MICROSTRUCTURAL STUDIES ON ALUMINIUM METAL MATRIX

COMPOSITE BY STIR CASTING PROCESS

VIKRAM C.K, RAGHAVENDRA S, SYED IMRAN ALI, ABDUL RAHEEM

[email protected], [email protected], [email protected], [email protected]
Mechanical Department
P.E.S College of Engineering, Mandya-571401
ABSTRACT

Present industrial revolution is focusing on performance of the composite materials with better
performance even at an elevated temperature. The materials are used in many applications like
automobile sector, marine, sports, aerospace and medical applications. In order to enhance the
performance, the materials will be subjected to various heat treatment processes. Irrespective of the
materials, the heat treatment relay on changing the microstructure of the materials which leads to
changes in the wear resistance and mechanical properties. Micro Structural analysis has been carried out
and following results are observed that the particles are having irregular grain structure with sharp
corners. SEM images also indicate that the presence of SiC is being increased; Formation of SiC
clusters at some locations is also being identified in few of the SEM images. X- Ray Diffraction
analysis of Composite material with 6% SiC powders indicate the peaks related to aluminium and
carbon which are present in the processed composite. High and narrow peaks are obtained for the carbon
materials and the composite containing 6% SiC has higher peaks compared to others. Similar peaks are
also seen in other compositions.

Keywords: Microstructure; SEM; XRD

1. INTRODUCTION

Metal Matrix Composites (MMCs) have gained widespread attention in recent years due to their
excellent mechanical and physical properties. They are fabricated by reinforcing a metal matrix with a
second material, often a ceramic or a polymer, to improve the overall performance of the composite. Stir
casting is a commonly used process for the fabrication of MMCs, where the reinforcement material is
mixed with the molten metal matrix using a stirring device. In this process, the reinforcing material is
evenly dispersed throughout the matrix, resulting in improved properties such as increased strength,
stiffness, and wear resistance. Aluminum alloys have been commonly used as the matrix material in
MMCs for the area of research production and application in industries. Composites of aluminium metal
matrix are highly engineered materials with high modulus strength, improved hardness & tensile
strength, high elevated temperature and higher resistance and consequently lower thermal expansion
coefficient [1]. Moreover, when evaluated with other materials such as Ti or Mg, these materials are low
cost. This material is well understood from the other point of observation in corrosion, ductility and
strength and can be easily adjusted for the necessary application like automobile sector, aerospace and
medical applications [2]. Y.U. Ishii et al [3] have used Al6061 with different propositions of SiC
particles by high pressure infiltration process and the processed composites are subjected to wear study
with varying parameters like speed and load conditions. Results obtained from the present study indicate
that the presence of the reinforcement material has helped in reducing the wear rate even at increased
load conditions. Davis Joseph et al [4] Studied on Reinforcement materials like Silicon carbide (SiC),
Aluminium oxide (Al2O3) and Boron carbide (B4C) are normally used in particulate form in order to
enhance the mechanical and thermal properties of Aluminium alloy matrix phase in the composite
structure. SiC is one of the most widely used reinforcement materials in the aluminium based MMCs
because it is very compatible with aluminium matrix. Singla et al [5] Studied on the Aluminium alloys
which are relatively striking because of their light weight, their ability to have good mechanical property
and better anti- corrosion property. They are typically reinforced by SiC, Al2O3, B4C, BN, graphite,
SiO2 etc. Many of the transportation industries have been using discontinuously reinforced aluminium
matrix composites for their structural components. They are extremely attractive due to their isotropic
 mechanical characteristics with lower price. Composites reinforced with particulates offer enhancements
over the matrix alloys in all aspects and a greater resistance to wear and an enhancement in rupture
stress. Ye Haizhi et al [6] Studied on Al-SiC alloys are extensively used for applications in the
mechanical and tribological elements of IC engines, such as piston, cylinder blocks, cylinder heads, etc.,
because of their good cast ability, good formability, resistance against corrosion and light weight.
However, the poor seizure resistance property of the materials restricts their use for the tribological
application, addition of reinforcement materials leads to enhancement in the tribological characteristics
of the materials. T Jong et al [7] showed that Particulates of Silicon carbide are reinforced in the MMCs
due to their enhanced specific properties which are of most important in the applications of automotive
components. T.P.D. Rajan et al [8] Studies on Fabrication and characterization of Al–7Si– 0.35Mg/fly
ash metal matrix composites processed by different stir casting routes where in two stage of particle
distribution is being carried out. The temperature of the melt is being reduced slightly to have better
bonding of matrix and reinforcement material followed by addition of reinforcement particles. This two
stage processing as helped in reducing the agglomerates and led to the improvement of the composites
with uniform distribution. Ravi Raj et al [9] Studied on certain other process optimizing techniques that
are used in the stir casting process to obtain a sound casting. One of them is the pre- heating of the
reinforcement particles before its being immersed into the liquid melt. Pre-heating helps to avoid the
thermal mismatch and enhances then wettability of the particles. K Raj Kumar et al [10] Studies have
shown that even with at most care there is a possibility to have a porous structure inside the cast
composite which are normally termed as porosity. The porosity in cast materials is generated due to
entrapment of the gases (Oxygen, Hydrogen and Nitrogen) that are trapped inside the metal which
reduces the strength of the material in that vicinity. This study focuses on the microstructural analysis of
Aluminium Metal Matrix Composites (AMMCs) produced by stir casting. The objective is to
understand the effect of the process parameters on the microstructure of the composite and to identify
the optimal processing conditions for maximum reinforcement dispersion and improvement in the
composite's mechanical properties. The study will provide valuable insights into the fundamental
aspects of AMMCs and will pave the way for the development of high-performance AMMCs with
tailored properties.
The objectives of the present research work which are drawn from the literature study are discussed
below:
 Processing of composite materials by stir casting process with Al 6061 has base material, SiC
particles of 30µm are reinforced with varying percentage of reinforcements of 2%, 4%, 6% &
8%.

 Microstructural study of processed composite materials.

2. EXPERIMENTAL PROCEDURE
The experimental procedures used in the present investigation for processing of composites and their
characterization with respect to microstructure are discussed in detail.

2.1Selection of Matrix Material (Aluminium 6061)

It’s the predominant material in the series which consist of SiC as an alloying element and Magnesium
of higher percentage. This material is widely used due to its superior benefits ranging from its strength
to thermal conductivity. The presence of SiC makes the material harder compared to other series of the
materials. When the present grade material is reinforced with additional amount of SiC, the strength will
be further enhanced but care should be taken such that the brittleness phenomenon is not being
incorporated due to higher percentage of SiC. Table 2.1 shows the Physical properties of Al6061 used in
the present work.
 Table 2.1: Physical properties of Al 6061
Properties Values
Young’s Modulus (E) GPa 68.9
Density (g/cc) 2.70
Poisson’s ratio 0.33
Tensile strength (MPa) 120-290
Melting temperature(°C) 6500C
Linear thermal expansion coefficient (α) 2.32*10-5K-1
Thermal conductivity(k) W/(m-k) 151-202
2.2 Selection of Reinforcement Silicon Carbide
In the present work SiC particle (30µm) is added as reinforcement material along with Al 6061 matrix
material for a weight percentage of 2%, 4% 6% and 8%, processed by liquid stir processing technique
which is normally termed as Stir casting process. Table 2.2 shows the physical properties of the
reinforcement material used in the present work.
Table 2.2: Physical properties of Silicon Carbide
Properties Values
Density (g/cc) 3.1
Color Black
Elastic modulus(MPa) 410
Poisson’s ratio 0.14

Compressive strength(MPa) 3900

Maximum use temperature (°C) 1650
Linear thermal expansion coefficient(α) 4
Thermal conductivity(k) W/(m-k) 120
2.3Liquid Processing Technique
Stir casting process is selected to process the composite material. Furnace consists
of graphite crucible (Fig 2.3 (a)) for melting the aluminium material, once the liquid state is
obtained the SiC powders particles of 30 µm size will be added as the reinforcement for the
Al 6061 matrix material. In order to obtain a better reinforcement stirrer is used; this
facilitates the vortex formation and helps the reinforcement particle to get bonded with the
matrix material. The impeller forces the particles towards the matrix material at greater
force which helps the materials to get adhered to each other. A medium speed of 300-
500rpm will be employed to carry out the process. Along with the speed the shape of the
impeller also has a high impact, blades with curved shape has higher impact on the vortex
formation. Round shaped mould (Fig 2.3 (b)) made of mild steel will be utilized to obtain
the composite material with a dimension of 40 mm diameter and length 180 mm.
Ceramic-coated impeller (Fig 2.3 (c)) is been immersed up to 3/4 of molten metal
from melt top and a speed of 500 rpm will be maintained to create the vortex in the molten
metal. Curved shaped blade/impeller is used in the present investigation, the shape of the
blade facilitate in forming the vortex in the molten metal which aids in better mixing of
reinforcement particle with the matrix.
 (a) Stir casting furnace (b) Mould boxes with casting (c) Rotating impeller
Fig. 2.3(a)-(c) Stir casting process setup.
2.4 Percentage of compositions of the composites
Composites specimens were casted by adding reinforcements with 2, 4, 6 and 8% by weight. Figure 3.4
indicates the raw material in the form of blocks which is being used as the base material; the required weight
composition of the base material is being weighed and selected with respect to the reinforcement percentage.

Fig 2.4 Aluminium 6061 blocks

2.5 Micro structural Analysis
Structural analysis has been carried out to know the behavior of different percentage of silicon carbide in
aluminium matrix by using SEM/TEM analysis. Samples with identical sizes are cut from various sections having
flat surfaces. These samples will be grinded with emery papers of 300, 600, 800 and 1000 grit sizes followed by
fine polishing with velvet cloth using polishing grade II alumina suspension by using a polishing machine and then
etching done by adding few drops of 40% concentrated Hydro Fluoric (HF) acid. Figure 3.5 indicates the JSM F100
SEM equipment used for the microstructural analysis of the processed composite material and the specification of
the equipment is listed.

Fig 2.5 SEM Machine and specifications

3. RESULT AND DISCUSSIONS:
3.1Metallurgical test results
Structural analysis has been carried out to know the behavior of different percentage of Silicon
Carbide reinforcement in Aluminium matrix by using SEM/TEM analysis. The Scanning Electron
Microscope (SEM) is a type of electron microscope that images the samplesurface by scanning it
with a high-energy beam of electrons in a raster scan pattern. The electrons interact with the atoms
that make up the sample producing signals that contain information about the sample's Surface
Topography, Its Composition etc. SEM can produce very high-resolution images of a sample surface,
revealing details about less than 1 to 5nm insize. Due to the very narrow electron beam, SEM
micrographs have a large depth of field yielding a characteristic three-dimensional appearance which
will be useful for understanding the surface structure of a sample. A wide range of magnifications is
possible, from about 10 times (about equivalent to that of a powerful hand-lens) to more than
500,000 times, about 250 times the magnification limit of the best light microscopes. Optical
microscopes analysis can also be made to identify the dispersion reinforcing particles, and to check
the formation of agglomeration. The analysis is performed on JSM F100 equipment operating at an
accelerating voltage of 15 kV. The standard metallography procedure followed by cloth polishing
using emery sheets and a polishing machine were carried out to prepare the specimens.

Fig 3.1 SEM image of SiC particulates Fig. 3.2(a) SEM of Al6061 Alloy

Figure 3.1 indicates the SEM images of the SiC particles; it can be observed from the figure that
the particles are having irregular grain structure with sharp corners. This sharp corners helps in
getting the reinforcement particles embedded into the matrix material. The average particle size is
found to be 30µm which can be evidenced from the above SEM analysis. SEM images of the
composite materials reinforced with varying percentages of SiC are discussed below.
For the micro structural studies, specimens were cut from cast bars and ground with grit paper of
various size. The mounted samples were then mechanically polished with a 1μm alumina-powder and
fine polishing to near mirror like finish was achieved using 0.5μm diamond paste and etched with
Keller’s reagent. Fig.3.2 (a) indicates the SEM image of Aluminium Al6061 alloy, Figure 3.2 (b)-(e)
indicates the SEM images of the composite material reinforced with 2% and 4% SiC at 1500X
magnification. It can be observed form the images that as the percentage of reinforcement are being
increased, the reinforcement particles will be more which leads to higher load carrying capacity of
the material when subjected to hardness test. It can be observed that the reinforcement particles are
embedded within the matrix material and share a good bonding between them. It is also observed that
Aluminium Silicon Carbide composite having cluster particles which is found to be more with
increase in the percentage of reinforcement and some places are identified without SiC inclusions.
 Pores

Fig 3.2 (b)Al6061 with 2% SiC Normal Fig 3.2 (c) Al6061 with 2% SiC Cryo Treated

Dendrite
Growth

Fig 3.2 (d) Al6061 with 4% SiC Normal Fig 3.2 (e) Al6061 with 4% SiC Cryo Treated

Fig 4.2(b)-(e) SEM Images of Al 6061 Reinforced with SiC

Grain SiC Particles
Nucleation

Fig. 3.3 (a) Al6061 with 6% SiC Normal Fig.3.3 (b) Al6061 with 6% SiC Cryo Treated
 Cluster Cluster

Fig. 3.3 (c) Al6061 with 8% SiC Normal Fig. 3.3 (d) Al6061 with 8% SiC Cryo Treated

Fig. 4.3(a-d) SEM Images of Al 6061 Reinforced with SiC

It can be seen from the Figures 3.3 (c) & (d) that there is an increase the particles cluster
corresponding to an increase in the percentage of SiC and the composite material with 8% SiC has an
irregular grain structure. It can be observed in the images of 3.3 (a) & (b) that the particles have
formed a clusters in the matrix material and there is uneven distribution in the matrix material which
has led to decrease in the mechanical properties of the material, Whereas the composite material
reinforced with 6% SiC better results compared to other percentages of reinforcements which has
fetched good bonding with matrix material and enhances the mechanical properties of it. It was
observed that the tendency for formation of particle cluster was greater in the higher percentage even
after stirring the molten metal completely until the casting process is being carried out. During the
stirring time, the geometry of the blades has helped in a clear vortex formation and has led to the
uniform distribution whereas for the composite with 8% SiC, particles were found to be more and
lead to formation of cluster which initiates the porosity with prolonged contact between matrix and
reinforcement.
Processing of composites comes along with the challenge of homogeneous distribution of the
reinforcement phases into the matrix for a defect- free microstructure was possible for the material
with 6% SiC, other percentages also showed similar distribution but with more amount of
agglomerates. The segregation of reinforcing particles in to the matrix is of major concern which is
caused by the settling of the reinforcement particles during the melting and casting process. The
microstructure 6% reinforced SiC in Al alloy matrix has a homogeneous distribution of the activated
carbon and there is no indication of cracks and porosity in castings. This is can be related to
optimized process parameters employed for processing of castings. Similar results are also obtained
in the Cryo Treated composites, where in some amount of porous nature and clusters is visualized in
some images. Some of the images of cryotreated also shows the grain growth which has helped in
improving the properties.
3.4.XRD Analysis of SiC Powders
X-Ray Diffraction (XRD) analysis of Composite material with 6% SiC powders is shown in
Figure 3.4(a), Fig 3.4(b) indicates the HKL Values, From the graph, it is verified that peaks
corresponding to activated carbon and aluminium present in all materials, but the activated carbon
peaks present in Al 6061 composites and no reaction peaks are seen which confirms there is no
chemical reaction between two activated carbon and aluminium.
With reference to XRD peaks of composites, it is evident that intensity of peaks resultant to
activated carbon is higher with more amount of activated carbon in materials. This is for Al6061 with
6% of activated carbon which has high gross intensity. In all the four compositions XRD results
show there are no formation other compounds. This shows that it has a good mixture. The results
show that presence of aluminum in the largest peak and the activated carbon in the second largest
peak. In this, a clearly visible activated carbon peak can be observed in the Al 6061 composite. The
increase in the intensity of the activated carbon peaks with the aluminum content of the composite is
evident.

Fig 3.4(a) XRD Analysis of Al 6061 with 6% Silicon Carbide Powders

Fig 3.4(b) XRD Analysis of Al 6061 with 6% SiC Powders with HKL Values

3.5 EDAX Analysis of SiC Powders

Fig 3.5(a) EDAX of Silicon Carbide Powders

 Table 3.5(a): Elemental Analysis of SiC Powders

Element Weight %
Si 80.12
O 9.34
Al 6.14
C 4.4
Total 100.00
Fig 3.5(a) indicates the EDAX analysis of SiC powders, The major element
composition of the particles is Si (Silicon), C (Carbide), Al (Aluminium), and O (Oxide), as shown in
Table 3.5(a). Indicates that the powders consists of higher amount of Silicon and few amount Carbide
elements, other compositions includes Aluminium and few traces of oxides.

Fig 3.5(b): EDAX of Aluminium Silicon Carbide (6%) composite.

Table 3.5(b): Elemental Analysis of Composite (6% SiC)

Element Weight %
Al 85.45
Si 10.03
O 2.54
C 1.98
Total 100.00
Figure 3.5(b) shows the EDAX of Composite with Al and SiC (6%), Table 4.5(b) shows the
elemental composition of the material. Major element is found to be aluminium and Si which is being
reinforced. Other elements are present in the material are at smaller ratio compared to the major
elements. Similar result is also obtained for material reinforced with other percentages of SiC into Al
6061.

4. CONCLUSIONS
Structural analysis has been carried out to know the behavior of different percentage of Silicon
Carbide reinforcement in Aluminium matrix by using SEM/TEM analysis. From the SEM images of
the SiC particles, it can be observed from the figure that the particles are having irregular grain
structure with sharp corners. SEM images also indicate that as the presence of SiC is being increased,
the SiC particles will be more which leads to higher load carrying capacity of the material when
subjected to hardness test. Formation of SiC clusters at some locations is also being identified in
 few of the SEM images. These clusters increase with corresponding to a SiC addition. Composite
material with 8% SiC has an irregular grain structure and the composite material reinforced with 6%
SiC showed better results compared to other percentages of reinforcements which has fetched good
bonding with matrix material and enhances the mechanical properties of it.
X- Ray Diffraction (XRD) analysis of Composite material with 6% SiC powders indicate the
peaks related to aluminium and carbon which are present in the processed composite. High and
narrow peaks are obtained for the carbon materials and the composite containing 6% SiC has higher
peaks compared to others. Similar peaks are also seen in other compositions.

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