Synthesis and mechanical characterization of nano B4C particulates reinforced Al7475

alloy composites
Chandrasekhar G. L., Y. Vijayakumar, Madeva Nagara, and Hariprasad

Citation: AIP Conference Proceedings 2039, 020017 (2018); doi: 10.1063/1.5078976

View online: https://doi.org/10.1063/1.5078976
View Table of Contents: http://aip.scitation.org/toc/apc/2039/1
Published by the American Institute of Physics

Articles you may be interested in

Performance and emission characteristics of a CI engine using preheated Simarouba biodiesel blends
AIP Conference Proceedings 2039, 020018 (2018); 10.1063/1.5078977

Performance evaluation of a solar-aided liquid desiccant evaporative cooling system

AIP Conference Proceedings 2039, 020004 (2018); 10.1063/1.5078963

Effect of 5 hole nozzle and re-entrant toroidal piston bowl geometry on dairy scum biodiesel operated diesel
engine
AIP Conference Proceedings 2039, 020003 (2018); 10.1063/1.5078962

An exploration of customer churn prediction models of telecommunication orbit

AIP Conference Proceedings 2039, 020008 (2018); 10.1063/1.5078967

Modeling of environmental parameters in industrial suburb

AIP Conference Proceedings 2039, 020013 (2018); 10.1063/1.5078972

Design and development of solar panel tracking mechanism

AIP Conference Proceedings 2039, 020014 (2018); 10.1063/1.5078973
 Synthesis and Mechanical Characterization of Nano B4C
Particulates Reinforced Al7475 alloy Composites

Chandrasekhar G L1,a), Y.Vijayakumar2, Madeva Nagara3, Hariprasad4

1
Department Department of Mechanical Engineering, MVJ College of Engineering, Karnataka, India.
2
Department of Mechanical Engineering, Sri Sai Ram College of Engineering, Anekal, Karnataka, India.
3
Design Engineer, Aircraft research and Design Centre, HAL, Karnataka, India.
4
Head of the Department of Industrial Engineering and Management, MVJ College of Engineering, Karnataka, India.

Email: kumar_vy@rediffmail.com

Abstract: In this present work, stir casting technique is used to fabricate particulate metal matrix composites of Al 7475
with varying weight percentages of nano B4C. The matrix material used for the present study is Al7475 alloy. Nano size
B4C particles with varying amounts of 2, 4 and 6% are being used as reinforcing material to fabricate composites.
Initially calculated amount of Al7475 alloy was charged into Graphite crucible and superheated to a temperature of
750oC in an electrical resistance furnace. The furnace temperature will be controlled to an accuracy of 10oC using a
digital temperature controller. Once the nano composites are prepared, they are subjected to characterization. The
Scanning Electron Microscope images revealed that there was uniform distribution of nano particles in the aluminum by
showing a good bonding with matrix and EDS confirmed the presence of Boron and Carbon elements. Mechanical
properties have been studied for the same composite samples. The mechanical testing results have shown an
improvement in the propertieslike yield strength, ultimate tensile strength, and hardness. The same mechanical properties
are compared with the base metal.

Keywords : Al-7475, Nano B4C, Stir casting, Mechanical properties

INTRODUCTION
The metal matrix composites (MMCs), like all other composites consist of at least two chemically and
physically distinct phases, suitably distributed to provide properties not obtainable with either of the individual
phases. For many researches the term MMCs is often equated with the term light metal matrix composites.
Substantial progress in the development of light metal matrix composites has been achieved in recent decades, so
that they could be introduced into the most important applications. Aluminum matrix composites (AMCs) are the
competent material in the industrial world. Efforts have been made to develop aluminum metal matrix nano
composites in recent years due to their low density,high strength, superior creep resistance, high damping capacity
and good dimensional stability and have great potential in automotive and aerospace applications. [1]

Aluminum (Al) is the second most widely used metal in the world today after iron. It has a low density
(2.7g/cc), superior malleability, excellent corrosion resistance, good thermal conductivity (237W/mK), very low
electrical resistivity (2.65*10-8Ωm) and good formability. It’s Young’s modulus is 70GPa and its Vickers hardness
is160–350 MPa. Aluminum has a melting point of 660.32 °C and at high temperatures, the strength of the metal
decreases. However, the demand for Aluminum and its alloys having a much higher strength is increasing. Al-matrix
composites (AMCs) have been widely used in automobile and aerospace industries due to their excellent physical
and mechanical properties. To overcome these shortcomings and to meet the ever-increasing demand of modern day
technology, composites are one of the most promising materials [2, 3].Boron carbide is a superior ceramic

International Conference on Sustainable Engineering and Technology (iConset 2018)

AIP Conf. Proc. 2039, 020017-1–020017-7; https://doi.org/10.1063/1.5078976
Published by AIP Publishing. 978-0-7354-1765-6/$30.00

020017-1
reinforcement material for AMCs than SiC and Al2O3 due to its high hardness, low density, high strength, high wear
and impact resistance, high melting point, low coefficient of thermal expansion and good chemical stability.Many
techniques are currently available to fabricate the metal matrix nano composites (MMNCs), such as mechanical
alloying, high-energy ball milling, spray deposition, powder metallurgy, nano-sintering and various casting
techniques. The powder metallurgy processing method cannot be used for bulk production of large and complex
structural MMNCs components. The fabrication of MMNCs by powder metallurgy route is time-consuming,
expensive and energy intensive. The liquid phase processing method can produce AMC parts with a uniform
reinforcement distribution and complex shape, and this method offers better matrix-particle bonding and an easier
control of the matrix structure. It is economical for bulk production.
Several researchers have proposed the ultrasonic cavitation technique to distribute and disperse ceramic
nano- sized particles in an aluminum melt which enhances their wettability, the degassing of liquid metals and the
dispersive effects for homogenizing [6,7]. The liquid phase processing of MMNCs using high-intensity ultrasonic
waves could be useful to disperse B4C nano particles in molten aluminum because this process features transient
cavitation and acoustic streaming. Acoustic cavitation is the formation and collapse of thousands of micro-bubbles
in molten aluminum liquids under cyclic high intensity ultrasonic waves. The collapsing of micro-bubbles in molten
aluminum produces transient micro-hot spots that can have pressures of approximately 1000 atm. Transient
cavitation could result in strong impact coupling with the local high temperatures. It is sufficient to break up the
clustered nano particles, disperse nano particles, refine grains, remove gas and homogenize the material. Recent
studies have attempted to fabricate B4C nano particle reinforced aluminum matrix composites.
Boron carbide is characterized by a unique combination of properties that make it a material of choice for a
wide range of engineering applications. Boron carbide is used in refractory applications due to its high melting point
and thermal stability. It is used as abrasive powders and coatings due to its extreme abrasion resistance, it excels in
ballistic performance due to its high hardness and low density and it is commonly used in nuclear applications as
neutron radiation absorbent. In addition, boron carbide is a high temperature semiconductor that can potentially be
used for novel electronic applications. B4C is a robust material having excellent chemical and thermal stability, high
hardness (HV = 30 GPa), and low density (2.52 g/cm3) and it is used for manufacturing bullet proof vests, armor
tank etc. Hence, B4C reinforced aluminum matrix composite has gained more attraction with low cost casting route.
However, very little information is available as regards the mechanical and tribological properties of
Al7475 reinforced with Nano B4C particulates MMC’s processed by stir casting method. With the increasing
demand of lightweight materials in the emerging industrial applications, the aluminum–boron carbide composites
play an important role. Keeping the above observations in view, it is proposed to develop Al 7475 Nano B 4C
composites with varying weight percentages of B 4C particulates. In this study, it is planned to investigate
mechanical and tribological properties of Al7475 alloy-based composites with nano sized B4C particulates by
varying weight percentages like 2, 4, 6, 8 and 10 wt. % by using liquid metallurgy technique.

MATERIALS AND EXPERIMENTAL DETAILS

Matrix Material
The matrix material used in experimental investigation is aluminum 7475 alloy. The theoretical density is
taken as2.84 gm/cm3.

Elements Al Zn Mg Si Mn Cu Fe Cr Ti
Weight % Bal 5.7 2.5 1.5 0.06 1.2 0.12 0.22 0.06

Al 7475 alloy to the family of aluminum alloys-7xxx. This alloy is age-hardenable and shows the highest yield
strength amongst all aluminum alloys. Higher Zn:Mg ratios produce the best strength and response to heat treatment,
together with the highest susceptibility to stress corrosion. Copper reduces the corrosion susceptibility. Cr and
Mn have some strengthening effect, but their main purpose is for control of stress corrosion. Ti is a normal grain
refiner. This alloy is widely used in fuselage of an aircraft. For bulkhead and wing spars, this alloy is used. In the
current work, the alloy is reinforced with nano B 4C (500 nm). The nano B4C particles are extensively used in
increasing the mechanical and tribological properties and became the choice for most of the engineers.

020017-2
Reinforcement Material
Boron carbide is a ceramic material and has high hardness (up to >30 GPa). It has the density of 2.52 g/cm 3
and melting temperature of 2763oC.Since it has the high thermal and chemical stability, it became the good choice
for stir casting. The main advantage of introducing reinforcement material to base metal or alloy is to increase the
properties thereby enhancing the mechanical properties of composites. The addition of B4C helps in decreasing the
deformation of the metal and enhancing the temperature resistance of the material. This In the current research Nano
B4C of size 500nm is used as reinforcement a material which was procured from Reinste Nano Ventures
PrivateLimited, New Delhi.

Preparation of Nano Metal matrix composites

In this present work, stir casting technique is used to fabricate Al7475 with varying weight percentages of
nano B4C particulate MMC’s. The matrix material used for the present study is Al7475 alloy. Nano size B 4C
particles with varying amounts of 2, 4 and 6 wt. % are being used as reinforcing material in the preparation of
composites. Initially calculated amount of Al7475 alloy was charged into Graphite crucible and superheated to a
temperature of 750oC in an electrical resistance furnace. The furnace temperature will be controlled to an accuracy
of 10oC using a digital temperature controller. A novel two stage mixing combined with preheating of the
reinforcing particles is followed. Ceramic B 4C particulates were preheated to a temperature of 300OC in an oven to
remove the adsorbed gases and moisture from the particle surface and to avoid high drop of temperature after
addition of particulates. Preheated B4C particles were introduced into the vortex of the molten alloy after effective
degassing using solid hexachloroethane (C2Cl6). Vortex is generated with the help of a zirconia coated steel
impeller. The extent of incorporation of B 4C particles in the matrix alloy will be achieved in steps of 2. i.e., total
amount of reinforcement required was calculated and is being introduced into the melt 2 times rather than
introducing all at once. At every stage before and after introduction of reinforcement, mechanical stirring is carried
out for a period of 5 min. The stirrer is preheated before immersing into the melt and is located approximately to a
depth of 2/3 height of the molten metal from the bottom and run at a speed of 300 rpm. Composite mixture is poured
into permanent cast iron mould having diameter 15mm and length of 125mm at a pouring temperature of 710OC.
The prepared composites are characterized by microscopic studies. Specimens of 12mm diameter and
thickness of 5mm were cut from the central portion of the casting for microstructural XRD and SEM//EDAX
microanalysis. The density of the samples will be measured by weight method while theoretical density is computed
by taking densities of Al7475 matrix and B4C particles as 2.84 and 2.52g/cm3 respectively.Further, mechanical and
tribological properties will be evaluated as per ASTM standards at room temperatures.

RESULTS AND DISCUSSION

Characterization by SEM and EDS

Scanning Electron Microscope is used to evaluate the microstructure of the composites with different
percentages of reinforcements. The equal distribution of the reinforcement is evident from the below images. The
samples were prepared for microstructure evaluation. The cut sections of the samples were properly polished using
different grades of emery papers (coarse emery is to remove deep scratches and fine is to remove fine scratches).
After fine polishing, the samples are etched by Keller’s reagent (1.5 ml HCl + 2.5 ml HNO 3 + 1.0 ml HF + 95 ml
Water). In the below figure (a), the microstructure shows that there are no traces of reinforcement. Figure (b) shows
the uniform distribution of reinforcement (2%).It is evident from scanning electron micrographs (b), (c), (d) that
there is no agglomeration of reinforcement. Reinforcement is uniform throughout the matrix and no clusters have
been found. Good interfacial bonding between matrix and reinforcement helps in enhancing the properties of the Al
7475 alloy.

020017-3
 (a) (b)

(c) (d)
Figure 1: Scanning electron micrographs of (a) as cast Al7475 alloy (b) Al7475-2% B4C
(c) Al7475-4% B4C and (d) Al7475-6% B4C composites.

The amount of reinforcement is constantly increased (from 0 to 6%). In case of 6% B 4C, there more
reinforcingparticles in the matrix. This combination shows good wetting and casting characteristics.The amount of
Silicon available in the matrix helps in maintaining the castability and Mg helps in maintaining wettability.
It is evident that the as cast specimen shows no reinforcement. The EDM image shows only the major alloying
elements.

Figure 2: EDS image of Al 7475 (as cast)

020017-4
 Figure 3: EDS image of Al 7475 composite with 6% B4C

Element B C Zn Mg Al Mn Fe Cu Ti Cr Si
Weight % 7.03 33.08 5.7 2.53 48.5 0.06 0.12 1.2 0.06 0.22 1.5

The EDS image of 6% B4C, confirms the Boron and Carbon in matrix along with other alloying elements.

Yield strength and Ultimate Tensile Strength

Figure 4 shows the effect of nano B4C particulates on the tensile behaviour of Al 7475 alloy. From the
graphs, it is evident that nano composites have shown better yield and ultimate strength as compared to the Al 7475
base matrix. In addition to that, the weight percentages of nano B 4C increase from 2 to 6%, have resulted in
enhancing yield and ultimate strength of the material. 2% of B 4C showed 175 MPa as the yield strength and further
increase in reinforcement i.e. 4%, showed 181 MPa. The alloy which is added with 6% B 4C showed the highest
yield strength i.e. 190 MPa. There is a surge in ultimate strength values also. The B 4C with 2%, 4% and 6% showed
210, 220, 245 MPa respectively. This upsurgein yield strength and ultimate strength is mainly due to the presence of
B4Cnano particulates in the matrix. These particulates act as the barrier for dislocations and hinders deformation.
The mechanical properties of nano particulate reinforced MMCs are controlled by an interaction between
the Aluminum matrices and reinforcements. The addition of a reinforcing phase of different elastic properties
induces strain concentration in the lattice. In order to maintain the displacement compatibility across the interface
when a far-field strain is applied, dislocations are generated at the composite interface [16]. Also, the difference in
thermal expansion coefficients between the two phases necessitates the generation of dislocations to accommodate
thermal strain on changing temperature.

(a) (b)

020017-5
 (c) (d)

Al7475 as cast Al7475-4% B4C

Al7475-2% B4C Al7475-6% B4C

Figure 4: Mechanical properties of the Al 7475- Nano B4C. (a) yield strength (b) ultimate strength (c) compressive
strength (d) Hardness
Compressive strength measurement
Figure 4 shows the effect of nano B4C particulates on the compressive strength of Al 7475 alloy. From the
graphs (c), it is evident that the addition of nano B4C has shown increase in compression strength of the base metal.
2 to 6% B4C has better compressive strength than the alloy Al7475. The compressive strength value is increased
from 588 MPa to 660 MPa.The upsurge in the compression strength is mainly due to the presence of reinforcement
particles. These B4C nano particles act dislocation barriers.

Hardness measurement
Figure 4 shows the effect of nano B4C particulates on the hardness of Al 7475 alloy. From the graphs (d), it
is evident that the nano particle reinforced composites showed better hardness values than Al base matrix. Further,
as the weight percentage of nano B4C increases from 0 to 6 %, in Al 7475 composites, it is observed that the
hardness increased from 78 BHN to 109.3 BHN. This increase in hardness is mainly due to the presence of nano
B4Cparticles in the matrix. These particulates act as the barrier for dislocation motion. The higher hardness values
for composites containing finer nano B 4C particles can be attributed to the larger surface area of these particles in
contact with the matrix alloy. Therefore, due to the co-efficient of thermal expansion mismatch between Al 7475
and B4C phases, higher dislocations densities are generated during processing. Higher dislocation densities result in
higher hardness values by minimising the deformation.

CONCLUSION
In this research, nano B4C-Al 7475 composites are fabricated by stir casting method by taking 2 to 6 wt. %
of reinforcement. The mechanical properties like yield strength,ultimate tensile strength, compression strength and
hardness are studied. In addition to that the microstructural analysis is done. It is evident from the SEM images that
the matrix is almost pore free and B4C particles are uniformly distributed. The EDS analysis confirms the presence
of nano B4C particles in the Al alloy matrix. The mechanical properties of Al 7475-2 to 6 wt. % nano B4C
composites are superior to those of unreinforced material. The ultimate tensile strength of Al 7475 alloy is increased
from 180 MPa to 245 MPa for 6 wt. % nano composites. The hardness and compressive strength values have been
increased as compared to the unreinforced Al 7475 alloy.

020017-6
 REFERENCES
[1]. Zeeshan Ahmad, Dr. Sabah Khan, “A review paper on tribological and mechanical properties of Aluminium metal matrix
composites manufactured by different route,” IJCESR ISSN: 2393-8374, VOLUME-1, ISSUE-4, 2014.
[2]. Wei-chen Zhai, Zhao-hui Zhang, Fu-chi Wang, Xiang-bo Shen, Shu-kui Lee, Lu Wang, “Effect of SI content on
microstructure and properties of Si/Al composites”, Trans. Nonferrous Met. Soc. China, 24, pp. 982-988, 2014.
[3]. H. Ribes, M. Suery, G. L.Esperance, J.G. Legoux, “Microscopic examination of the interface region in 6061-Al/SiC
composites reinforced with asreceived and oxidized SiC particles,” Metallurgical and Materials Transactions A, vol. 21, pp.
2489–2496, 1999.
[4]. Govind Nandipati, Ravindra kommineni, Nageswara Rao Damera, Ramanaiah Nallu, “Fabrication and Study of the
Mechanical Properties of AA2024 Alloy Reinforced with B4C Nano-particles using Ultrasonic cavitation method”, IOSR
Journal of Mechanical and Civil Engineering e-ISSN: 2278-1684,p-ISSN: 2320-334X, Volume 7, Issue 4 (Jul. - Aug. 2013),
PP 01-07.
[5]. Gopal Krishna U B, Sreenivas Rao K V & Vasudeva B, “Effect Of Boron Carbide Reinforcement On Aluminium Matrix
Composites”, International Journal of Metallurgical & Materials Science and Engineering (IJMMSE), ISSN 2278-2516 Vol.
3, Issue 1, Mar 2013
[6]. Yusof Abdullah, Mohd Reusmaazran Yusof, Azali Muhammad, Nadira Kamarudin, Wilfred Sylvester Paulus, Roslinda
Shamsudin, Nasrat Hannah Shudin and Nurazila Mat Zali, “Al/B4C Composites with 5 And 10 wt% Reinforcement Content
Prepared by Powder Metallurgy”, Journal of Nuclear and related Technologies, Volume 9, No. 1, June, 2012.

020017-7