 300 2.51 3.2
4 400 3.35 3.4
5 500 4.18 3.7

Table 7.4 Values of weight loss for 3% titanium & 13% silicon

1 100 0.83 1.3
2 200 1.67 1.6
3 300 2.51 2.9
4 400 3.35 3.1
5 500 4.18 3.2
4
Wear Loss
3.5
3
Wear loss (mg)
2.5
Wear loss for 13% silicon
2 with 3% addition of
titanium
1.5 Wear loss for 13% silicon
without addition of
1
titanium
0.5
0
100 200 300 400 500
Speed (rpm)
Fig. 7.2 Variation of wear loss of Al4032 and 13% silicon alloys with and without addition of titanium
The above figure shows the variation of aluminium composites with addition of 13% of
silicon with and without addition of titanium. It can be seen that the wear loss decreases
with addition of titanium to the aluminium silicon alloy. Titanium metal exhibit high
hardness property which reduces the wear loss of composite materials.
Table 7.5 Values of weight loss for 14% Silicon

1 100 0.83 1.2
2 200 1.67 2.3
3 300 2.51 2.7
4 400 3.35 3.2
5 500 4.18 3.5


1 100 0.83 1.1
2 200 1.67 1.6
3 300 2.51 2.6
4 400 3.35 2.8
5 500 4.18 3.0
4
Wear loss
3.5
3
Wear loss (mg)

2 with 3% addition of
titanium
1 without addition of
titanium
0.5
0
100 200 300 400 500
Speed (rpm)
Fig. 7.3 Variation of wear loss of Al4032 and 14% silicon alloys with and without addition
of titanium
hardness property which reduces the wear loss of composite materials.
Table 7.7 Values of weight loss for 15% silicon

1 100 0.83 1.5
2 200 1.67 2.2
3 300 2.51 2.5
4 400 3.35 2.8
5 500 4.18 3.1


1 100 0.83 1.0
2 200 1.67 1.4
3 300 2.51 2.3
4 400 3.35 2.7
5 500 4.18 2.9
3.5
Wear loss
3
2.5
Wear loss (mg)
2 Wear loss for 15%

silicon with 3%
addition of titanium
1.5
Wear loss of 15%
silicon without
addition of titanium
1
0.5
0
100 200 300 400 500
Speed (rpm)
Fig. 7.4 Variation of wear loss of Al4032 and 15% silicon alloys with and without addition of titanium
hardness property which reduces the wear loss of the composite materials.
The test was carried out considering the three parameters like load, speed and the sliding
distance. The wear loss is measured for each set of samples, by varying the speed by
maintaining load as 20N and a mean time of 3min.

Hardness Test
Table 7.9 Values of hardness number for different compositions
Sl. No. Composition Brinell hardness number
1 AL4032 63
2 AL4032+ 13% Si 73.2
3 AL4032+ 14% Si 83.2
4 AL4032+ 15% Si 88.5
5 AL4032+ 3% Ti +13% Si 96.1
6 AL4032+ 3% Ti +14% Si 107
7 AL4032+ 3% Ti +15% Si 113.2
Leeb Hardness Test

120
Leeb hardness number
100
80
60
40
20
0
Leeb Hardness Test
Composites
Fig. 7.5 Variation in hardness of Al4032 and silicon alloys with and without addition of titanium
The above graph shows variation of hardness of Al4032 with increasing the percentage of
silicon and varying titanium. It can be seen that with increasing of silicon and titanium
the hardness of the material increases.

SEM TEST
The scanning electron microscope (SEM) is a type of electron microscope that images the
sample surface by scanning it with a high-energy beam of electrons in a raster scan
pattern. The electrons interact with the atoms make up the samples producing signals that
contains information about the samples surface topography, composition and other
properties such as electrical conductivity.
The most common SEM mode is detection of secondary electrons emitted by atoms
excited by the electron beam. The number of secondary electrons that can be detected
depends, among other things, on specimen topography. By scanning the sample and
collecting the secondary electrons that are emitted using a special detector, an image
displaying the topography of the surface is created.
Fig. 7.6 Al4032+13% Si

Fig. 7.7 Al4032+14%Si
Fig. 7.8 Al4032+15% Si

Fig. 7.9 Al4032+3% Ti+13% Si
Fig. 7.10 Al4032+3% Ti+14% Si

Fig. 7.11 Al4032+3% Ti+15% Si
SEM images reveals the distribution of particles, it shows a fair distribution of particles
into the matrix.

Chapter 8
ADVANTAGES, DISADVANTAGES and
APPLICATIONS
8.1 ADVANTAGES OF COMPOSITES
 High resistance to fatigue and corrosion degradation.
 High strength or stiffness to weight ratio.
 Due to greater reliability, there are fewer inspections and structural repairs.
 Directional tailoring, capabilities to meet the design requirement.
 High resistance to impact damage.
 It is easier to achieve smooth aerodynamic profiles for drag reduction
 Improved dent resistance is normally achieved. Composite panels do not sustain
damage as easily as thin gauge sheet metal.
8.2 DISADVANTAGES OF COMPOSITES

 High cost of raw materials and fabrication
 Composites are more brittle than wrought metals and more easily damaged.
 Transverse properties may be weak.
 Re-use and disposal may be difficult.
8.3 APPLICATIONS OF COMPOSITIES

 To manufacture the various components of engine such as piston, cylinder,
connecting rods, air conditioner compressors, engine blocks, cylinder liners,
brake drums etc. etc.
 To manufacturing aircraft passenger seat, windows and other parts.
 It is used in telescopic antenna of the Hubble space telescope, hydrogen tank
used in rocket and tip of rocket.
 Solid fuel rocket boosters are made by Al metal matrix composites.
 It is used in modern aircraft everywhere such as in wings, planes, rudder, exhaust
pipe, in the feeding blocks, in the refuelling hoses, in the door and floor, in
hydraulic system, engine turbine etc.,
 To manufacture the irrigation tubing.

Chapter 9
CONCLUSION
The effect of incorporation of Silicon and Titanium powder particles on mechanical
properties of Al4032 has been investigated. Based on the results the following
conclusions are drawn
1. Aluminium based metal matrix composites have been successfully fabricated by

stir casting technique with fairly uniform distribution of Silicon and Titanium
particulates.
2. The prepared Aluminium Silicon alloys have homogenous distribution of Silicon

and Titanium throughout the cast.
3. Yield strength and ultimate tensile strength increases with increase of weight
percentage of silicon.
4. Addition of Silicon and Titanium powder particles increases the hardness of the
matrix alloy.
5. SEM images show a good distribution of reinforcements.
6. Significant improvement in the tensile properties of the material with the

incorporation of Silicon and Titanium powder particles.
7. Wear loss decreases with increase in weight percent of reinforcement due to
harder material.
8. Wear rate increases with increase in silicon content for hyper eutectic Al-Si
alloys.
9. The addition of titanium in the aluminium silicon alloys reduces the wear rate.
The Al4032 alloy reinforced with 13, 14, 15% Silicon and 3% Titanium shows a
significant improvement in the hardness, tensile strength compared to other weight
percent composition. Hence this combination used for light weight and high strength
applications.

Chapter 10
SCOPE FOR FUTURE WORK

Aluminium alloys is widely used for the manufacturing in the field of automotive,
aircraft, marine, etc. Due to their low density, high strength, high corrosion resistance and
also have less wear rate. Use of aluminium along with the reinforcement the properties
can be enhanced more efficiently with a more economic process. The work done in
present investigation has led to some conclusions which have been described in this
chapter.
 The Aluminium-Silicon has the higher strength, wear resistance, effective load
carrying capacity, higher thermal stability and less weight compared to any
mechanical materials. The future scope for this material is in Automobile
application that manufacturing of Camshaft with Composite material. This helps
in reduction of weight and wear of it. This improves the working life of Camshaft.
 The selection and exploitation of the new aluminium materials and manufacturing
technologies will be a key issue in the competition between aircraft manufacturers
in terms of production costs, performance and enhanced structural integrity.
 The developed composites can be further investigated for their tensile strength,
corrosion resistance along with some electrical and thermal measurement. It will
help to widen their area of application in different engineering designs and
applications.
 The wear behaviour of the composites can be further analyzed at different
environmental conditions like under lubricating condition and corrosive
environment where temperature variation can be done.
 Effect of heat treatment on wear properties of the composites can also be
examined to have their wider applications.
 High strain rate properties of the developed composite can be found out to explore
the possibilities of using rutile reinforced composite for different military
applications

REFERENCES
[1] Tsushima-Naka,“An investigation into solidification a behaviour of Al-Si casting
alloys” International journal of mechanical &mechatronics engineering ijmme-ijens vol:
10 no. 04, August 2015.
[2] Dheerendra Kumar Dwivedi, “Sliding temperature and wear behaviour of castal–si
mg alloys”, Materials science and engineering , pp. 328–334, 2015.
[3] Milind G. Kalhapure “Impact of silicon content on mechanical properties of
aluminum alloys” International journal of science and research (ijsr) issn (online) pp.
2319-7064, Volume 4, 2015.
[4] M. Gupta, “Microstructure and mechanical properties of hypo/ hyper-eutectic Al–Si
alloys synthesized using a near-net shape forming technique” Journal of alloys and
compounds, pp. 284–294, 2015.
[5] Hesham Elzanaty, “Effect of different Si content on the mechanical properties in al
based alloy”, International journal of research in engineering & technology (impact:ijret)
(p): 2347-4599 vol. 2, pp. 49-54 issue 7, July 2014.
[6] Rajneesh Kumar Verma, “Effect of variation of silicon and copper contents in
aluminium-silicon-copper alloy” International journal on emerging technologies pp. 149-
156, 2013.
[7] R. S. Rana, Rajesh Purohit, S Das,” Review on the Influence of Alloying elements on
the Microstructure and Mechanical Properties of Aluminum Alloys”, International
Journal of Scientific and Research Publication, Volume 2, Issue 6, June 2012.
[8] Francis Uchenna Ozioko, “Synthesis and study on effect of parameters on dry sliding
wear characteristics of Al-Si alloys”, Leonardo electronics of practices and technologies,
issue (20), pp. 39-48, 2012.
[9] Francis Uchenna Ozioko, “Synthesis and study on effect of parameters on dry
slidingwear characteristics of Al-Si alloys”, Leonardo electronics j. of practices and
technologies, issue (20), pp. 39-48 ,2012.
[10] Das S., Mondal D.P., Sawla S., Ramkrishnan N.; Synergic effect of reinforcement
and heat treatment on the two body abrasive wear of an Al–Si alloy under varying loads
and abrasive sizes, Wear, Vol. 264, pp. 47–59, 2008.
[11] Gaber A., Gaffar M.A., Mostafa M.S., Abo Zeid E.F. Precipitation kinetics of Al
1.12 Mg2Si–0.35 Si and Al–1.07 Mg2Si–0.33 Cu alloys, J. Alloys Compd., Vol. 429 pp.
47–59, 2007.

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Tribological Analysis of Hypereutectic Al-Si Alloys With and Without Addition of Titanium

1.2 Classification of Composites

1. Polymer Matrix Composites (PMC’s)

The Second Level of classification refers to the reinforcement form

1. Fiber Reinforced Composites

1.2.1 Classification Based on Matrix

Dept. of Mechanical Engg., RIT, Hassan 1

Metal matrix Ceramic

Fig. 1.1 Classification based on matrices

 Metal Matrix Composite (MMC)

1.2.2 Classification Based on Reinforcement

Dept. of Mechanical Engg., RIT, Hassan 2

Long-fiber reinforced composites: Long-fiber reinforced composites consist of a matrix

 Unidirectional orientation of fibers.

Laminate Composites are found is as many combinations as the number of materials.

Dept. of Mechanical Engg., RIT, Hassan 3

1.4 Aluminium Alloys

Dept. of Mechanical Engg., RIT, Hassan 4

development and processing of engineering materials is to control the microstructure,

1.5 Designation of Aluminium alloys

Table 1.1 Designation of aluminium alloys and their applications

Alloy Main alloying element Applications

Dept. of Mechanical Engg., RIT, Hassan 5

1.6 Properties of Aluminium Alloys

1.7 Aluminium-Silicon Alloy

1.8 Problem Identification

Dept. of Mechanical Engg., RIT, Hassan 6

Dept. of Mechanical Engg., RIT, Hassan 7

Dept. of Mechanical Engg., RIT, Hassan 8

M. Gupta, [2015], says that three aluminum–silicon alloys containing 7, 10 and 19 wt %

Dept. of Mechanical Engg., RIT, Hassan 9

Dept. of Mechanical Engg., RIT, Hassan 10

Gowri Shankar M. C. et.al., [2013], The unique thermal properties of aluminium

Dept. of Mechanical Engg., RIT, Hassan 11

OBJECTIVES AND METHODOLOGY

With addition of 3% of Titanium.

iii) To study of their mechanical properties.

iv) To carry out various tests on the specimens.

v) To evaluate their wear behaviour.

Result and discussion

Dept. of Mechanical Engg., RIT, Hassan 12

(i) Distribution in the liquid as a result of mixing,

(ii) Distribution in the liquid after mixing,

Dept. of Mechanical Engg., RIT, Hassan 13

MATERIALS AND COMPOSITE FABRICATION

Fig. 4.1 Al 4032 alloy

Table 4.1 Chemical composition of aluminium alloy 4032

Wt % 85 12.2 1 0.9 0.9

Dept. of Mechanical Engg., RIT, Hassan 14

The properties of Aluminium 4032 are outlined in following table

Table 4.2 Properties of Al4032

Properties Metric Unit

Density 2.68 g/cm3

Poisonn’s Ratio 0.33

Thermal Conductivity 154 W/moC

Young’s Modulus 82 GPa

Tensile Strength 379 MPa

2. Ease of fabrication and low cost

3. Good chemical stability

4. Density and distribution

 Silicon Powder as Reinforcement

The reinforcement we used for preparing composite is silicon.

Dept. of Mechanical Engg., RIT, Hassan 15