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International Journal of Scientific and Research Publications, Volume 4, Issue 12, December 2014 1

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Mechanical Behavior Of Al 6063/ Mos2/ Al2o3Hybrid

Metal Matrix Composites

Mitesh Kmar1! Asho" Kmar Mishra2

1"#$ech in "anufacturin% $echnolo%& ' (utomation, )#R#*#" *+$, )ahal2(ssociate Professor ' -D, "echanical +n%ineerin% De.artment, )#R#*#" *+$, )ahal

Abstract# In the .resent in/esti%ation research or is based on de/elo.ment of (l 0! base h&brid metal matri3

com.osite reinforced ith 10 ei%ht .ercenta%e of (luminium -3ide (l2-!, and /ar&in% ei%ht .ercenta%e of "ol&bdenum

disul.hide i#e# !6, 56, 76 ' 86# $he com.osite as .re.ared b& usin% stir castin% techni9ue# $he densit& of (l 0!: "oS2:

(l2-! ere increasin% hen reinforcement of "oS2 increases from !6 to 86# $he ;ltimate $ensile Stren%th decreasin% due to the

additions of !6 to 86 of "oS2 and also reinforced ith alumina (l2-! into the base matri3# It as seen that hile the (l 0!

allo&s shos the .re dominantl& ductile fracture base matri3# $he com.osite s.ecimens ith a "oS2 addition sho an increase in

the mi3ed mode ductile and brittle re%ions# In/esti%ation also .redicts that hardness increases due to /ar&in% addition of "oS2#

"icro%ra.hs of the com.osite s.ecimen are taen for the stud& of .articular or o/erall beha/iour of the material#

1# IN$R-D;*$I-N

(luminium silicon allo&s and com.osites are bein% used in automoti/e a..lications lie .istons, brae rotors and en%ine

bloc c&linder liners#$ribolo%ical beha/iour is an im.ortant as.ect in the use of aluminium metal matri3 com.osites in automoti/e

a..lications# $he ear beha/iour of (lSi allo&s can be further enhanced b& addin% ceramic .articles# (brasi/e .articles lie silicon

carbide, alumina, and diamond are added to im.ro/e the tribolo%ical beha/iour b& increasin% the hardness of a com.osite#

Ne/ertheless, lubricatin% .articles lie %ra.hite and "oS2ha/e also been added to im.ro/e the tribolo%ical beha/iour of different

materials b& .ro/idin% a solid lubricatin% la&er# $he additions of these .articles considerabl& affect the mechanical beha/iour of the

com.osites#

$here are /arious methods of .roducin% com.osites lie blendin% and consolidation, /a.or de.osition and consolidation, stircastin%, infiltration .rocess, s.ra& de.osition and consolidation, as ell as insitu reactin% .rocess# -f all these .rocesses, stir castin%is the sim.lest and the most economical method# Selflubricatin% (l"oS 2com.osites ha/e been .re.ared b& usin% the .odermetallur%& route# In this in/esti%ation, four selflubricatin% com.osites of mol&bdenum disul.hide, namel&, (l 0! : !6 "oS 2: 106

(l2-!, (l 0! : 56 "oS2: 106 (l2-!, (l 0! : 76 "oS2: 106 (l2-!and (l 0! : 86 "oS 2: 106 (l2-!ha/e been .roducedith the stircastin% route# $he chan%es in the mechanical and tribolo%ical .ro.erties caused b& the addition of "oS2are studied#

2# D+$(IP+RI"+N$

$%& Materials

(l 0! as used as the matri3, alumina as hard reinforcement and mol&bdenum disulfide as soft reinforcement# $his matri3

allo& as used for intricate, thinalled castin%s that demand hi%h stren%th, such as castin%s for the automoti/e industr& and %eneral

en%ineerin%#

'able & Chemical (roperties of Al 6063

Component "n =e "% Si ?n $i *r *u -thers

)ei*ht + 0#0 0#0 0#45 0#20 0#0 0#0 0#0 0#0 0#0

0#10 0#!5 0#80 0#0 0#10 0#10 0#10 0#10 0#15

It has /er& %ood castabilit& and is suitable for sand, %ra/it& diecastin%, and hi%h.ressure die castin%# $o .roduce com.osites, the

stir castin% techni9ue as used# Particle si@e of 400 micron alumina and 400 micron .article si@es of mol&bdenum disulfide

reinforcements ere used in this com.osite# "ol&bdenum disulfide in /ar&in% amounts ran%in% beteen !6, 56, 76, and 8 t# 6

as mi3ed ith (l 0! and 10 t# 6 alumina com.osite# $he densities of the com.osites ere measured usin% (rchimedes

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.rinci.le# $he ei%ht of the com.osite sam.les as measured ith the hel. of an electronic balance#

$%$ (reparation of the composite

=irst of all sand mould is .re.ared# $he four main com.onents for main% a sand castin% mold is base sand, a binder,

additi/es, and a .artin% com.ound# In this castin% .rocess a .attern is made in the sha.e of the desired .art i#e# c&linder# $his .attern

is made of metal# Stir castin% techni9ue is used for the .re.aration of material# $his a..roach in/ol/es mechanical mi3in% of the

reinforcement .articulate into a molten metal bath and transferred the mi3ture directl& to a sha.ed mould .rior to com.lete

solidification# (fter the meltin% of material .ourin% is accom.lished ith %ra/it *ast in%ot surface is clean b& machinin% .rocess#

$%3 'estin* of materials

$he densit& of metal matri3 com.osites as determined b& (rchimedes .rinci.le# $he microstructure of the com.osite

s.ecimens as identified usin% an o.tical microsco.e# =irst of all rou%h %rindin% of s.ecimen as done usin% emer& .a.ers of

different %rades# (fter the rou%h %rindin% fine .olishin% of the s.ecimen as done# $his .olishin% as done to remo/e fine scratches

of s.ecimen# =or this .ur.ose to different %rades of .olishin% .oder ere used of si@e 0#017Am and 0#014 Am# +tchin% of the

s.ecimen as done to remo/e an& surface contamination and to re/eal the %rain boundaries# $he tensile stren%th testin% as carried

out usin% uni/ersal testin% machine# $he ultimate tensile stren%th of the s.ecimen as calculated from the load at hich a fracture

occurred# $he hardness testin% as carried out usin% /icers hardness machine# $he hardness of the s.ecimen is defined as the load

di/ided b& the surface area of the indentation#

'able $ "echanical .ro.ert& of "etal "atri3 *om.osites

"etal "atri3 ;$S Densit& ardness Decrease in Increase in Increase in

*om.osites N:mm2 %:mm! ) ;$S, 6 Densit&, 6 ardness, 6

(l 0! : !6 72#41 2B0 !#2

"oS2: 106 (l2-!

(l 0! : 56 7#45 2B80 !#! #B5 1#05 0#27

"oS2: 106 (l2-!

(l 0! : 76 5#4B 28!0 !# 1#2 1#!B 0#B!

"oS2: 106 (l2-!

(l 0! : 86 25#0 2870 !7#1 5#4 1#! 1#!7

"oS2: 106 (l2-!

!# R+S;

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,i*re & (l 0! C!6 "oS2C 106 (l2-! ,i*re $ (l 0! C56 "oS2C 106 (l2-!

,i*re 3 (l 0! C76 "oS2C 106 (l2-! ,i*re - (l 0! C86 "oS2C 106 (l2-!

3%$ Mechanical (roperties

$he mechanical .ro.erties of the com.osites densit&, hardness and tensile stren%th, %i/en in $able 2# Shos the a/era%e

.ro.erties of /arious test s.ecimens at different com.osition#

$he densit& of "ol&bdenum disulfide "oS2 is hi%her than that of the aluminium allo& and hence an increase in the"ol&bdenum disulfide "oS2 content ill raise the densit& of the com.osite# $he densities of increase in "ol&bdenum disulfidefrom !6 to 86 ere mar%inall& hi%her than the densit& of the aluminium allo& b& 1 6 and 2 6 res.ecti/el

$he tensile stren%th decreases considerabl& due to the additions "ol&bdenum disulfide "oS 2 from !6 to 86 b&mass# $he obser/ed decrease in ;$S ma& be due to /arious mechanisms lie the .article .ullout and crac .ro.a%ation, hich areinitiated b& the .resence of "oS2#

$he hardness increases considerabl& due to the additions "ol&bdenum disulfide "oS 2 from !6 to 86 b& mass#$his is due to an increase in the .ro.ortion of the hard .articulates in the com.osites, hich increases the com.osites resistance toindentation in com.arison to the monolithic allo

-% CO.C12O.1

In this research or, (l 0!: "oS2: (l2-!com.osites are fabricated usin% the stircastin% techni9ue and the mechanical

beha/iour of the metal matri3 com.osites ere studied# $he folloin% im.ortant obser/ations can be noted

1# Vicers hardness of (l 0! ith mol&bdenum disul.hide "oS2, (lumina (l2-! and "a%nesium "etal "atri3 *om.osites

""*s are increases hen increasin% the ei%ht .ercenta%e of "ol&bdenum disul.hide#

2# Densit& of (l 0! ith mol&bdenum disul.hide "oS2, (lumina (l2-! and "a%nesium "etal "atri3 *om.osites ""*s are

increases hen increasin% the ei%ht .ercenta%e of "ol&bdenum disul.hide#

!# ;ltimate tensile stren%th of (l 0! ith mol&bdenum disul.hide "oS2, (lumina (l2-! and "a%nesium "etal "atri3

*om.osites ""*s are decreases hen increasin% the ei%ht .ercenta%e of "ol&bdenum disul.hide#

4,44.C41

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1# Vinoth, E# S#, Subramanian, R#, Dharmalin%am, S#, (nanda/el, )#, 2012, F"echanical and tribolo%ical characteristics of stircast(lSi10"% and selflubricatin% (lSi10"%:"oS2com.ositesG "aterials and technolo%&, Vol#4, 5, ..# 487H501#

2# Dharmalin%am, S#, Subramanian, R#, Vinoth, E# Somasundara, and (nanda/el, )#, 2010,

F-.timi@ation of $ribolo%ical Pro.erties in (luminum &brid "etal "atri3 *om.osites ;sin% ra&$a%uchi "ethodG, Journal of"aterials +n%ineerin% and Performance, Volume 20B, ..# 145714#

!# "ishra, (sho Er#, Eumar, Vinod, Sri/asta/a, Raesh Er#, Jul& 2014, F-.timi@ation of $ribolo%ical Performance of (l 01 $156 Si*.156 (l2-!&brid "etal "atri3*om.osites ;sin% $a%uchi "ethod ' re& Relational (nal&sisG Journal of "inerals and"aterials *haracteri@ation and +n%ineerin%, /ol# 2, ..# !51!1#

4# Venatraman, )#, and Sundaraan, #, 2000, F*orrelation beteen the *haracteristics of the "echanicall& "i3ed