FABRICATION OF Al-SiC COMPOSITE AND STUDY OF ITS SINTERING KINETICS

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Introduction

Aluminium matrix composites (AMCs) refer to the class of light weight high performance aluminium centric material systems. Properties of AMCs can be tailored to the demands of different industrial applications by suitable combinations of matrix, reinforcement and processing route. Presently several grades of AMCs are manufactured by different routes. AMCs have been utilized in high-tech structural and functional applications including 4/19/12

Composite

The term composite broadly refers to a material system which is composed of a discrete constituent (the reinforcement) distributed in a continuous phase (the matrix), and which derives its distinguishing characteristics from the properties of its constituents, from the geometry and architecture of the constituents, and from the properties of the boundaries (interfaces) between different constituents. Composite materials are usually classified on

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The major advantages of AMCs compared to unreinforced materials

Greater strength Improved stiffness Reduced density(weight) Improved high temperature properties Controlled thermal expansion coefficient Thermal/heat management Enhanced and tailored electrical performance Improved abrasion and wear resistance 4/19/12

Types of AMCs

Particle-reinforced AMCs (PAMCs)-equiaxed ceramic reinforcements, oxides or carbides or borides reinforced, manufactured by solid state (PM processing) or liquid state (stir casting) processes. Whisker-or short fibre-reinforced AMCs (SFAMCs)- reinforcement is not continous, manufactured by PM processing or by infiltration route. (c) 4/19/12 Continuous fibre-reinforced AMCs

Effect of ceramic reinforcements on the behaviour of aluminium matrix in AMCs

Presence of relatively large (more than 10%) volume fraction of ceramic reinforcement (whisker/particle/short fibre/continuous fibre) profoundly effect the behaviour of aluminium matrix in aluminium matrix composites during manufacturing, heat treatment and their subsequent use in service. Two types of changes that occur are Intrinsic Extrinsic

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Intrinsic effects

Intrinsic effects include microstructural changes, heat treatment characteristics and thermal stresses. Salient features of intrinsic effects caused by ceramic reinforcements are: Solidification structure of AMCs-act as barrier to diffusion of heat, catalyse the heterogeneous nucleation of phases crystallising from the melt, and induce morphological instabilities in the solidliquid interface. Effect on the age-hardening characteristics of 4/19/12

Extrinsic Effect

Incorporation of ceramic reinforcement in Al alloys leads to significant improvement in the sliding wear resistance of Al MMCs. In recent years extrinsic effect of SiC reinforcement in Al MMCs has been beneficially utilised in Al MMC brake disc/ brake pad tribocouple

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Problem Formulation

In order to estimate the properties of Al-SiC composites at different temperature and at different composition and study of their sintering kinetics, we studied from literature about the processes, variants which can result in change in properties of these composites and hence we tried to visualize the microstructure and their grain 4/19/12 boundaries.

FABRICATION OF METAL MATRIX COMPOSITES

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Green Compacts

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Sintering

Sintering of powder sequentially involves the establishment and growth of bonds between the particles of powder at their areas of contact and migration of the grain boundaries formed at the bonds. Bonds form between the particles during sintering, and the number of particle bonds increases as the temperature increases. Sintering 4/19/12 was done in Muffle Furnace

Sintered Pellets

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Analysis of Microstructure

Sample were polished on emery paper no. 320,400,600 & 800 Then final polishing is done on velvet cloth with brasso. Etching is done using HF as an etchant Then microstructure were studied using optical microscope.
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Al-5%SiC at 700 deg C

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Al-10%SiC at 900 deg. C

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Al-15%SiC at 500 deg. C

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Conclusion

Melting point of aluminium is 660 deg C. As a result, sintering upto 660 deg C is solid phase sintering and as the temperature increases above 660 liquid phase sintering starts as shown in the microstructures shown above. Microstructure obtained at 550 deg C, grain boundaries of aluminium are clearly visible and SiC embedded in Al matrix can be seen clearly. 4/19/12