FABRICATION AND STUDY OF ALUMINIUM

GRADE REINFORCED WITH COW DUNG

ASH AND COCONUT SHELL ASH
Under the GUIDENCE of:
Raghu S
Assistant Professor
Dept of IP, PESCE
Mandya
PRESENTED BY:
MADHU M 4PS16IP014
NETHRALAKSHMI V 4PS16IP016
NITESH HR 4PS16IP017
PAVAN KUMAR 4PS16IP020
INTRODUCTION
Composites :
A composite material is made by combining two or more
materials , often ones that have very different properties.
The two materials work together to give the composite
unique properties.
The properties of a composite as a whole are enhanced as
compared to the properties of its components.
The two phases that make up a composite are known as
REINFORCING phase and MATRIX phase.
Advantages of Composites:
Low density
Better wear resistance
Improved corrosion resistance
Better temperature dependent behaviour
High Design flexibility

Disadvantages of Composites:
Some raw materials and manufacturing methods are
expensive.
Strength analysis are usually challenging due to anisotropic
structure of many composites
Role of Reinforcement:
Carry the load and provide strength and stiffness to the matrix.
It helps the composite to obtain the desired property in the
direction preferred.
 It serves certain additional purpose of heat resistance or
resistance to corrosion etc.

Role of Matrix:
 Holds the reinforcement material together and keep them
aligned .
Protects the reinforcements from mechanical and
environmental attack.
 Distributes the loads evenly between the reinforcements
material.
OBJECTIVES
Preparation of reinforcement of cow dung and coconut
shell.
To synthesis Al4008 reinforced with 024 weight percent
of cow dung ash and coconut shell ash by using Bottom
pouring stir casting furnace.
Evaluation of mechanical characteristics developed by
the composite.
Microstructural analysis of developed composite.
Comparison of developed matrix with base aluminium.
LITERATURE SURVEY
Joythi P N et al. carried out research work on Comparison
of Mechanical properties of Aluminium 5% Si alloy
reinforced with cow dung ash and rice husk ash. They
fabricated hybrid aluminum metal matrix composites using
electric induction furnace following stir casting technique.
They observed that hardness of the specimen prepared
found higher than aluminium alloy. The porosity in the cast
composite was found higher when compared to cast
Aluminium 5% Si alloy.
P B Madison et al. carried out research work on
characterization of coconut shell ash for potential
utilization in metal matrix composites. They analyzed
coconut shell powder in terms of composition, hardness
and density. The particle size analysis results revealed that
the grain fineness number of coconut shell ash as 75.08.
the density of coconut shell ash found have 2.05 gm/cc.
From referred literatures it can be inferred that not much
research work has been carried out using Al 4008
reinforced with cow dung ash and coconut shell ash.
Hence fabrication and machining of Al 4008 and coconut
shell ash and cow dung ash composites were considered
for the project work.
ALUMINIUM
Aluminum based composites are finding wide spread
acceptance especially in applications where weight and
strength are prime concern.
Aluminum is now the second most widely used metal in
the world.
The characteristics of aluminum include: low density and
therefore low weight, high strength, easy machining,
excellent corrosion resistance and good thermal and
electrical conductivity are amongst aluminium’s most
important properties.
 Chemical composition of Al4008 grade
TABULAR COLOUMN
Al Cu Mg Si Fe Mn Ni Pb Sn Ti Zn Cr

92.87 0.033 0.084 6.703 0.161 0.041 <0.0 0.023 <0.0 0.010 0.040 0.016
3 1

Table 1.1 -Chemical composition of Al4008 grade

PROPERTIES
•The product is non reactive under normal condition of use
storage and transport
•It is stable at normal condition
COW DUNG ASH
Cow dung, which is usually dark brown Color is used
as manure(agricultural fertilizer).
It is rich in minerals.
The chemical properties of cow dung ash have rich in
nitrogen, potassium and calcium.
It has relatively high carbon to the Nitrogen ratio. 
Cow dung ash has normally added up to 30%.
 ADVANTAGES :
Within these limitations, the advantages of cow dung ash is,
• lightness of weight.
• low thermal conductivity.

COCONUT SHELL ASH

Coconut shell ash is agricultural waste.
Their effective, conductive and eco-friendly utilization has
always been a challenge for scientific applications.
 PROPERTIES RATING
Strength High
Thermal Expansion Low
Density Low
Thermal Conductivity Low
Hardness High
Table 2: Properties of Cow dung ash

PROPERTIES RATING

Strength High
Thermal Expansion Low
Density Low
Thermal Conductivity Low
Hardness High

Table 3: Properties of Coconut Shell Ash

EXPERIMENTAL SET UP
Materials used:
Cow dung
Coconut shell(without fibres)
Aluminium
Aluminium foil
APPARATUS USED
BOTTOM POURING
STIR CASTING FURNACE
CRUCIBLE
TONGS
SEIEVE
METHODOLOGY
The first step is to collect cow dung
and coconut shell and dry it for 10 days.
The collected cow dung sample
was broken into small pieces.
With the help of crucible the cow dung samples were fed
to the furnace which was exposed to the temperature of
550 degree C.

Next , with the help of tongs the crucible was removed .

•The ash was sieved to obtain fine dust which is required
to carry out the experiment.
FABRICATION OF COMPOSITE
Fabrication of composite material carried out using following
apparatus:
Sand casting
Sand mould

Sand Casting and Sand Mould:

Sand casting, also known as sand molded casting, is a
metal casting process characterized by using sand as the
mould material.
Moulds made of sand are relatively cheap, and over 70% of
all metal castings are produced via sand casting process in
specialized factories called foundries.
Sand casting allows for smaller batches to be made
compared to permanent mould casting.
From castings that fit in the palm of your hand to train beds
can be done with sand casting.
Sand casting also allow for most metals to be cast
depending on the type of sand used for the moulds.
A suitable bonding agent (usually clay) is mixed with the
sand and the mixture is moistened, typically with water, but
sometimes with other substances, to develop the strength
and plasticity of the clay.
The sand is typically contained in a system of frames or
mould boxes known as a flask.
The mould cavities and gate system are created by
compacting the sand around models, or patterns,or carved
directly into the sand.

Sand Mould Cavity Sand casting

PREPARATION FOR FABRICATION:
Casting
Casting is a manufacturing process by which a liquid
material is poured into a mould that contains a hollow
cavity of the desired shape and then liquid metal is allowed
to solidify. which is ejected or broken out of the mould to
complete the process.
Casting is most often used for making complex shapes.
Procedure:
Initially the chosen aluminum bar were weighed, and the
weights were noted down.
Based upon the obtained weights the percentage of
reinforcement and magnesium to be added were determined.
The cleaned crucible with the aluminium bar within it was
placed inside the sand pit and heated upto its melting point.
Once the aluminium reached its melting point magnesium
was added to remove excess of air in it and stirred
occasionally.

After stirring occasionally the prepared reinforcement of

cow dung and coconut shell ash was added at a constant
rate.
The melt was allowed to superheat and soak for a while at
high temperature
The crucible was removed and the melt was poured in the
metal mould. A little extra melt was added to counter the
contraction of the metal during cooling.

Mould is preheated and molten metal is poured into the mould.

The pouring was done at a uniform rate to prevent porosity.
The mould was allowed to cool.
Vent holes were made so as to remove entrapped air. If we
fail to remove the gases, they cause serious
porosity/blowholes in the casting. Further, expanding air
can cause serious force in the die resulting in the increase in
parting line gap.
The End product which is obtained after knocking the
mould is shown in figure.

Casted Al4008 specimen after cooling

The casted alloy was further machined and polished to get
fine and structured specimen to carry out further testing
process.
Lathes are specially designed for turning operation and they
help in cutting the metal in most precise way. The work
piece is placed on the chuck and the machine rotates the
stationary tool to cut the unwanted parts from the piece.

Turning Operation
WORK COMPLETED
Collection of samples
Preparation of reinforcement
Process of Casting
Machining
WORK PENDING
 Testing of Properties of prepared cast
POSSIBLE OUTCOME
The following experimentation may enhance the
properties of Aluminium.