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Original Article

Investigation on mechanical, tribological andmicrostructural properties of AleMgeSieT6/SiC/muscovite-hybrid metal-matrix composites forhigh strength applications

Shubham Sharma a, Jujhar Singh a, Munish Kumar Gupta b,c,Mozammel Mia d,*, Shashi Prakash Dwivedi e, Ambuj Saxena e,Somnath Chattopadhyaya f, Rupinder Singh g, Danil Yu Pimenov c,Mehmet Erdi Korkmaz h

a Department of Mechanical Engg., IKG Punjab Technical University, Jalandhar-Kapurthala Road, Kapurthala,

144603, Punjab, Indiab Key Laboratory of High Efficiency and Clean Mechanical Manufacture, Ministry of Education, School of Mechanical

Engineering, Shandong University, PR Chinac Department of Automated Mechanical Engineering, South Ural State University, Lenin Prosp. 76, Chelyabinsk,

454080, Russiad Department of Mechanical Engineering, Imperial College London, Exhibition Rd., SW7 2AZ, London, UKe Department of Mechanical Engineering, G.L. Bajaj Institute of Technology and Management, Greater Noida,

201308, Indiaf Indian Institute of Technology (Indian School of Mines), Dhanbad, 826004, Indiag Department of Mechanical Engineering, University Institute of Engineering, Chandigarh University, Gharuan,

Mohali, Punjab, Indiah Karabuk University, Engineering Faculty, Mechanical Engineering Department, Karabuk, Turkey

a r t i c l e i n f o

Article history:

Received 22 December 2020

Accepted 23 March 2021

Available online 27 March 2021

Keywords:

Aluminium metal matrix composite

(Al-MMC)

Silicon carbide

Muscovite or hydrated aluminium

potassium silicate

Mechanical properties

* Corresponding author.E-mail address: [email protected]

https://doi.org/10.1016/j.jmrt.2021.03.0952238-7854/© 2021 The Authors. Published bcreativecommons.org/licenses/by-nc-nd/4.0/

a b s t r a c t

The wide range of aluminium variants (alloys and composites) has made it an important

material for aviation, automotive components, auto-transmission locomotive section

units, S.C.U.B.A. tanks, ship, vessels, submarines fabrication and design etc. regardless of

the fact that the aluminium alloys were being utilized in myriads of sectors owing to its

exceptional superior and versatile functional characteristics, the property such as wear-

resistant ought to be enhanced in order to further prolong diverse spectrum of applica-

tions. An aluminium alloy having lower hardness and tensile strength has been incorpo-

rated with silicon carbide that drastically strengthens the properties. This study involves

fabrication of aluminium silicon carbide with muscovite/hydrated aluminium potassium

silicate/aluminosilicate in stir casting method to obtain a hybrid metal matrix composite.

Maintaining a constant amount of aluminium and silicon carbide, muscovite or hydrated

aluminium potassium silicate is varied to obtain three distinctive compositions of (Al/SiC/

muscovite) composites. The mechanical characteristics like tensile-strength, flexural-

(M. Mia).

y Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://).

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j o u r n a l o f m a t e r i a l s r e s e a r c h and t e c hno l o g y 2 0 2 1 ; 1 2 : 1 5 6 4e1 5 8 1 1565

Tribology

Stir casting

strength, toughness, hardness, scratch adhesion, percent-porosity and density were

studied. The dispersion of muscovite and silicon carbide particles were observed by

viewing the microstructure photographs obtained using optical microscopy and Scanning

Electron Microscope (SEM). EDAX analysis affirms the presence of reinforcing constituents

in AleMgeSieT6 alloy matrix. A drum type wear apparatus was utilized to evaluate the

percentage of wear-loss in different compositions using different loads and it was found

that the wear-loss decreases linearly as the muscovite percentage was increased.

© 2021 The Authors. Published by Elsevier B.V. This is an open access article under the CC

BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).

1. Introduction

Aluminium is the third most abundant material available in

nature. It has replaced the ferrous element in wide range of

applications due to its specific properties like low density,

corrosion-resistance due to passivation, light in weight etc.

Aluminium also possesses undesirable characteristics that

preclude it from being used in certain sectors. A new material

called aluminium-composite was discovered to resolve and

combat the flaws/imperfections/inconsistencies in pure

aluminium-alloys. Aluminium composites are also called as

AleMMC. A metal matrix composite is a combination of two

distinct metals to obtain a compounded material known as

reinforcedmaterial. In metal matrix, matrix is the continuous

material in which the reinforcing material is added in whis-

kers, fabrics and particulates. The reinforcement may be

continuous or discontinuous. When more than one

reinforcing-constituent is incorporated with the matrix, it is

said to be a Hybrid metal matrix composite (HMMC). The

aluminium alloy components are replaced with metal matrix

aluminium composites (MMC). The MMCs play a vital role in

our modern day today life. Graphite or steel with high carbide

contents or tungsten carbides or metallic binders also come

under this category. It is mainly used when a conventional

material does not achieve the required standards or specific

demands. Reinforcement of the metal matrix is chosen based

on the required property to be achieved with a base metal.

Such a MMC’s are called as particulate metal matrix com-

posites (PMMCs). The PMMCs lead to obtain a higher-strength

and higher-wear resistive material by the reinforcement of

hard particles like SiC and B4C etc., HMMCs are modern day

composites wheremore than one-type of material of different

shapes and sizes are used to improve the properties. They are

still advantageous than PMMCs as it involves with advantages

more than two materials.

Metal matrix composites such as cobalt matrix with tung-

sten carbide particles is used to manufacture carbide drills,

steel reinforced with boron nitride is used in tank armours, in

power electronic modules aluminium graphite composites are

used because of their high thermal conductivity. These com-

posites have wide range of application space systems because

of their wide range of operating temperatures and resistance to

absorb moisture etc. Macke et al. [1] in their work described

about the opportunity in reduction of weight and increase in

performance of automobiles using MMCs. Narale et al. [2]

carried-out drilling experimental studies to examine the

influence of drilling operation-parameters like feedrate,

spindle-velocity, drill bit-material and various other parame-

ters of materials as percent-reinforcing constituents on the Al/

B4C/muscovite HMMCs. During the drilling process of fabri-

cated specimens, thrust force and drilling torque were deter-

mined, along with surface roughness (SR) of specimens after

process was analysed and response based on GRA method is

discussed. Results reported that the thrust- and drilling

twisting forces increases as the percent reinforcing-

constituents and feedrate raise. As the percent reinforcing-

constituents increases, the SR of the drill-hole reduces. How-

ever, as the feedrate rises, the SR also increases. It seemed to be

concluded that the superior percent wt. of reinforcing was 10

percent, feedrate was 0.1 mm/revolutions, cutting-velocity was

2000 revolutions/minutes, and Titaniumealuminiumenitride

coated carbide-tool was the drill-bit material as it provides

highest grey-relational-grade. In another study, authors

revealed that the ground muscovite or hydrated aluminium

potassium silicate coated with copper found to have good

strength and used for bearing applications [3].

Pargunde et al. [4] successfully casted SiC particulate

reinforced aluminium matrix composites by varying weight

fraction (ranging from 5 to 20% in steps of 5) and grit size (220,

300 and 400 mesh) of SiC. The hardness (HRB) of samples was

evaluated using Brinell hardness tester. The impact strength

is calculated with the help of Charpy test. The tests were

conducted on sample of size SQ10 mm � 55 mm consisting V-

notch of 45� and 2 mm depth. The metallographic analysis

was carried out using inverted metallurgical microscope. For

this, the cylindrical samples were prepared and etched with

0.5% hydrofluoric acid. Square cross-section recorded and

microstructure. The authors were observed better quality of

castings obtained through stir casting with minimum air

entrapment and minimum setup time. Barekar et al. [5] used

high pressure die casting process to formulate the Al (LM24)-

Gr aluminium matrix composites. Authors observed regular

dispersion of graphite particulates within the aluminium

grain structure as a result of shearing technology. Also, a

strong bonding is obtained between the constituents which

improves the mechanical properties (better tensile strength

and elongation) when compared with composite produced

through ordinary methods. The improved properties uniform

dispersion of reinforcement particulates ensures the benefits

of this new casting process.

Guan et al. [6] evaluated the effect of stirring parameters on

the microstructural and tensile strength of novel





Al6061eSiCeABO hybrid composites. The investigators

described the homogeneity in the dispersion of re-

inforcements. Also, the improved in tensile strength is ob-

tained with increasing the stirring-time and reducing the

temperature. The authors also reported the optimal values of

stirring time and temperature as 30 min and 640�c for better

microstructure and tensile behaviour. Also, the preheating of

reinforcement particulates improves wettability and reduces

the possibility of interfacial reactions among the ingredients.

In another research, Songmene and Balazinski [7] reported

that nickel-coated graphitic AleAl2O3 aluminium matrix

composite exhibits better machinability than the AleSiCeGr

or AleSiC composites reinforced with graphite and SiC or SiC

alone. This improvement attributes to the existence of

graphite particulates, which serves as dry-lubricating agents

during the machining process. Lokesh et al. [8] evaluated the

variation of hardness in stir casted, squeeze casted and stir

casted followed by rolling process for Ale4.5Cu alloy com-

posites reinforced with SiC (2e6 by weight with steps of 2) and

fly ash (2e4% by weight). Experimental results indicated that

squeeze casted composites exhibited more hardness

compared to stir casted. This is because of higher pressure

applications in this process which reduced porosity, made the

composite denser, improved the resistance of plastic defor-

mation and in turn increased the hardness. Furthermore, the

rolling process removed the internal voids and refined the

materials, results in increased the hardness compared to stir

casted or squeeze casted ones.

Carvalho et al. [9] have investigated that hardness of hybrid

composite of the matrix alloy (Al/SiC alloy), Al-CNT and

AleSiC composites and AleCNTeSiC hybrid composite. The

hardness was increased with addition of CNT and SiC rein-

forcement material and highest value observed in the hybrid

composite when compared with matrix alloy and single

reinforcement material. Alidokht et al. [10] also observed that

hardness of matrix alloy (A356 alloy) and composite materials

with addition of SiC and MoS2. With the addition of SiC and

MoS2 material, the hardness was increased and the highest

values were reported in the A-356/SiC composite as compar-

ison to the matrix alloy and AleSiCeMoS2 hybrid composite.

Krishnamurthy et al. [11] (2012) developed Al2O3 and calcia

stabilized zirconia coating on Aluminium 6061 with the help

of spraying method. By comparing the properties of both

coatings, density of calcia-stabilized zirconia coatings was

found to be denser than alumina coatings, which lead to less

erosion of calcia-stabilized zirconia coating under erosion

test. By comparing hardness, alumina coating is harder than

calcia-stabilized zirconia coating. Strength, young modulus

and strain hardening rate shows increment with the increase

in reinforcement. They also observed decrease in percentage

elongation with reinforcement. Shin et al. [12] evaluated the

effects of temper, specimen orientation and temperature on

mechanical properties of Al 6061/SiC composites. The author

observed that strength and stiffness was improved with the

reinforcement but cannot be proved beneficial at 3000 �C.Fracture toughness decreases with SiC reinforcement. Aruri

et al. [13] fabricated surface hybrid composites of aluminium

alloy with reinforcement of SiC, Gr, Al2O3. They observed in-

crease in micro hardness with the reinforcement of SiC and

Al2O3 particles due to their pining effect. Tensile strength

decreaseswith the reinforcement of Al2O3 and SiC particles. S.

Gopalakrishnan et al. [14] investigated effects of reinforce-

ment of Titanium carbide (TiC) particles in aluminium alloy

6061. The author found that specific-strength of composites

enhances with the raising percentage of TiC particles.

Mittal et al. [15] explored the mechanical characteristics of

aluminium 7075 with reinforcement of SiC, Red mud and

Al2O3. The author revealed that hardness of composites hav-

ing reinforcement of Al2O3 and red mud is more than the SiC

reinforced composites and also increases with the percentage

of reinforcement. €Ozdemir et al. [16] evaluated the properties

of Al/SiC MMCs and revealed that tensile and yield strength

improves with the percent-content of SiC up to 17% and

decline with further increment in percentage. The elastic

modulus increases with % of SiC while ductility of composite

decreases. Singh et al. [17] fabricated composite material of

aluminium alloy as base matrix and carbon fibre as rein-

forcement. They found that UTS (Ultimate tensile-strength)

and yield-strength increases up to 4 wt.% of carbon fibre.

Hardness of composites initially shows an increment with

carbon fibre and then decreases with further addition of car-

bon fibre. Akbari et al. [18] researched the effect of nanosized

Al2O3 and copper as a reinforcing-particulates in A-356 alloy.

They observed superior compressive strength and hardness of

composites than base metal alloy. It increases with the addi-

tion of Al2O3 and have maximum hardness and compressive

strength with the reinforcement of Al2O3eCu. Hardness

changes over the length of components (cylinder) due to dif-

ference in Nano particles and porosity contents, however

compressive strength remains constant. Zhang et al. [19]

examined the mechanical characteristics of SiCp/Al compos-

ites and revealed that the Brinell hardness and modulus of

composite increases with the volume-fraction of SiC but no

trend was observed for bending strength.

Kumar et al. [20] explored the effects of reinforcement of

Silicon carbide in Al 6061. The authors found that the me-

chanical properties of composite enhance with the increment

in percent-content of SiC. Ductility of material reduces with

the reinforcement of SiC. Yue et al. [21] fabricated composite

of Al 6061 reinforced with aluminium borate whiskers and

investigated its mechanical properties. They observed supe-

rior mechanical properties of composites and increases with

the reinforcement. Ma et al. [22] observed that Al/SC com-

posites bear excellent mechanical properties and can attain

compressive strength up to 304.28 MPa. Kumara et al. [23]

studied the effects of reinforcement of SiC and Al2O3 in

aluminium matrix and observed that composite with 5% SiC

and 2.5% Al2O3 have high microhardness and toughness. Cao

et al. [24] examined the mechanical behavioural of carbon-

efibre reinforced aluminium composites and observed that

when compared with the aluminium-matrix, the hardness of

composites increases by 46.8%. They also got 18.6% increment

in tensile-strength and 13% improvement in elongation of

composites fabricated at 100 rpm and at a speed of 75 mm/

min.

Gireesh et al. [25] investigated the mechanical behavioural

of aluminium composite with aloevera powder as a reinforc-

ing constituent, and achieved better tensile strength, impact

strength and hardness than basematerial. However, themain

application of metal matrix composites lies in automobile




field where it is used as driveshaft’s, disc brakes, push rods,

cylinder linings and also as a reinforcing in cylinder sleeves.

All the above applications have a direct relationshipwithwear

of the component. Thus, improvement in the wear loss found

itself very useful. The investigators have gone through

different studies in which the addition of silicon carbide and

muscovite or hydrated aluminium potassium silicate has

been made and has a significant impact in the wear loss.

Basavarajappa et al. [26] stated that wear rate of Al-15SiCp-

3graphite at weight percent hybrid composite, Al-15SiCp at

weight percent composite and matrix alloy (Al 2219 alloy) at

various sliding-speed. Thewear-rate was found to be constant

with a sliding-velocity of 4.61m/s in the composite andmatrix

alloy, but further increased sliding speed showed that wear

rate was increased in the alloy and Al-15SiCp at weight

percent composite in comparisonwith Al-15SiCp-3 graphite at

weight percent hybrid composite. Alidokht et al. [27] also

observed low wear rate in the SiC and MoS2 reinforced hybrid

composite than A356 alloy and AleSiC composite at different

applied-loads due to the SiC acted as load-carrying material

and MoS2 served as dry-lubricating agent.

Corrochano et al. [28] investigated dry-sliding behavioural

of AA-6061-Molybdenum disilicide under dry-environment

and revealed that composite bears higher wear-resistant

than monolithic alloys. They also reported the improved

wear-resistant of composites as the particulate-size of rein-

forced material decreased. Benal et al. [29] studied the wear

properties of Aluminium 6061 composites with the rein-

forcement and ageing durations. Researchers observed that

heat treated specimens have high hardness and improved

wear properties. Wear-rate of hybrid composites also reduces

with enhancement in percent-wt. of reinforced material.

Baradeswaran et al. [30] analysed the wear-behavioural of

composites fabricated by introducing B4C particles in Al 7075

alloymatrix. The result showed increase in the wear-resistant

of composites. Wear rate decreases as compare to metal ma-

trix and found only 11% of pure metal at 10vol% B4C rein-

forcement. Hamid et al. [31] studied the effects of porosity and

dispersion of MnO2 particles on the wear-behavioural of

Al(Mn)eAl2O3(MnO2) composite. They observed decrease in

volumetric-loss and improved wear properties of in cast in

situ composites as compare to AleMn base alloy and com-

mercial aluminium at high load conditions. Wear-resistant

rises with significantly rise in percent volumetric proportion

content of in situ porosity composites.

Jha et al. [32] compared the tribological behaviour of

Cenosphere-filled aluminium synthetic foamwith aluminium

composite reinforced with 10 wt.% SiC particles. Authors

observed the wear behaviour at an applied load of 29.43 N& at

different sliding velocity. They concluded that aluminium

synthetic foam (ASF) has superior wear performance than the

aluminiummatrix composite (AMC) under similar conditions.

Baradeswaran et al. [33] explored the wear-behavioural of

aluminium composite fabricated with the Al2O3 and graphite

as reinforcing-particulates. Liquid metallurgy route was used

to fabricate material. They observed less wear due to thin

layer of graphite particles on sliding surface and increase in

hardness due to Al2O3 particles. Sharma et al. [34] investigated

the wear-characteristics of aluminium fly ash composites.

Vortex technique was utilized to process the composites

having 2, 4 and 6 wt.% of fly ash content. Author revealed that

composites having 6 wt.% of flyash shows less wear (0.32 g),

while low friction coefficient (0.12) was achieved at 4 wt.% of

fly ash.

Pramanik [35] explored the effects of Al2O3 reinforcing-

particulates in AA-6061. Author observed that the reinforce-

ment of Al2O3 enhances the wear-resistant of composites and

useful to control wear. Zhu et al. [36] analysed the wear-

characteristics of AA-356/fly-ash-mullite interpenetrating

composites. Wear-resistant of the composites increase with

reinforcement and the dry-sliding wear-rate were reported to

be quite somewhat less than half the base metal (A356 alloy).

Phanibhushana et al. [37] examined the wear-behavioural of

Haematite reinforced aluminium composites. Weight loss of

specimens was used to calculate the wear-rate of the com-

posites and the result shows improved wear resistance with

increase in reinforcement. At reinforcement of 8%, they get

30e40% decrease in wear factor as compare to the base metal.

Eskandari et al. [38] prepared Strontium titanate and

CoFe2O4 based nano composites successfully using sol gel

technique. For this, initially CoFe2O4 were prepared using

hydrothermal process and SrTiO3with sol gel technique. Then

after the nano composites viz. CoFe2O4eSrTiO3 and SrTiO3:

NeCoFe2O4 were synthesized were produced with the help of

sol gel route. Results indicated that nano-particles agglomer-

ated with the increase of reaction time. However, increasing

the temperature has a beneficial impact on the morphology of

nano-particles, resulting in the development of homogeneous

and spherical nanoparticle. Results also results also indicated

that photo-catalytic activity of cobalt ferrite-strontium tita-

nate nanocomposite under UV light was higher than that of

pure strontium titanate. Also, the structure of the SrTiO3 was

successfully doped with nitrogen.

Etminan et al. [39] presented a comparative study on the

chemical procedures adopted for the preparation of tin ferrite

nano particles. These chemical procedures were included sol

gel, co-precipitation, sol gel and hydrothermal routes. Authors

also prepared tin ferriteetin oxide nano-composite with the

help of co precipitation route, taking 1:1 ratio of the constit-

uents. The XRD pattern was used to analyse the crystal

structures of nanoparticles and nanocomposite. SEM was

used to determine the particle size. The magnetic character-

istics of the products were evaluated using a vibrating sample

magnetometer. The purity of the substance was also

measured using a Fourier transform infrared spectrometer

(FTIS). Ultraviolet and visible spectroscopy (UVeVis) is used to

investigate the photo-catalytic behaviour of nanoparticles and

nanocomposites. The results indicate that prepared nano-

composites can be used for magnetic and photo-catalytic ap-

plications, and that they can degrade azo dyes (organic dyes)

when exposed to UVeVis radiation.

Joulaei et al. [40] prepared MgFe2O4 nano-particles with the

help of sol gel method using various fruit extracts. Results

indicated that at room temperature, the MgFe2O4 nano-

particles exhibit ferromagnetic behaviour. Also, the formation

of nanocomposite and the distribution of MgFe2O4 into the

polymeric matrix improved coercivity.

Kiani et al. [41] formulated MgTiO3 and MgFe2O4 based

nano particles microwave assisted technique and then after

utilized them to MgTiO3 and MgFe2O4 based nano composites



Fig. 1 e Scientometric map analysis chart.


using sol gel technology. XRD and SEMwere used to verify the

crystallinity and purity of the materials and morphology.

Vibrating sample magnetometry was used to determine the

magnetic properties of the manufactured material. The re-

sults show that organic dyes photo degrade well when

exposed to visible light. Our results suggest that the MgFe2-O4eMgTiO3 nanocomposite can be used for successful charge

separation and charge carrier lifetime enhancement. The

photo catalytic activity of this substance is higher than that of

MgTiO3 nanostructures.

Moradi et al. [42] developed iron oxide-Caesium oxide nano

composites in the presence of lemon extracts using hydrother-

mal process. Authors initially, prepared Fe3O4 (iron oxide) nano

particleswith thehelp of using fast precipitation route and then

introduced in the nanocomposites. XRD, SEM, vibrating sample

magnetometer (VSM) and FTIS were used to characterize the

prepared composites. Results showed that iron oxide nano-

particles exhibited super-paramagnetic behaviour. It was sug-

gested that the prepared nanocomposites have application for

photocatalytic and magnetic outcomes.

Naghikhani et al. [43] formulated copper iron oxide rein-

forced copper oxide nano composites using water solvent

method. The copper iron oxide nano particles initially pre-

pared using hydrothermal route using various surfactants like

gelatin, saffron, etc. the composites were characterized with

the help of advanced testing routes like XRD. SEM, FTIS, etc.

The results show that the nanocomposite prepared is ideal for

the degradation of toxic azo dyes.

Fig. 1 exhibits the scientometric chart generated through

Vosviewer analytical tool which indicates that limited

research has been carried out on the fabrication, Phys-

icomechanical, scratch adhesion, tribological and morpho-

logical characterizations of AleMgeSieT6/SiC/muscovite

based Hybrid metal matrix composites. This analysis in-

dicates that AleMgeSieT6/SiC/muscovite based Hybrid metal

matrix composite must be considered for application in

various structural designs/prototypes and their practical us-

ages in engineering, automotive, aerospace, bearing and other

related usages. Therefore, from the above review of literature

it was concluded that very few articles communicated relating

to the effect of silicon carbide and hydrated aluminium po-

tassium silicate reinforcements on the Physicomechanical,

specific-wear-rate and morphological characteristics of

AleMgeSieT6 Hybrid-Composite. Efforts were taken to prove

that the increase in percentage of muscovite content in the

stir-casting fabricated, AleMgeSieT6/SiC/muscovite based

Hybrid metal matrix composite which may result in the sig-

nificant increase in the wear resistance. Although it is showed

in this work that the hydrated aluminium potassium silicate

has substantial effect on the wear property such that when

aluminosilicate particulate is added, it minimizes the wear-

loss and enhances the wear-resistance of the AleMgeSieT6/

SiC/hydrated aluminium potassium silicate-based Hybrid

metal matrix composite.

2. Experimentation

2.1. Materials

The matrix that has been used here is AleMgeSieT6 heat

treated alloy. A micron size of 6 mm black silicon carbide is

used as the first reinforcement and muscovite a type of hy-

drated aluminium potassium silicate particulates of 28 mm is

taken as the second reinforcement. Three different composi-

tions, taking 2%, 3% and 4% of muscovite flakes and 5% SiC

powder as a constant required composite were fabricated.

Table 1 shows the percent-weight composition of the fabri-

cated AleMgeSieT6/SiC/hydrated aluminium potassium sili-

cate hybrid metal-matrix composite.



Table 1 e Percent-weight compositions of AleMgeSieT6/SiC/hydrated aluminium potassium silicate hybrid metal matrixcomposite.

Percentage weight composition

AleMgeSieT6 SiC (%) Muscovite or hydrated aluminium potassium silicate (%)

Al þ SiC (5%) þ muscovite or hydrated aluminium potassium silicate (2%) 5 2




AleMgeSieT6 heat treated alloy was purchased from

Khanna Industries, Jalandhar in the form of rods and then

were cut into pieces to as per requirement of the crucible.

Muscovite, a type of hydrated aluminium potassium silicate

particulates was obtained for study from Delcray chemicals,

Chandigarh. Tables 2 and 3 shows the chemical composition

of AleMgeSieT6 heat treated alloy and its mechanical prop-

erties respectively [44]. Table 4 illustrates the chemical

composition of muscovite or hydrated aluminium potassium

silicate.

Reinforcing constituents must be uniformly dispersed in

the basematrix for obtaining optimal testing results. To verify

whether the distribution is uniform, a microstructure study is

to be conducted [21e33]. A scanning electron microscope was

performed based on its superior magnification range of 5� to

300,000�. The surface of the specimen is to be adequately

cleaned, polished, and etched before performing the micro e

structural analysis.

Scanning electron microscope (SEM) analysis was per-

formed to indicate the particle size and shape of the powder

before going to use in the composites. The morphology of

reinforcement materials is shown in Fig. 2. Themorphological

analysis of AleMgeSieT6 heat treated alloy reveals the

microdendrites structure in the peripheral with flux

embedded in the AleMgeSieT6 matrix alloy state, thus

identifies the particulates grain-size and corresponding

dendrite crystalline growth in the continuous dispersed ma-

trix stage with the fragment intrusion of grain refiners prev-

alent in the grain boundaries and grain peripherals. SEM

images results that the silicon carbide particles have flaky,

discrete, acicular or angular shapes and discrete with non-

uniform in particle size.

The muscovite particles revealed cuboidal structure that

could agglomerate with several other aluminosilicate pellets

and became significantly larger blocky layout. The micro-

graphs also illustrate that the powdery hydrated aluminium

potassium silicate fragments displayed a brittle patchy,

elongated, flaky aggregate inmorphology with relatively even,

smoother texture/surface.

2.2. Fabrication-method

The fabrication of composites is done by stir casting method,

due to its suitability in producing uniformly distributed re-

inforcements. Stir casting was done using a furnace with a

Table 2 e Composition of AleMgeSieT6 heat treated alloy.

Cu Si Mg Mn

0.15e0.4 0.4e0.8 0.8e1.2 Max 0.15

maximum temperature setting as 1000 �C. A graphite crucible

of 2 kg capacity was selected according to the furnace’s

dimensional specifications. The base material that is

aluminium was placed inside the graphite crucible and was

kept into the furnace at a temperature of 850 �C which is

higher than the melting point of aluminium which is around

630 �C so as to obtain the molten state [12e18]. The re-

inforcements were also kept at the same temperature to

improve its wettability with aluminium.

The cylindrical rods are cut into required sizes and placed

into the crucible. SiC and hydrated aluminium potassium

silicate are taken in separate vessels and preheated alongwith

the crucible in the furnace up to a temperature of 850 �C. Themetallic moulds of required shapes are placed in the pre-

heated and heated up to a temperature of 500 �C. After 850 �Cis reached the molten aluminium is taken out and 5 g of

degasser is added to remove the impurities and small amount

of coverall is added to prevent oxidation. For a good wetta-

bility a small amount of magnesium is added. The heated SiC

and hydrated aluminium potassium silicate are added to the

crucible and placed again into the furnace. The furnace is once

again heated up to a temperature of 850 �C [22e33]. The cru-

cible is placed perpendicular to the stirrer and the stirrer is

inserted into the crucible. The stirrer is made to stir at a speed

of 300 rpm.

The dies were washed utilizing emery paper, and then

graphite in addition with the kerosene was applied to avoid

thematerial from adhesion to the surface of the dies. The dies

were pre-heated to a temp. of 500 �C to mitigate the occur-

rence of shrinkage and blowholes once molten metal was

pouring into it. Three different compositions were taken

keeping percent weight of silicon carbide a constant 5% and

increasing the muscovite percentage from 2, 3 and 4%

respectively in each composition.

For, preparing the specimens for wear analysis according

to ASTM standards, cylindrical die of sizes of 20 mm diameter

and 175 mm long were taken. Magnesium was added to

compensate for the heating-loss but also to enhance the

wettability among thematerials. As the temperature set in the

furnace was achieved the crucible was taken out, degasser

and coverall were added to the molten metal to remove the

impurities of the material. The reinforcing particulates were

incorporated with the molten aluminium-matrix, and were

placed within the furnace to attain a temp. of 850 �C. Once the

temperature has been attained, a stirrer was placed inside the

Fe Ti Zn Al

Max 0.7 Max 0.15 Max 0.25 Balance



Table 3 e Mechanical properties of AleMgeSieT6 heat treated alloy.

Density(g cm�3)

Ultimate Tensile strength(MPa)

Yield tensile strength(MPa)

Elongation(%)

Modulus of elasticity(GPa)

Poissonratio

2.7 310 276 12 68.9 0.33


furnace which rotate at 300 rpm such that the reinforcements

was distributed uniformly. The stirring was carried-out by

maintaining the constant temp. and was conducted for

approximately 10-min. The resultant molten material is then

started pouring into the cylindrical-dies and left to cool for 3 h

after which the die was opened to acquire the specimens for

dry-sliding wear analysis.

The preheated metal moulds are placed over river sand.

The crucible with melt is poured into the mould. The melt is

poured until the metal rises from the riser. The mould is then

allowed to be cooled and then the metal of the moulds shape

is obtained which is then later cut into require dimensions of

the specimen.

3. Results and discussions

3.1. Morphological characterization

The specimen of 10 � 10 � 10 mm3 prepared as per the ASTM

Standards has polished for evaluating the microstructural

characterization and fracture-behaviour. The 5% volume

content of Hydrofluoric acid (HF)etchant is used to etch the

surface of the sample and it is washed in distilledwater before

carrying out SEM. Optical-OmaxMetallurgical Microscopewas

used to characterize the morphology of AleMgeSieT6 alloy/

SiC/muscovite hybrid composites as well as reinforced-

particle dispersion of SiC and muscovite particles in

AleMgeSieT6 alloy matrix.

As indicated in Fig. 3(a), the particles of AleMgeSieT6

alloy/5%SiC/2% muscovite or hydrated aluminium potassium

silicate sample are not homogeneously distributed and tend to

be strewn about. Throughout Al solutions, the surface

morphology reveals a strong inter-dendritic formation of

AleSi eutectic particles. The grain-boundary void cavities

were filled by composite particles. Further, from Fig. 3(b) it was

observed that particles of AleMgeSieT6 alloy/5%SiC/3%

muscovite sample are not homogeneously distributed and

tend to be strewn about. Throughout Al solutions, the surface

morphology reveals a strong inter-dendritic formation of

AleSi eutectic particles. The proportion of composite particles

is significantly lower, and also the matrix dispersion is uni-

formly homogenous. Next, Fig. 3(c) depicts the particles of

AleMgeSieT6 alloy/5%SiC/4%muscovite or hydrated

Table 4 e Chemical properties of muscovite or hydratedaluminium potassium silicate (mass fraction %).

SiO2 Al2O3 K2O Fe2O3 Na2O TiO2 CaO MgO

45.57 33.10 9.87 2.48 0.642 Traces 0.21 0.38

aluminium potassium silicate sample are not evenly

dispersed yet appears to still be widely disseminated. The

larger proportions of composite particulates in the metal-

matrix have significantly contributed towards a larger

dispersion. The composite fragments filled the latent voids,

micro-cavities and cracks at the grain boundaries in poly-

crystalline material structure.

The micrographs obtained by scanning electron micro-

scopy show the dispersion of the reinforcement particles in

the matrix as illustrated in Fig. 4(aec). The SiC particles were

evenly distributed and muscovite or hydrated aluminium

potassium silicate was clogged at some places. There is an

agglomeration of particles. An existence of tiny openings and

shallow pits is owing to the surface oxidation through a sur-

face abrasion or grinding or etchants. The fine reinforcing

particulates blended in with the matrix generate thread-like

grain boundary-layers.

The SEM photographs acts as evidence for the proper dis-

tribution of silicon carbide and muscovite or hydrated

aluminium potassium silicate particle in the aluminium ma-

trix. SEM and EDAX analysis have confirmed the existence of

carbon (10.77% by wt.), oxygen (0.30% by wt.), aluminium

(88.17% by wt.) and silicon (0.76% by wt.) [35]. Fig. 5 depicts the

existence of an elemental-compositions by percent wt.

3.2. Mechanical properties

3.2.1. Tensile strengthTensile strength is one of the important parameters which is

used to determine the applications of a material. The ASTM

standard applied for tensile test was E8. The cylindrical rod

casted by stir casting method is machined with respect to

standard. A dumbbell shaped specimen was fixed at the ends

of the universal testing machine. Tensile load was applied

until the break point and the corresponding values were

recorded. Table 5 shows the mechanical characteristics of

AleMgeSieT6 alloy/SiC/muscovite hybrid metal matrix com-

posite of each percent-weight compositions.

Figs. 6e8 demonstrates the relationship between tensile

strength, yield stress and elongation percentage of the com-

positions respectively. The tensile strength specimen in-

creases from 2% of muscovite or hydrated aluminium

potassium silicate composite content to 3% of it. Above 4% of

muscovite, the tensile strength is observed to be decreased.

This shows that 3% muscovite composition is the threshold

region of AleMgeSieT6/SiC/muscovite hybrid metal matrix

composite. The elongation percentage of all the three-

composition remained constant. The consistency in elonga-

tion percentage is due to constant silicon carbide 5% content.

The brittleness increases with increase in SiC and thereby it is

observed that 3% muscovite or hydrated aluminium potas-

sium silicate constituent is good.



Fig. 2 e (a) SEM micrograph of AleMgeSieT6 alloy, (b) Silicon carbide powder, and (c) Muscovite or hydrated aluminium

potassium silicate particulate.


3.2.2. Flexural strengthFor flexural testing, rectangular specimen was casted which

was later machined into standard specimen. The specimen

was placed over the universal testing machine and then a

vertical load is applied until breakeven point and the value are

recorded. Table 6 displays the flexural/bending strength of

AleMgeSieT6 alloy/SiC/muscovite hybrid metal matrix com-

posite of each percent-weight compositions.

The flexural test is made to know the load at which a

material starts to bend. Fig. 9 shows that the 2% muscovite or

hydrated aluminium potassium silicate composite possess

higher bending load than the other composites. Therefore, on

increasing muscovite content, the bending load gets

decreased by greater difference at first and followed minimal

differences.

3.2.3. Impact strengthThe method of impact strength that has been applied here is

charpy impact test. A standard test piece of required dimen-

sion is machined and then the test was carried out. Table 7

illustrates the Impact strength of AleMgeSieT6 alloy/SiC/

muscovite hybrid metal matrix composite of each percent-

weight compositions.

The toughness of the composites obtained through charpy

impact tester portrays that the toughness of the composite

Fig. 3 e (a) Optical microscopy of Al þ SiC (5%) þ muscovite or

(b) (3%) composition, and (c) (4%) composition.

decreases at first and then increases as revealed in Fig. 10. The

yield strength of the composite decreases as the composition

of muscovite or hydrated aluminium potassium silicate

increases.

3.2.4. HardnessBrinell hardness test was carried out with a finely polished

plate surface. The workpiece was placed below diamond

indentor and three sets of impressions were made and, on an

average, the Brinell Hardness Number (BHN) was obtained.

Table 8 exhibits the Hardness of AleMgeSieT6 alloy/SiC/

muscovite hybrid metal matrix composite of each percent-

weight compositions.

Three impressions were made on the specimen of each

composition in different places so as to get the aggregate value

of hardness of the sample.

The hardness result obtained by Brinell Hardness test from

Fig. 11, shows that the composition with 3% of muscovite or

hydrated aluminium potassium silicate content possessed

higher hardness than other two compositions. It shows that

with increasing hydrated aluminium potassium silicate con-

tent, the hardness of aluminium silicon carbide decreases. As

this decrease in hardness, improves the machinability of the

composite, thus shows muscovite a good substitute for Al/SiC

composite as a hardness reducing agent. Muscovite or

hydrated aluminium potassium silicate (2%) composition,



(a) (b) (c)

MuscoviteMuscovite

SiC

MuscoviteSiC

Al-Mg-Si-T6

Al-Mg-Si-T6

Al-Mg-Si-T6

SiC

Fig. 4 e (a) SEMmicrograph of Alþ SiC (5%)þmuscovite or hydrated aluminium potassium silicate (2%) composition, (b) (3%)

composition, and (c) (4%) composition.


hydrated aluminium potassium silicate will be a good sub-

stitute for graphite because of its ductile nature.

The effect of various volume fraction (0e20 vol.%) and

grain size (29, 45, 110 mm) on the hardness in squeeze casted Al

(2014)-SiC composites and results revealed that the hardness

value of newly developed composites follows proportionally

trendw.r.t. weight fraction of SiC because of their hardness as

reported by Sahin [45].

3.2.5. Density and porosityThe true as well as actual densities of the composites were

determined, and also the porosity rate for each composite was

computed. An actual density was measured by utilizing Met-

tler Toledo set-up in accordance with the Archimedes’

concept (equation (1)), and true density was estimated by

Fig. 5 e EDS spectra analysis of AleMgeSieT6 alloy/5%SiC/

4% hydrated aluminium potassium silicate sample

composites.

using theory of mixtures (equation (2)). Equation (3) is then

used to evaluate the porosity value.

rAct: ¼ma=½ma �mw� � rw (1)

rTh: ¼ rMatrix �WMatrix þ rSiC �WSiC þ rMuscovite �WMuscovite (2)

%Porosity¼1� ½rAct = rTh � � 100 (3)

Fig. 12 depicts the impact of SiC and muscovite inclusions

on the porosity as well as density of hybrid Al-MMC’s. The

composite materials had reported higher density than that of

the base matrix, as per the findings. It was because of the

massive dense and compact nature of the SiC and muscovite

fragments within a base-matrix granular size structure. In

Ale5SiCe3muscovite MMC, there is a modest increase in

porosity, which enhanceswith escalatingmuscovite contents.

It is due to the cluster aggregation as well as uneven erratic

distribution of particulate elements. This rise in permeability

or porosity could be owing to the higher density of muscovite,

air and gas trappedwith constituent fragments duringmixing,

casting shrinkage throughout solidifications, or molecular

hydrogen-evolution.

3.2.6. Microscratch testsThe Micro-scratch tests on the composites were performed to

assess both the surface-integrity as well as mechanical per-

formance using scratch-adhesion analyzer in reference to the

ASTM C-1624 standard, and the resulting traction force was

measured. The three-scratch test-trials per specimen were

conducted for accuracy perspective, and then an average

reading was taken. The parameters in context with the testing

are exhibits in Table 9.

Prior to carry-out test, the specimen was burr-free and

smoothed utilizing different grades of an abrasive emery-

sand paper. The evident abrasive frictional coefficient (ma) was

computed by dividing the traction-forcewith the normal-load.

Results reported that the scratch test was conducted for

the Al þ SiC (5%) þ muscovite (2%), Al þ SiC (5%) þ muscovite



Table 5 e Tensile strength variation of each composition.

S.no.

Compositions Tensile strength inMPa

Yield stress inMPa

Elongation in%

1 Al þ SiC (5%) þ muscovite or hydrated aluminium potassium silicate (2%) 96.08 87.21 5.32




(3%), and Al þ SiC (5%) þmuscovite (4%) based MMCs, and the

surface-quality in the form of an abrasive frictional coefficient

as well as traction forcewasmeasured in comparisonwith the

base matrix (traction force ¼ 8.77 N and abrasive frictional

coefficient ¼ 0.4385), respectively. The findings of a scratch

test indicate that traction force is improved by escalating the

reinforcement content in the matrices with a slight

improvement in the apparent abrasive frictional coefficient as

indicated in Fig. 13. This enhancement of traction strength

ascribes to significantly harder SiC and muscovite particles,

which prevent the patching, adhesion, and scraping of sample

surface-layer. The results of inline trials were revealed for

micro-hardness. Chandla et al. [46] had prepared alumina and

bagasse ash reinforced Al (6061 alloy) based composites using

stir casting. Results revealed that hardness increased with

increasing bagasse ash up to 6% and then decreased; however,

the achieved value is more than that of unreinforced

aluminium alloy. Similar trend was observed in the strength

variation. Moreover, inclusion of bagasse ash reduced impact

strength and ductility. The increasing trend of porosity level

was also reported with respect to the reinforcement contents

[47].

3.3. Tribological studies

3.3.1. Wear-test analysisWear is one of the important tribological properties that play a

major role in deciding the use of the material. There are

various methods used to check wear loss in a material, of

which a pin on drum type apparatus was selected. This test

simulates the wear that occurs during crushing and grinding

action which happens to produce a more realistic result when

compared to othermethods. Thewear-resistant is determined

by sliding a test specimen over the substrate of an abrasive

layer sheet attached to a rotating drum and has been

measured as volumetric wear-loss in mm3. The confirmatory

testing samples are polished and then machined in accor-

dance with ASTM requirements D 5963-96 according to which

a cylindrical sample of 15.8 mm diameter and 10 mm thick-

ness is required.

The test method is performed under specified conditions

using a cylinder drum of 150 mm diameter, sliding distance of

500 mm, equivalent revolution of 84 times, rotational fre-

quency of 40 rpm, and different contact pressures of 1, 2 and

3 kg. An Abrasion tester is mainly comprised of a machine

framework which supports a laterally interchangeable/

adjustable test-specimen holding carrier, a rotating columnar

cylindric drum to which an abrasive layer is being affixed. An

Aluminium oxide or corundum is used as the abrasive paper

with a grit size of 60. The test piece is initially weighed and

then fitted in the holder which is loaded with the given con-

tact pressure. The drive system is operated to rotate the drum

in clockwise direction. The holder is made to move laterally

from right to left so that the material encounters the grain

faces of the abrasives. After the test piece reaches the end of

the drum, it is removed and is weighed. The difference in the

weight gives us the weight loss of the material due to wear.

When the difference in weight is divided by the initial weight

of the material before wear, the wear loss of the material can

be determined.

Three different compositions are taken to determine the

effect of increase in muscovite or hydrated aluminium po-

tassium silicate on the wear property of AleMgeSieT6/SiC

composite as demonstrate in Table 10. Three different loading

were also done for each composition to determine the effect of

increase in load.

Fig. 14 shows the variation of wear loss present in each

composition by varying the loading conditions. It is a well-

known fact that as the contact pressure between any two

surfaces increases, the wear loss between them also in-

creases. This can be well seen in each of the compositions. As

the contact pressure is increased the wear loss also increases.

From the graph, it is also observable than the wear loss de-

creases from first composition to third composition. This is

mainly because of the increase in muscovite/hydrated

aluminium potassium silicate percentage, as the percentage

of silicon carbide is kept as a constant. Kumar et al. [6] con-

ducted a comparative study for Al6061/SiC and Al7075/Al2O3

AMCs in terms of hardness, tensile strength and wear resis-

tance. The composites are prepared using the technique of

liquid metallurgy, in which 2 to 6 weight percentage of par-

ticulate matter is dispersed in the base matrix as 2 units step

up. It is found that the micro hardness of the composites is

increased with the increase in filler material, and the hard-

ness of Al 6061eSiC and Al 7075eAl2O3 is found to be 97VHN

and 80e109VHN, respectively. The composites’ tensile

strength properties are found to be higher than that of the

base matrix. The composites Al 6061eSiC have higher tensile

resistance characteristics than the composites Al 7075eAl2O3.

For Al 6061eSiC composites the wear resistance of the com-

posite is higher due to SiC’s contribution to enhancing wear

resistance.

3.3.2. Morphological analysis of worn-out surfacesSEM analysis was conducted on the specimens examined

under sliding wear. Fig. 15(aec) exhibit SEM pictures after



0

20

40

60

80

100

120

140

Al-Mg-Si-T6+SiC (5%)+Hydratedaluminium potassium silicate

(2%)


(3%)


(4%)

)aPM(

htgnertSelisneT

Reinforcements (weight percent)

Tensile Strength (MPa) of Al-Mg-Si-T6/SiC/Hydrated aluminium potassium silicate hybrid composites

Fig. 6 e Tensile strength of AleMgeSieT6 alloy/SiC/muscovite hybrid metal matrix composite.

0

20

40

60

80

100

120

140


(2%)


(3%)


(4%)

)aPM(ssertS

d leiY


Yield Stress (MPa) of Al-Mg-Si-T6/SiC/Hydrated aluminium potassium silicate hybrid composites

Fig. 7 e Yield stress of AleMgeSieT6 alloy/SiC/muscovite hybrid metal matrix composite.

5.1

5.15

5.2

5.25

5.3

5.35

5.4

Al-Mg-Si-T6+SiC (5%)+Hydratedaluminium potassium silicate (2%)



)%(

kaerbtanoitagnol

E


Percentage Elongation at break of Al-Mg-Si-T6/SiC/Hydrated aluminium potassium silicate hybrid composites

Fig. 8 e Percentage elongation at break of AleMgeSieT6 alloy/SiC/muscovite hybrid metal matrix composite.




Table 6 e Variation of flexural strength of each composition.

S. no. Compositions Flexural load in kN

1 Al þ SiC (5%) þ muscovite or hydrated aluminium potassium silicate (2%) 3.99



00.5

11.5

22.5

33.5

44.5




)Nk(

daoLlaruxelF


Flexural Load (kN) of Al-Mg-Si-T6/SiC/Hydrated aluminium potassium silicate hybrid composites

Fig. 9 e Flexural strength of AleMgeSieT6 alloy/SiC/muscovite hybrid metal matrix composite.

Table 7 e Variation of Impact strength of each composition.

S. no. Compositions Impact in Joules




0

1.5

3

4.5

6

7.5

9

10.5




)J(htgn ertstcap

mI


Impact strength with the function of reinforcements

Fig. 10 e Impact strength of AleMgeSieT6 alloy/SiC/muscovite hybrid metal matrix composite.

Table 8 e Variation of hardness of each composition.

S. no. Compositions Hardness in HBW

1 Al þ SiC (5%) þ muscovite or hydrated aluminium potassium Silicate (2%) 46.15






44

45

46

47

48

49

50




)N

HB(

rebmunssendra

HllenirB


Hardness of Al-Mg-Si-T6/SiC/Hydrated aluminium potassium silicate hybrid composites

Fig. 11 e Hardness of AleMgeSieT6 alloy/SiC/muscovite hybrid metal matrix composite.

0

1

2

3

4

5

6

7

2.05

2.1

2.15

2.2

2.25

2.3

2.35

2.4

1 1.5 2 2.5 3 3.5 4 4.5 5

Perc

enta

ge P

oros

ity

)cc/mg(

ytisneDlautc

A/eurT

Weight Percentage of Muscovite

True Density Actual Density Percentage Porosity

Fig. 12 e Density and percent Porosity at a distinct percent-weight of muscovite.

Table 9 e Pre-requisites specs for scratch-adhesiontesting.

S. no. Parameters Value

1 Start load 20 N

2 Finish load 20 N

3 Stroke-length 10 mm

4 Scratching-velocity 100 mm/s

5 Scratching-offset 1 mm

6 No. of scratches/sample 3


wear analysis of worn-out surfaces of the muscovite or

hydrated aluminium potassium silicate-reinforced

AleMgeSieT6/SiC hybrid metal matrix composites. Such

micrographs illustrate several long ridges, sharp edges, in-

dentations, pitting and craters on deteriorated (eroded)

areas at a sliding speed of 0.314159 m/s, with load rises to

29.42 N. When the applied load increases, the composite

wear behaviour vicissitudes from abrasion to delaminating

fracture failure as revealed through the SEM micrographs.

The lines of crevices, slits, deep depression grooves and

delamination were the evidence of permanent plastic

distortion or deformation, as shown in Fig. 15(aec). When

the percent-weight proportion/concentration of muscovite

or aluminosilicate increases, the wear resistance initially

decreases, and after then eventually increases. The wavy-

wear trace/mark obviously indicates the prevalence of

oxidized thin-layer coating, often implies the frictional heat

is generated by the relative motion among metal pins as

well as steel discs surface, and thus severely impairs the

wear-rate of steel pins. The findings reported in this

experimental research study encounters the predominance

of endogenous oxidative fretting wear at atmospheric room

temperature. These are uniformly homogeneously

dispersed around the worn deteriorated layer and inevitably



0.4

0.44

0.48

0.52

0.56

9

9.2

9.4

9.6

9.8

10

1 1.5 2 2.5 3 3.5 4 4.5 5

Coe

ffic

ient

of A

bras

ive

Fric

tion

)N(

ecroFnoitcarT

Weight percent of Muscovite

Traction Force Coefficient of Abrasive Friction

Fig. 13 e Effect of muscovite particle contents on the traction-force and abrasive frictional coefficient.

Table 10 e Variation of wear loss due to loading of different compositions.

Applied load(N)

Wear Loss (%)

Al þ SiC (5%) þ muscovite orhydrated aluminium potassium

silicate (2%)


silicate (3%)


silicate (4%)

9.81 3.41 3.43 3.21

19.61 4.38 4.05 3.73

29.42 5.49 5.54 5.00

0

1

2

3

4

5

6




Wea

r L

oss (

%)


Cummulative wear loss (%) of Al-Mg-Si-T6/SiC/Hydrated aluminium potassium silicate hybrid composites tested under sliding distance of 500

mm and sliding speed of 0.314159 m/sec

Applied load at 9.81N Applied Load at 19.61N Applied Load at 29.42N

Fig. 14 e Wear loss of various compositions at different loading conditions.


break down off and be detritus debris/fragments. During

wear the frictional heat responds quite effectively to the

oxidization and degradation of the fine smoother debris as

compared to rough denser wear fragments.

Similar results had been observed in the AleB4C-Mica

hybrid composites using stir casting route with an aim to

evaluate characteristic properties, andmachinability with the

help of drilling process [48]. Results indicated that Mica par-

ticles make it possible to glide between the different elements

of the drilled hole and increases localized dislocation of base

alloy and chips. High value of hardness was obtained near the

drilled surface due to strain hardening, which increases with

increasing B4C contents and decreases with increasing pro-

cess parameters [48].



Fig. 15 e (a) Worn-surface of AleMgeSieT6/SiC composite with 4 percent muscovite or hydrated aluminium potassium

silicate reinforcing particulates at 29.42 N of applied load and sliding speed of 0.314159 m/s, (b). Worn-surface of

AleMgeSieT6/SiC composite tested at load of 9.81 N and 0.314159 m/s of sliding speed with 4 per cent muscovite or

hydrated aluminium potassium silicate reinforcement pellets/flakes and (c). Worn-surface of AleMgeSieT6/SiC composite

with 4 percent muscovite or hydrated aluminium potassium silicate reinforcement tested under 19.61 N load and

0.314159 m/s of sliding speed.


4. Conclusions

Aluminium reinforced with silicon carbide is the vital com-

posite with less machinability characteristics. To improve the

properties of AleMgeSieT6, based-composite various mate-

rial is reinforced by researchers. The experimental results

show that muscovite or hydrated aluminium potassium sili-

cate or Aluminosilicate is a good substitute to soften the (Al/

SiC/muscovite) hybrid metal matrix composite. Based upon

an experimentation, the subsequent outcomes were being

elucidated as followed.

i. It was observed that fabrication of AleMgeSieT6/SiC/

muscovite hybrid metal matrix composite can be

accomplished using stir casting method. The micro-

graphs obtained from SEM proved that the dispersion of

reinforcement particles was finer with stir casting

method. SEM exposed good interfacial bonding, less

agglomeration with uniform distribution, less voids.

EDS spectra affirms the presence of reinforcing con-

stituents (SiC and muscovite or hydrated aluminium

potassium silicate particulates) within AleMgeSieT6/

SiC/muscovite hybrid metal matrix composite. The

grain boundaries show themixing of particles with little

clusters of particles.

ii. The hardness of the compositions first increases and

then decreases with higher hardness in 3% muscovite

composition. The toughness of the composition first

decreases and then increases. The tensile strength of

the composition increases from 2% to 3% composition

followed by a fall in 4% muscovite or hydrated

aluminium potassium silicate composition. The flex-

ural load for bending first decrease followed by an

increase. The composite materials had reported higher

density than that of the basematrix, as per the findings.

It was because of the massive dense and compact na-

ture of the SiC and muscovite fragments within a base-

matrix granular size structure. In Ale5SiCe3muscovite

MMC, there is a modest increase in porosity, which

enhances with escalating muscovite contents. It is due

to the cluster aggregation as well as uneven erratic

distribution of particulate elements.

iii. The findings of a scratch test indicate that traction force

is improved by escalating the reinforcement content in

the matrices with a slight improvement in the apparent

abrasive frictional coefficient. This enhancement of

traction strength ascribes to significantly harder SiC

and muscovite particles, which prevent the patching,

adhesion, and scraping of sample surface-layer.

iv. The 3% composition of muscovite or hydrated

aluminium potassium silicate is the better reinforce-

ment that showed an effective property. As a result of

which the percentage of reinforcement was kept to be

lesser than 10%. If the percentages of reinforcements

are increased, uniform distribution cannot be achieved

and the specified percentage composition cannot be

obtained. From the SEMmicrographs, it is clear that the

reinforcements have been uniformly distributed in all

the three compositions.

v. Results revealed that the wear loss decreases as the

muscovite percentage content has been increased.

Thus, it is proved that hydrated aluminium potassium

silicate has an effect on wear property such that when

muscovite particulate is added it reduces the wear loss

and increases the wear resistance of the material.

vi. The microstructural analysis of the worn surface of

AleMgeSieT6/SiC/muscovite or hydrated aluminium




potassium silicate hybrid metal matrix composite re-

veals that the abrasive behaviour is in the context of

dry-sliding or swaying mechanism. For hybrid com-

posite materials, the particulate wear detritus/rubble is

fine-grained and more even-refined as compared to the

standard traditional materials.

5. Future-outlook

The composites produced may be further investigated for

their resistance to corrosion, including various thermal and

electrical measurements. This would facilitate to broaden

their field of application in various structural designs/pro-

totypes and their practical usages in engineering.

i. Composite wear behaviour can be further examined

throughout diverse environmental conditions, such as

in lubricating regimes and harsh corrosive environ-

ments where temperature difference can be attained.

ii. The influence of heat-treatment on the wear-behaviour

of composite may also be explored to have extensive

applicability.

iii. High cyclic-fatigue and controlled-strain rate charac-

teristics of the fabricated composite being built could be

identified to broaden the scope of using rutile composite

with muscovite as reinforcing constituents for several

defence applications.

Declaration of Competing Interest

The authors declare that they have no known competing

financialinterestsor personal relationships that could have

appeared to influence the work reported in this paper.

Acknowledgements

The authors wish to acknowledge the Department of RIC,

IKGPTU, India for providing opportunity to conduct this

research task.

Appendix A. Supplementary data

Supplementary data to this article can be found online at

https://doi.org/10.1016/j.jmrt.2021.03.095.

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