INVESTIGATION OF MICROSTRUCTURAL AND

MECHANICAL BEHAVIOR OF ALUMINIUM 6063/Gr

POLYMER COMPOSITES

A PROJECT REPORT

Submitted by

M.GOKUL (311819114005)
A.SHEIK HUSSAIN (311819114020)
S.SALAUDEEN BADUSHA (311819114306)

In partial fulfilment for the award of the degree

of

BACHELOR OF ENGINEERING

In
MECHANICAL ENGINEERING

MOHAMED SATHAK A. J. COLLEGE OF ENGINEERING,

CHENNAI 603 103

ANNA UNIVERSITY: CHENNAI 600 025

MAY 2023
i
 ANNA UNIVERSITY: CHENNAI 600 025

BONAFIDE CERTIFICATE

Certified that this project report INVESTIGATION OF

MICROSTRUCTURAL AND MECHANICAL BEHAVIOR OF ALUMINIUM

6063/Gr POLYMERCOMPOSITES is the bonafide work of “M.GOKUL

(311818114005), A.SHEIK HUSSAIN (311818114020), and S.SALAUDEEN

BADUSHA (311818114306), who carried out the project work under my supervision.

SIGNATURE SIGNATURE

Dr. M.SHUNMUGASUNDARAM Ph.D., Mr. M.SURESH, M.E.,

HEAD OF THE DEPARTMENT SUPERVISOR

Mechanical Engineering Assistant professor

Mohamed Sathak A. J. College of Mohamed Sathak A. J. College of

Engineering, Engineering,

Chennai – 603103. Chennai – 603103.

Submitted for the university practical examination held on

INTERNAL EXAMINER EXTERNAL EXAMINER

ii
 ACKNOWLEDGEMENT
First and foremost, we thank the almighty for helping us in all situations for
bringing out this project successfully.
At this pleasing moment of having successfully completed our project. We
express our sincere thanks and gratitude to the management of our college and
our beloved chairman who provided all facilities to us.
We would like to express our sincere thanks to our principal
Dr.K.S.SRINIVASAN, Ph.D., Chennai for granting permission to undertake
the project in our college.
We are also thankful to Dr.M.SHUNMUGASUNDARAM, M.E., Ph.D., for
his advice and guidance to complete the project.
We are highly thankful to our Project Guide Mr.M.SURESH, M.E., Assistant
professor of the Department of Mechanical Engineering for his constant
encouragement and guidance for spending his precious time with us to complete
the project.
We wish to express our sincere thanks to our Teaching & Non-Teaching staffs
in the Department of Mechanical Engineering for their valuable support and co-
operation.
We also thank our parents and friends for their support throughout this project.

iii
 LIST OF CONTENTS

CHAPTER NO. TITLE PAGE NO.

ABSTRACT

LIST OF FIGURES viii

LIST OF TABLES x

1. INTRODUCTION 1

1.1 INTRODUCTION 1

1.2 COMPOSITE MATERIAL 2

1.3 CLASSIFICATION OF 2

COMPOSITES

1.4 METAL MATRIX COMPOSITES 4

1.5 MATRIX 6

1.6 REINFORCEMENT 7

1.7 PROPERTIES OF COMPOSITES 8

1.8 OBJECTIVES OF METAL MATRIX 8

COMPOSITES

iv
 1.9 APPLICATIONS 9

1.10 REINFORCEMENT OF ALUMINIUM 9

ALLOY

1.11 UN-REINFORCEMENT ALUMINIUM 10

1.12 POLYMER MATRIX COMPOSITES 10

1.13 CERAMIC MATRIX COMPOSITES 10

1.14 PROCESSING OF MMCs 11

1.15 LIQUID METAL TECHNIQUES 11

1.15.1 Stir casting process 11

1.15.2 Squeeze casting infiltration 13

1.15.3 Pressure die infiltration 13

2 LITERATURE REVIEW 14

2.1 INTRODUCTION 14

3 EXPERIMENTAL WORK 21

3.1 ALUMINIUM ALLOYS 21

3.2 TYPES OF ALUMINIUM ALLOYS 21

3.3 WROUGHT ALLOYS 22

v
 3.4 ALUMINIUM ALLOY 6063 SERIES 28

3.5 MECHANICAL PROPERTIES 28

3.6 APPLICATIONS OF 6063 ALUMINIUM 29

3.7 REINFORCEMENT PARTICLE 30

3.8 PET 31

(POLYETHYLENE TEREPHTHALATE)

3.8.1 Applications 31

3.8.2 Physical properties of PET 32

3.8.3 Production of PET 33

3.9 STIR CASTING 37

4 RESULTS AND DISCUSSION 57

4.1 TENSILE TEST 57

4.2 IMPACT TEST 68

4.3 COMPRESSION TEST 72

4.4 MICROSTRUCTRE 78

5 SCOPE OF PROJECT 83

6 CONCLUSION 84

7 REFERENCES 85

vi
 ABSTRACT

In the present day, Aluminium polymer composites are widely used in the
field of engineering applications, especially in automobile, aerospace, marine,
and processing industries, because of their improved higher specific strength,
wear resistance, low density, high strength, and good structural rigidity.
Presently hybrid composites play a vital role in engineering applications. In this
present work, Aluminium alloy 6063 has been used as the matrix and recycled
polymer as the reinforcement. The Aluminium composite is produced by liquid
metallurgical route (stir casting). This method is less expensive and very
effective. The objective of this work is to predict the tensile strength,
compression, impact, and Corrosion behavior of the Composites.

KEYWORDS
Aluminum 6063, Recycled Polymer, Tensile test, Compression test,
Impact test & Microstructure test.

vii
 LIST OF FIGURES

FIGURE TITLE PAGE

NO. NO.
1.1 STIR CASTING SETUP 12
3.1 ALUMINIUM 6063 LENGTH ROD 25
3.2 ALUMINIUM 6063 LENGTH ROD 6MM DIA 25
3.3 ALUMINIUM 6063 LENGTH ROD 1INCH 26
3.4 PET BOTTLE PIECES 26

3.5 FURNACE TEMPERATURE CONTROLLER 33

3.6 STIR CASTING FURNACE 34
3.7 HEATING OF AL6063 35

3.8 GRAPHITE CRUSIBLE CUP 36

3.9 STIRRER 37
3.10 MELTING OF REINFORCEMENT 38
3.11 POURING OF MIXTURE IN THE MOLD 40

3.12 CASTING MATERIAL 40

3.13 MATERIAL CUTTING PROCESS 41

3.14 CASTING MATERIAL 41

3.15 CNC & WIRE CUT EDM MACHINE 41

3.16 TENSILE TESTING MAHINE 42
3.17 COMPRESSION TESTING MACHINE 43
3.18 IMPACT TESTING MACHINE 45
3.19 MICROSTRUCTURE TESTING 45
4.1 FINAL RESULT OF TENSILE SPECIMEN TEST 51

viii
4.2 FINAL RESULT OF TENSILE SPECIMEN TEST 52
4.3 FINAL RESULT OFIMPACT TEST 53
4.4 FINAL RESULT OFIMPACT TEST 53
4.5 FINAL RESULT OF COMPRESSION TEST 55

4.6 FINAL RESULT OF COMPRESSION TEST 55

4.7 FINAL RESULT OF MICROSTRUCTURE TEST 59

4.8 FINAL RESULT OF MICROSTRUCTURE TEST 59

ix
 LIST OF TABLES

TABLE TITLE PAGE NO.

NO.
3.1 WEIGHT PERCENTAGE OF THE COMPOSITE 47
MATERIALS
4.1 TENSILE TEST 48
4.2 TEST CONCLUSION 51
4.3 IMPACT TEST 53
4.4 IMPACT RESULT 54
4.5 COMPRESSION TEST 56

4.6 TEST CONCLUSION 58

x
 CHAPTER 1
INTRODUCTION
1.1 INTRODUCTION

The engineering fraternity has always been on the lookout for wonders
materials that would fit the bills for all types of service conditions. It stems from
the need to make progressive discoveries made by scientists, affordable. This
affordability quotient has persuaded many researchers to develop such materials
which would satisfy various unexplored conditions. In today's world, all generic
materials have been tried for various uses and their limitations have been met.
But the never-ending quest of civilization requires that materials qualify for
harsher environments.

This unavoidable situation demands that new materials be created from

various combinations of other compatible materials. It is to be noted here that this
method is not new; it has been with mankind for ages. In every part of the world,
various materials have been combined to achieve some intended properties, albeit
each case differs from the others, i.e., one can create new materials with unique
properties, which can be tailor-made and are different from their base ingredients.
This concept holds true for a genre of materials called composite materials in
which the various types of materials are combined with the reinforceme nts, which
contribute to the enhancement of the properties. Neither the matrices nor the
reinforcements taken alone can stand up to the requirement, but the composite
may be able to do so. This alteration in properties can be controlled in many ways,
viz. controlling the matrix reinforcement quality, their proportion, or the
fabrication route. This flexibility in manufacturing allows one to develop
composites with varying properties in a precisely controlled fashion.

1
1.2 COMPOSITE MATERIALS

Composite material is a material composed of two or more distinct phases

(matrix phase and reinforcing phase) and having bulk properties significantly
different from those of any of the constituents. Many common materials (metals,
alloys, doped ceramics, and polymers mixed with additives) also have a small
number of dispersed phases in their structures; however, they are not considered
composite materials since their properties are similar to those of their base
constituents (the physical property of steel are similar to those of pure iron).
Favourable properties of composite materials are high stiffness and high strength,
low density, high-temperature stability, high electrical and thermal conductivity,
adjustable coefficient of thermal expansion, corrosion resistance, improved wear
resistance, etc.

1.3 CLASSIFICATION OF COMPOSITES

Composite materials are classified

a. On the basis of the matrix material,

b. On the basis of filler material.

(a) ON THE BASIS OF MATRIX

1. Metal Matrix Composites (MMC):

Metal Matrix Composites are composed of a metallic matrix (aluminium,

magnesium, iron, cobalt, copper and a dispersed ceramic (oxides, carbides) or
metallic (lead, tungsten, molybdenum) phase.

2. Ceramic Matrix Composites (CMC):

Ceramic Matrix Composites are composed of a ceramic matrix and

embedded fibers of other ceramic material (dispersed phase).

3. Polymer Matrix Composites (PMC):

2
 Polymer Matrix Composites are composed of a matrix from thermoset
(Unsaturated polyester (UP), Epoxy) or thermoplastic (PVC, Nylon, Polystyrene)
and embedded glass, carbon, steel, or Kevlar fibers (dispersed phase).

(b) ON THE BASIS OF MATERIAL STRUCTURE

1. Particulate Composites

Particulate Composites consist of a matrix reinforced by a dispersedphase in

form of particles.

 Composites with random orientation of particles.

Composites with preferred orientation of particles.
 The dispersed phase of these materials consists of two-
dimensional flat platelets (flakes), laid parallel to each other.

2. Fibrous Composites

1. Short-fiber reinforced composites: Short-fiber reinforced composites

consist of a matrix reinforced by a dispersed phase in form of discontinuous fibers
(length < 100* diameter).

 Composites with random orientation of fibers.

 Composites with preferred orientation of fibers.

2. Long-fiber reinforced composites: Long-fiber reinforced composites

consist of a matrix reinforced by a dispersed phase in form of continuous fibers.

 Unidirectional orientation of fibers.

 Bidirectional orientation of fibers (woven).

When a fiber-reinforced composite consists of several layers with different fiber
orientations, it is called a multilayer (angle-ply) composite.
3
1.4 METAL MATRIX COMPOSITES

A metal matrix composite (MMC) is a composite material with at least two

constituent parts, one being a metal necessarily, and the other material may be a
different metal or another material, such as a ceramic or organic compound.
When at least three materials are present, it is called a hybrid composite.

The sustained interest to develop engineering materials that could cope with
the raised performance standards resulted in the emergence of a newer class of
materials, called Metal Matrix Composites (MMCs).

They constitute a family of customizable materials with customizable

critical property relationships. Such materials are known for their exceptionally
high modulus, stiffness, wear resistance, fatigue life, strength-to-weight ratios,
tailor-able coefficient of thermal expansion, etc. With these enhancements in
properties, they pose for strong candidature for replacing conventional structural
materials. Such advantages have made this group of materials a nice pick for use
in weight-sensitive and stiffness-critical components in transportation systems.

MMCs can be described as a group of materials in which a continuous

metallic phase (matrix) is combined with one or more reinforcement phases. The
aim of such a composite material is to enhance the suitability of the end of the
product by selectively enhancing the complementary properties, and making the
detrimental properties of the matrix and the reinforcement. While fabricating the
MMC, a solid material results when two or more substances are physically (not
chemically) combined to create a new material whose properties are superior to
those of the original substance for a specific application.

The matrix may be a pure metal or any alloy suitable for the intended
application. The reinforcement may be any other materials in the form of
particulates, whiskers, fibers, platelets, etc. The most common reinforcements are
ceramics and metals having a nominal size in the range of 0.1 to 100 micrometres.
4
 But in fact, just about anything suitable for the application may be utilized
as a potential reinforcement. Even though at times, the matrix and the
reinforcement both can be metallic since, such as process would mar the essence
of a composite. In alloys, the phases are not chemically and physically distinct.
But in a composite, such phases are intentionally kept distinct, to exploit the
properties of the constituents to the fullest.

The reinforcing phase is the nominal constituent of a composite material.

It is the principal load-bearing component in the system. Hence the reinforcement
with better mechanical properties than the matrix materials are chosen while
designing a composite. The matrix is responsible for holding the load-carrying
reinforcement together and retaining the bulk shape of the composite. It also
shares some portion of the total load which is transferred to the reinforcement via
the interface or vice versa. It is the effectiveness of the interface that decides how
much load is transferred to and from the matrix.

In MMCs a high degree of interaction between the matrix and

reinforcement is inherent. The resulting strength is a direct function of the
effectiveness of the interface between the matrix and the reinforcements. The
character of the interface depends upon the mechanical compatibility of the two
phases involved. The chemical incompatibility constraint can be overcome either
by opting for a low-temperature processing route or by selecting stable
constituents.

The thermal-mechanical incompatibility problem is sorted out by employing

a ductile matrix that accommodates the strain generated by the thermal alterations.
However, when it is chemically or thermo-mechanically not feasible to fabricate
a composite from a pair of constituents, an intermediate phase that is compatible
with the matrix and the reinforcement may be introduced in between the two that
masks the incompatibility of the original pair.

5
 This interphase prevents the chemical reaction between the matrix and the
reinforcement and/or aids the matrix in accommodating the strain generated due
to any incongruous strain build-up. A soft precipitate-free layer around the
reinforcing particulates limits the propagation of the crack generated at their
surface by effectively reducing the stress value gradually, thereby increasing the
ultimate strength.

Metal matrix composites have been under constant development since the
days of world war-Il. They were intended to be used in the aircraft as structural
materials. After the war ceased, no longer the purpose of war, rather MMCs found
interest in civilian uses.

1.5 MATRIX (PRIMARY PHASE)

1. The primary phase, having a continuous character,

2. Usually more ductile and less hard phase,

3. Holds the reinforcing phase and shares a load with it.

The matrix is the monolithic material into which the reinforcement is embedded,
and is completely continuous. This means that there is a path through the matrix
to any point in the material, unlike two materials sandwiched together. The
selection of suitable matrix alloys is mainly determined by the intended
application of the composite material.

The matrix is the monolithic material into which the reinforcement is

embedded, and is completely continuous. This means that there is a path through
the matrix to any point in the material, unlike two materials sandwiched together.
In structural applications, the matrix is usually a lighter metal such as aluminum,

6
magnesium, or titanium, and provides compliant support for the reinforcement.
In high-temperature applications, cobalt and cobalt-nickel alloy matrices are
common.

1.6 REINFORCEMENT

1. Second phase (or phases) is embedded in the matrix in a discontinuous

form.

2. Usually stronger than the matrix, therefore it is sometimes called the

reinforcing phase.

Composites as engineering materials normally refer to the material with the

following characteristics:

1. These are artificially made (thus, excluding natural materials such as wood).

2. These consist of at least two different pieces with a defined interface.

3. Their properties are influenced by the volume percentage of ingredients.

4. These have at least one property not possessed by the individual constituents.

The reinforcement material is embedded into the matrix. The

reinforcement does not always serve as a purely structural task (reinforcing the
compound) but is also used to change physical properties such as wear-resistance
friction coefficient or thermal conductivity. The Performance of the Composite
depends on:

1. Properties of matrix and reinforcement.

2. Size, shape, and distribution of constituents.
3. Nature of interface between constituents.

7
1.7 PROPERTIES OF COMPOSITES

The following are the various properties of composites;

 They are very light materials.

 They possess high resistance to corrosion, chemicals, and other

weathering agents.
 High strength-to-weight ratio.

 It is low density and high tensile strength.

 High creep resistance.

 High tensile strength at elevated temperature.

 High toughness.

 Composites possess excellent strength.

 Composites possess excellent stiffness.

 Composites are fire-resistant.

 Composites are low thermal conductivity.

1.8 OBJECTIVES OF METAL MATRIX COMPOSITES

 Increase in yield strength and tensile strength at room temperature.

 Increase in creep resistance at a higher temperature..

 Improvement of thermal shock resistance and corrosion resistance.

 Increase in young's modulus.

 Reduction of thermal elongation.

8
1.9 APPLICATIONS

 Some tank armors may be made from metal matrix composites, probably
steel reinforced with boron nitride, which is a good reinforcement for steel
because it is very stiff and it does not dissolve in molten steel.
 Some automotive disc brakes use MMCs.
 Early Lotus Elise models used aluminium MMC rotors, but they have less
than optimal heat properties and lotus has since switched back to cast iron.
 Honda has used aluminium metal matrix composite cylinder liners in some
of their engines, including the B21A1, H22A and H23A, F20C and F22C,
and the C32B used in the NSX
 Modern high-performance sports cars, such as those built by Porsche, use
rotors made of carbon fiber within a silicon carbide matrix because of their
high specific heat and thermal conductivity.
 Honda has used aluminium metal matrix composite cylinder liners in some
of their engines, including the B21A1, H22A, H23A, F20C, F22C and the
C32B used in the NSX.

1.10 REINFORCEMENT OF ALUMINIUMALLOY

1.11 NON-METALLIC

 Titanium carbide
 Molybdenum di silicide
 Molybdenum di sulphide

METALLIC

 Beryllium
 Niobium
 Stainless steel

9
1.12 UN-REINFORCEMENT ALUMINIUM ALLOY

ADVANTAGES

 High specific strength

 High specific stiffness
 Improve wear resistance

DISADVANTAGES

 Lower toughness and ductility

 More expensive and complicated production method

1.13 POLYMER MATRIX COMPOSITES

ADVANTAGES

 High transverse strength

 Higher toughness
 Improve environmental resistance
 Higher electrical and thermal conductivity

DISADVANTAGES

 Less developed technology

 Smaller database technology
 Higher cost

1.14 CERAMIC MATRIX COMPOSITES

ADVANTAGES

 High toughness and ductility

 Ease of fabrication
 Lower cost

10
1.15 PROCESSING OF MMCs

A metal matrix composite (MMC) is a composite material with at

least two constituent parts, one being a metal necessarily, and the other material
may be a different metal or another material, such as a ceramic or organic
compound. When at least three materials are present, it is called a hybrid
composite. Accordingly, the temperature of the metallic matrix during processing
the fabrication of MMCs can be classified into three categories.

 Liquid phase processes

 Solid state processes

1.16 LIQUID METAL TECHNIQUES

Liquid state fabrication of metal matrix composites involves a

molten matrix metal, followed by its solidification. In order to provide a high
level of mechanical properties of the composite, good interfacial bonding
(wetting) between the dispersed phase and the matrix. The simplest and the most
cost-effective method of liquid state fabrication is stir casting. The methods of
liquid-state fabrication of Metal matrix composites are

 Stir casting. Infiltration

 Squeeze casting infiltration
 Gas pressure infiltration
 Pressure die infiltration

1.15.1 STIR CASTING PROCESS

The above process is the most important of which liquid metallurgy

technique has been explored much these days. This involves the incorporation of

11
ceramic particulate into liquid aluminium melt and allowing the mixture tosolidify.

Fig1.1 Stir Casting Setup

A16063 and recycled polymers are mixed and melted. The melt is stirred slightly
above the liquid us temperature (800-850 °c).
Fig 1.1 shows the stir casting setup. Stir casting offers better matrix
particle bonding due to the stirring action of particles into the melts. Recent research
studies reported that homogeneous mixing and good wetting can be obtained by
selecting appropriate processing parameters like stirring speed, time and
temperature of molten metal, preheating temperature of mold, and uniform feed rate of
particles. Disadvantages that may occur if the process parameters are not
adequately controlled include the fact that non-homogeneous particle distribution

12
results in sedimentation and segregation.

1.15.2 Squeeze Casting Infiltration

Squeeze casting infiltration is a forced infiltration method of liquid phase

fabrication of metal matrix composites. The infiltration method is similar to the
squeeze casting technique used for metal alloy casting.
The squeeze-casting infiltration process has the following steps:

 The performance of the dispersed phase is placed into the lower

fixed mold half.

 A molten metal in a predetermined amount is poured into the

lower mold half.

 The upper movable mold half (ram) moves towards and

forces the liquid metal to infiltrate or perform.
 The infiltrated material solidifies under the pressure.

 The part is removed from the mold by means of the ejector pin.

1.15.3 Pressure Die Infiltration

Pressure die infiltration is a forced infiltration method of liquid phase

fabrication of metal matrix composites using a die casting technology when a
performed dispersed phase is placed into a die which is then filled with a molten
metal entering the die through a sprue and penetrating into the perform under the
pressure of a movable piston.

13
 CHAPTER 2
LITERATURE SURVEY

2.1 INTRODUCTION
Literally, the term composite means a solid material that results when two
or more different substances, each with its own characteristics are combined to
create a new substance whose properties are superior to those of the original
components for any specific application. The term composite more specifically
refers to a structural material within which a reinforcement material is
embedded. And the engineering definition would also go along side-A material
system composed of a mixture or combination of two or more constituents that
differ in form or material composition and air essentially insoluble in each
other. In principle, composites can be fabricated out of any combination of two
or more materials-metallic, organic, or inorganic; but the constituent forms are
more restricted. The matrix is the body constituents, serving to enclose the
composite and give it a bulk form. Major structural constituents are fibers
particulates, laminates or layers, flakes, and fillers.
When two or more materials are interspersed, there is always a
contiguous region. Simply this may be the common boundary of the two phases
concerned, in which case it's called an interface. A composite having a single
interface is feasibly fabricated when the matrix and reinforcement are perfectly
compactable.
On the other end, there may be an altogether separate phase present
between the matrix phase and the reinforcement phase. The matrix is a body
constituent, serving to enclose the composite and give it a bulk form. Major
structural are fibers, particulates, laminates or layers, flakes, and fillers.
Jawalkar, C. S., et.al (2017). The research on aluminium metal matrix
composites with particle reinforcement is summarised in this paper. Due to its
small weight, high strength-
14
to-weight ratio, corrosion resistance, and workability, the aluminium metal
matrix is becoming more and more popular in aviation, automotive, and other
industries. Due to their lower price, consistent characteristics, and capacity to act
as monolithic materials, particle-reinforced aluminium matrix composites are
preferred. Despite the fact that there are many ways to create a particulate metal
matrix composite, stir casting is the most practical and affordable option. The
current work analyses the issues raised and conclusions reached by many writers
who have made contributions in the field of stir-cast aluminium metal matrix
composites with particulate reinforcement.

Kumar, G. V., Pramod, R.,(2017).In order to achieve a high strength-to-

weight ratio, recent work on reinforcing E-glass into aluminium foil is presented
in this study. In addition to being resistant to corrosion, lightweight, and ductile,
aluminium also exhibits increased strengths that are desirable for high-tech
applications when alloyed with other metals. Pure aluminium has a 2.7 g/cm3
density. The most common fiber in reinforced plastic composites is by far
electrical grade glass, also referred to as E-glass. It is a material with high
strength, is lighter than steel, and is resistant to corrosion. A resin known as
Araldite Ly556 is used to connect the reinforcement and matrix. It has a density
of 1.15 to 1.20 g/cm3 at 25 °C. Giving a good binding structure as a result. In
the current effort, a laminate is created by combining aluminium, e-glass, and
epoxy.

Kim, H. J., et.al (2012).This study looked into how aluminum powder
surface modification affected the tensile, fracture, and tribological behaviours of
composites made of aluminum and epoxy. The surfaces of aluminum powders
were altered using 3- aminopropyltriethoxysilane. Cast molding was used to
create aluminum/epoxy composites utilizing 10-weight percent untreated and
silane-treated aluminum powders. Both composites underwent tensile, mode I
fracture, and tribological tests. According to the findings, silane-treated
aluminum/epoxy composites had tensile moduli and strengths that were,
15
respectively, 9% and 12% higher than those of untreated aluminium/epoxy
composites. The findings also revealed that silane-treated aluminium/epoxy
composites had wear resistance and fracture toughness that were, respectively,
32% and 56% higher than those of untreated aluminium/epoxy composites. An
analysis using a scanning electron microscope (SEM) revealed that the salinization
of aluminium powders increased the bonding and dispersion of aluminium
particles in the epoxy, which in turn improved the tensile and fracture
parameters of silane-treated aluminium/epoxy composites .

Prakash, C., et.al (2020).The current study focuses on creating hybrid

nanocomposites of aluminium (Al), carbon nanotubes (CNTs), and silicon
carbide particles (SiCP) by elementally alloying the powder particles of Al,
CNTs, and SiCP into a homogeneous powder mixture and sintering the powder
mixture using spark plasma sintering (SPS). The impact of SiCp as a
reinforcement and the weight percentage of CNTs (1, 3, and 5 wt%) on the
mechanical properties and microstructural features was examined. Al-CNTs-
SiCP hybrid Nano-composites surface topography, microstructure, and element
composition were examined using energy-dispersive X-ray spectroscopy,
optical microscopy, and field- emission scanning electron microscopy (FESEM)
(EDAX). The micro-hardness of the specimens is measured using the Vickers
hardness tester. The sintered Al- CNTs-SiCp composite has a good reinforcement
of CNTs and SiCP into the grain boundaries of the Al-matrix and reduces the
dislocation defects, which improves the microstructure and strengthens the
metallic bond, according to microstructure and scanning electron microscopy
(SEM) micrographs. As a result, the micro- hardness of the hybrid composite
(Al-5%CNTs-10%SiC) is two times more thanthat of pure Al.

16
 Dickson, A. N., et. al (2017).In this work, the performance of continuous
carbon, Kevlar, and glass fibre-reinforced composites created with the help of
additive manufacturing's fused deposition modelling (FDM) technology is
assessed. A Mark forged Mark One 3D printer was used to create the fiber-
reinforced nylon composites. Both tension and flexure tests were performed on
the composite materials' mechanical capabilities. Investigations were also done
into how fiber orientation, fiber type, and volume fraction affected mechanical
qualities. The results were contrasted with known values for material property
values from published literature as well as control specimens made of non-
reinforced nylon. The carbon fiber-made fibers produced the biggest improvement
in mechanical strength per fiber volume among the fibers examined, it was
shown. Its tensile strength values were up to
6.3 times greater than those of the nylon polymer without reinforcement. The
amount of air inclusion in the composite matrix grew together with the volume
percentage of carbon and glass fiber, which had an effect on mechanical
performance. Because of this, glass specimens showed a maximum efficiency in
tensile strength as the fiber content neared 22.5%, with greater fiber percentages
(up to 33%) only producing marginal gains in strength.
Stöbener, K., & Rausch, G.,(2009).Realizing the unique qualities of closed-
cell metal foam (low density, effective energy absorption, high vibration/sound
attenuation) in practical products has frequently proved challenging. A new and
less complicated production approach aimed at application in foam-filled
constructions (such as an automobile A-pillar) has been introduced with
enhanced pore morphology (APM) aluminium foam- polymer hybrids.
Spherical, tiny volume foam parts are bonded to one another in a different
production step to create APM foams. By using adhesive bonding to join the
components of aluminium foam, composite foam that contains 80% –95% aluminium
foam and 5%–20% adhesive is produced (polymer). Spherical foam elements
can be assembled into cellular structures for automatic part manufacture,
17
accurate pore morphology control, and economical aluminium foam application.
The display and discussion of an automated production line. Similar to other
closed-cell aluminium foams, APM aluminium foam-polymer hybrids have
mechanical qualities. The qualities of typically closed-cell aluminium foam
fillings were greatly improved when APM foams were incorporated into
profiles. APM composite foams are a desirable alternative because of their
special qualities that make them a practical and affordable building material
with specific applications like the reinforcing of composite buildings to absorb
energy.

Surappa, M. K.,(2003).Aluminium matrix composites (AMCs) are a type

of lightweight, high- performance material systems that are aluminium-centric.
In AMCs, reinforcement may take the shape of whiskers, particles, or
continuous or discontinuous fibers in volume fractions ranging from a few
percent to 70%. AMCs' properties can be adjusted to meet the needs of various
industrial applications by choosing the right combinations of the matrix,
reinforcement, and processing methods. Currently, several AMC grades are
produced using various processes. The intrinsic and extrinsic impacts of ceramic
reinforcement on the physical, mechanical, thermo-mechanical, and tribological
properties of AMCs
have been the subject of extensive research for the past three decades, yielding a
wealth of new scientific knowledge. AMCs have been used in high-tech structural
and functional applications, such as those in the automotive, thermal
management, aerospace, and defence industries, as well as in sports and
recreation, over the past several years. Intriguingly, research on particle-
reinforced cast AMCs began in India in the 1970s, reached industrial maturity in
the industrialized world, and is today on the verge of becoming a mainstream
material. This study provides a summary of the processing, microstructure,
characteristics, and application features of AMC material systems .

Babrekar, H.A., et. al (2010),Controlling the thermal emissivity’s from

18
metal/polymer composites made using the solution approach is the topic of this
paper. Polystyrene is employed as a polymer matrix and aluminium is used as a
filler. We used aluminium particles with varying morphologies that were both
micro meter and nanoscale-sized. When coarse grains and flakes of aluminium
were employed as fillers, the values of emissivity’s decreased, but when Nano-
aluminium was included in the composite, there was no discernible difference.
The composites' dielectric dispersion was measured, and the results were
examined in light of the Fresnel connection. The interfacial polarisation is
assumed to be the cause of the discrepancies in dielectric constant values
between experimentally measured values and theoretically predicted values .

Kumar, G. V., & Pramod, R., (2017).In terms of available techniques,

bonding procedures, mechanisms, and characteristics, the joining of CFRP and
aluminium alloys in the literature are thoroughly examined in this research.
Only CFRP and aluminium alloys are joined using the techniques of adhesive,
self-piercing rivet, bolt, clinching, and welding. Even though the welding
process has considerable promise for combining these materials, non-thermal
joining techniques have drawn a lot of attention. Surface preparation is not
necessary for connecting methods other than adhesive bonding and welding since
these methods rely on metallic pins penetrating the joining parts. It is
challenging to choose one model over another in applications since there is no
model that can accurately predict the characteristics of joint structures. The
particular applications determine which bonding techniques should be used.
Bolted joints primarily rely on friction, which is the first step of resistance, as its
load-bearing mechanism. When adhesives are used in conjunction with bolts,
rivets, or clinch, hybrid joints operate better .

Azghan, M. A., & Eslami-Farsani, R.,(2018).The current study sought to

determine how varied stacking patterns and heat cycling affected the flexural
characteristics of fiber metal laminates (FMLs). Two sheets of aluminium alloy
19
2024-T3 and epoxy polymer-matrix composites with four layers of basalt and/or
glass fibers and five different stacking sequences were used to create FMLs. The
thermal cycle time for FML samples was approximately 6 min for temperature
cycles from 25 °C to 115 °C. Samples' flexural characteristics were assessed
after 55 heat cycles and contrasted with unexposed samples. Aluminium has
been surface-modified using the electrochemical anodizing process, and its
surfaces have been studied using scanning electron microscopy (SEM) .

OBJECTIVES OF THE PROJECT

 Develop the new aluminium alloy composite.

 Use stircasting setup facilities to fabricate aluminium 6063 reinforced with
PET (Polyethylene Terephthalate).
 Use CNC wire EDM machine to cut the casting material into no. of pieces
with desired cutting standard.
 Study the tensile, impact, compression and corrosion properties of the
developed composite before and after heat treatment.

20
 CHAPTER 3

EXPERIMENTAL WORK

3.1 ALUMINIUM ALLOYS

Aluminium alloys are alloys in which Al is the predominant metal. The

typical alloying elements are copper, magnesium, manganese, silicon, and zinc.
There are 2 principal classifications, namely cast alloys and wrought alloys

3.2TYPES OF ALUMINIUM ALLOYS

AEROSPACE ALUMINIUM ALLOYS

 7068 aluminium
 7075 aluminium
 6061 aluminium
 6063 aluminium
 2024 aluminium
 5052 aluminium
 7050 aluminium

MARINE ALLOYS

 5052 aluminium
 5059 aluminium
 5083 aluminium
 5086 aluminium
 6061 aluminium
 6063 aluminium

AUTOMOTIVE ALLOYS

 6111 aluminium

21
  2008 aluminium
 5083 aluminium
 5754 aluminium
 2036 aluminium
 6016 aluminium
 5456 aluminium

3.3 WROUGHT ALLOYS

The International Alloy Designation System is the most widely accepted

naming scheme for wrought alloys. Each alloy is given a four-digit number,
where the first digit indicates the major alloying elements.

 1000 series is essentially pure aluminium with a minimum 99% aluminium

content by weight and can be work hardened.2000 series are alloyed with
copper and can be precipitation hardened to strengths comparable to steel.
Formerly referred to as duralumin, they were once the most common
aerospace alloys but were susceptible to stress corrosion cracking and are
increasingly replaced by 7000 series in new designs.
 3000 series are alloyed with manganese and can be work hardened.
 4000 series are alloyed with silicon. They are also known as Silumin.
 5000 series are alloyed with magnesium.
 6000 series are alloyed with magnesium and silicon easy to machine and
can be precipitation hardened, but not to the high strengths that 2000 and
7000 can reach.
 7000 series are alloyed with the zine and can be precipitation hardened to
the highest strengths of any aluminium alloy.

22
3.4 ALUMINIUM ALLOY 6063 SERIES

AL 6063 is aluminium, with magnesium and silicon as the alloying

elements. The standard controlling its composition is maintained by The
Aluminium Association. It has generally good mechanical properties and is heat
treatable and weldable. It is similar to the British aluminium alloy HE9.6063 is
the most common alloy used for aluminium extrusion. It allows complex shapes
to be formed with very smooth surfaces fit for anodizing and so is popular for
visible architectural applications such as window frames, door frames, roofs, and
sign frames.

Aluminium alloy 6063 is a medium-strength alloy commonly referred to

as an architectural alloy. It is normally used in intricate extrusions. It has a good
surface finish, high corrosion resistance is readily suited to welding, and can be
easily anodized.

3.5 MECHANICAL PROPERTIES

The mechanical properties of 6063 depend greatly on the temper, or

heattreatment, of the material.

6063

Un-heat-treated 6063 has a maximum tensile strength of no more than

130 MPa (19,000 psi), and no specified maximum yield strength. The material
has an elongation (stretch before ultimate failure) of 18%.

6063-T1

T1 temper 6063 has an ultimate tensile strength of at least 120 MPa

(17,000 psi) in thicknesses up to 12.7 mm (0.5 in), and 110 MPa (16,000 psi)
from 13 to 25 mm (0.5 to 1 in) thick, and yield strength of at least 62 MPa
(9,000 psi) in thickness up to 13 millimetres (0.5 in) and 55 MPa (8,000 psi) from
13 mm (0.5 in) thick. It has an elongation of 12%.

23
6063-T2

T2 temper 6063 has an ultimate tensile strength of at least 140 MPa

(20,000 psi) in thicknesses up to 13 millimetres (0.5 in), and 130 MPa
(19,000 psi) from 13 mm (0.5 in) thick, and yield strength of at least 97 MPa
(14,000 psi) up to 13 millimetres (0.5 in) and 90 MPa (13,000 psi) from13 to
25 mm (0.5 to 1 in). It has an elongation of 5%.

6063-T3

T3 temper 6063 has an ultimate tensile strength of at least 140 MPa

(20,000 psi) in thicknesses up to 13 millimetres (0.5 in), and 130 MPa
(19,000 psi) from 13 mm (0.5 in) thick, and yield strength of at least 97 MPa
(14,000 psi) up to 13 millimetres (0.5 in) and 90 MPa (13,000 psi) from13 to
25 mm (0.5 to 1 in). It has an elongation of 8%.

6063-T4

T4 temper 6063 has an ultimate tensile strength of at least 190 MPa

(28,000 psi) and a yield strength of at least 160 MPa (23,000 psi). In thicknesses
of 3.15 millimetres (0.124 in) or less, it has an elongation of 8% or more; in
thicker sections, it has an elongation of 10%.

3.6 Applications of 6063 Aluminium

3.6.1 As previously discussed, 6063 aluminium is often used in extrusion

projects because of its good workability, weldability, and moderate
strength. These properties allow 6063 aluminium to excel in architectural
applications, and it is used so often in this manner that it is commonly
referred to as “architectural aluminium”. 6063 aluminium alloy is
therefore used in the below examples, but know that this is nowhere near
an all-encompassing list:

24
3.6.2 Piping
3.6.3 Tubing
3.6.4 General extrusions for medical, automotive, parts profiling, and more
3.6.5 Architectural products
3.6.6 Building & construction extrusions
3.6.7 Recreational equipment
3.6.8 Furniture
3.6.9 window frames, door frames,
3.6.10 Roofs, and sign frames.

Fig.3.1 Aluminium 6063 length rod

Fig.3.2 Aluminium 6063 length rod 6mm dia

25
 Fig.3.3Aluminium 6063 Metal Cut 1inch size for Stir Casting.

3.7 Reinforcement particle

Reinforcement is a constituent of composite material which increases the
composite's stiffness and tensile strength. Here we used the PET (Polyethylene
Terephthalate) bottle as reinforcement. It is the most
common thermoplastic polymer resin of the polyester family and is used
in fibers for clothing, containers for liquids and foods, thermoforming for
manufacturing, and in combination with glass fiber for engineering resins.

Fig.3.4 PET bottle pieces

26
 The figure shows the no. of PET bottle pieces which are taken from the scrap
Plastic bottles made from PET are widely used for soft drinks and packaged drinking
water.

3.8 PET (Polyethylene Terephthalate)

It is the most common thermoplastic polymer resin of the polyester family
and is used in fibers for clothing, containers for liquids and
foods, thermoforming for manufacturing, and in combination with glass fiber for
engineering resins. Plastic bottles made from PET are widely used for soft drinks,
both still and sparkling. For beverages that are degraded by oxygen, such as beer,
a multilayer structure is used. PET sandwiches an additional polyvinyl
alcohol (PVOH) or polyamide (PA) layer to further reduce its oxygen
permeability. PET can be compounded with glass fibre and crystallization
accelerators, to make thermoplastic resins. These can be injection moulded into
parts such as housings, covers, electrical appliance components and elements of
the ignition system.

3.8.1 Applications

 A waterproofing barrier in undersea cables.

 As a fibre, spliced into bell rope tops to help prevent wear on the ropes as
they pass through the ceiling.
 Since late 2014 as liner material in type IV composite high-pressure gas
cylinders. PET works as a much better barrier to oxygen than earlier used
(LD) PE.
 As a 3D printing filament, as well as in the 3D printing plastic PETG.
 Film for tape applications, such as the carrier for magnetic tape or backing
for pressure-sensitive adhesive tapes. Digitalization has caused the virtual
disappearance of the magnetic audio and videotape application.
 Water-resistant paper.

27
3.8.2 Physical properties of PET

 PET in its most stable state is a colourless, semi-crystalline resin. However,

it is intrinsically slow to crystallize compared to other semicrystalline
polymers. Depending on processing conditions it can be formed into either
amorphous or crystalline articles. Its amenability to drawing makes PET
useful in fibre and film applications. Like most aromatic polymers, it has
better barrier properties than aliphatic polymers. It is strong and impact-
resistant. PET is hygroscopic.

 About 60% crystallization is the upper limit for commercial products, with
the exception of polyester fibers. Transparent products can be produced by
rapidly cooling molten polymer below Tg glass transition temperature to
form an amorphous solid.[24] Like glass, amorphous PET forms when its
molecules are not given enough time to arrange themselves in an orderly,
crystalline fashion as the melt is cooled. At room temperature the
molecules are frozen in place, but, if enough heat energy is put back into
them by heating above Tg, they begin to move again, allowing crystals
to nucleate and grow. This procedure is known as solid-state
crystallization.

 When allowed to cool slowly, the molten polymer forms a more crystalline
material. This material has spherulites containing many
small crystallites when crystallized from an amorphous solid, rather than
forming one large single crystal. Light tends to scatter as it crosses the
boundaries between crystallites and the amorphous regions between them,
causing the resulting solid to be translucent.

 Orientation also renders polymers more transparent. This is why BOPET

film and bottles are both crystalline to a degree and transparent.

 Amorphous PET crystallizes and becomes opaque when exposed to

28
 solvents such as chloroform or toluene.

 PET is stoichiometrically a mixture of carbon and H2O, and therefore has

been used in an experiment involving laser-driven shock compression
which created nanodiamonds and superionic water. This could be a
possible way of producing nanodiamonds commercially.

Shown below are the IV ranges for the main applications:

Fibers
 0.40–0.70: textile
 0.72–0.98: technical eg. tire cord
Films

 0.60–0.70: biaxially oriented PET film

 0.70–1.00: sheet grade for thermoforming
Bottles

 0.70–0.78: general purpose bottles

 0.78–0.85: bottles for carbonated drinks
Monofilaments, engineering plastics

 1.00–2.00

3.8.3 Production of PET

Polyethylene terephthalate is produced from ethylene glycol (usually

referred to in the trade as "MEG", for monoethylene glycol) and dimethyl
terephthalate (DMT) (C6H4(CO2CH3)2) but mostly terephthalic acid (known in
the trade as "PTA", for purified terephthalic acid). [31][5] As of 2022, ethylene
glycol is made from ethene found in natural gas, while terephthalic acid comes
from p-xylene made from crude oil. Typically, an antimony or titanium
compound is used as a catalyst, a phosphite is added as a stabilizer and a bluing
agent such as cobalt salt is added to mask any yellowing.
29
 There are two basic molding methods for PET bottles, one-step and two-
step. In two-step molding, two separate machines are used. The first machine
injection molds the preform, which resembles a test tube, with the bottle-cap
threads already molded into place. The body of the tube is significantly thicker,
as it will be inflated into its final shape in the second step using stretch blow
molding.

In the second step, the preforms are heated rapidly and then inflated against
a two-part mold to form them into the final shape of the bottle. Preforms
(uninflated bottles) are now also used as robust and unique containers themselves;
besides novelty candy, some Red Cross chapters distribute them as part of
the Vial of Life program to homeowners to store medical history for emergency
responders.

In one-step machines, the entire process from raw material to finished

container is conducted within one machine, making it especially suitable for
molding non-standard shapes (custom molding), including jars, flat oval, flask
shapes, etc. Its greatest merit is the reduction in space, product handling and
energy, and far higher visual quality than can be achieved by the two-step system.

Advantages of PET plastic

 High strength to weight ratio

 Highly transparent and shatterproof

 Easily Recycled

Disadvantages of PET plastic

 PET resins are susceptible to oxidation

 Partially derived from crude oils and non-biodegradabl

30
 PROJECT WORK PLAN

Selection of material

Mold making as per specimen

Composite preparation with Al6063/Recycled

Polymer

Casting of aluminum by stir casting process by

using Recycled polymer as reinforcements

Surface cleaning and finishing

Pouring and solidification

Testing of composite material

Results and Discussion

31
 EXPERIMENTAL PROCEDURE

3.9 STIR CASTING

Metal Matrix Composites (MIMCs) are generally produced either by

Liquid Metallurgy Route (LMIR) or Powder Metallurgy Technique (PMT). In
LMR the particulate phases are mechanically dispersed in the liquid phase before
solidification of the melt. Stir casting technique is one of popular LMR method
and also known as a very promising route for manufacturing near net shape hybrid
metal matrix composite components at a normal cost.

The execution of stir casting technique yields relatively homogenous and

fine microstructure which improves the addition of reinforcement material in the
molten metal. In addition, the porosity level of the composite should be
minimized and the chemical reaction between reinforcement and matrix should
be avoided.

The proper selection of process parameters such as pouring temperature,

stirring speed, and pre-heat temperature of reinforcement can produce good
quality composites. In this present work, the stir casting technique was used to
fabricate 6063 aluminium alloy with Recycled polymer as reinforcement.

The stir casting furnace is mounted on the floor and the temperature of the
furnace is precisely measured and controlled in order to achieve sound quality
composite. Two thermocouples and one PID controlled were used for this
purpose. Because mild steel materials have high-temperature stability, it is
selected as stirrer rod and impeller.

32
 This stirrer was connected to a 1 HP DC motor through the flexible link
and was used to stir the molten metal in the semi-solid state. The screw operator
lift is used to bring the stirrer in contact with the composite material. The metal
was maintained at a temperature between 800 to 850 °C for one hour. The vortex
was created by using a mechanical stirrer.

Fig.3.5 Furnace Temperature Controller

The Fig.3.5 shows the temperature of the stir casting furnace. The metal
was maintained at a temperature between 800 to 850 °C. Furnaces allow heat to
be generated and kept within a certain range in order to melt the metal.

33
 Fig.3.6 Stir Casting Furnace

The Fig.3.6 shows the stir casting furnace. Stir casting offers better matrix
particle bonding due to stirring action of particles into the melts. The recent
research studies reported that the homogeneous mixing and good wetting can be
obtained by selecting appropriate processing parameters liking stirring speed,
time and temperature of molten metal, preheating temperature of mould and
uniform feed rate of particles. The reinforcement was added at a constant feed
rate into the molten aluminium

The proper selection of process parameter such as pouring temperature,

stirring speed, pre-heat temperature of reinforcement can produce good quality
composites. The above process is the most important of which liquid metallurgy
technique has been explored much these days. This involves the incorporation of
ceramic particulate into liquid aluminium melt and allowing the mixture to
solidify.

Stir casting is a type of casting process in which a mechanical stirrer is

introduced to form vortex to mix reinforcement in the matrix material. It is a
suitable process for production of metal matrix composites due to its cost

34
effectiveness, applicability to mass production, simplicity, almost net shaping and
easier control of composite structure.

Stir casting setup as shown in Fig.3.6, consist of a furnace, reinforcement

feeder and mechanical stirrer. The furnace is used to heating and melting of the
materials. The bottom poring furnace is more suitable for the stir casting as after
stirring of the mixed slurry instant poring is required to avoid the settling of the
solid particles in the bottom the crucible. The mechanical stirrer is used to form
the vortex which leads the mixing of the reinforcement material which are
introduced in the melt. Stirrer consist of the stirring rod and the impeller blade.

The impeller blade may be of, various geometry and various number of
blades. Flat blade with three number is the preferred as it leads to axial flow
pattern in the crucible with less power consumption. This stirrer is connected to
the variable speed motors, the rotation speed of the stirrer is controlled by the
regulator attached with the motor. Further, the feeder is attached with the furnace
and used to feed the reinforcement powder in the melt. A permanent mold, sand
mold or a lost-wax mold can be used for pouring the mixed slurry.

Fig.3.7 Heating of Al6063

35
 The Fig.3.7 shows the Aluminium metal is placed in the crucible cup and
then it is placed inside furnace. The metal was maintained at a temperature
between 800 to 850 °C. Furnaces allow heat to be generated and kept within a
certain range in order to melt the metal.

Out of various furnaces, bottom pouring furnace is suitable for fabrication

of metal matrix composites in stir casting route, this type of furnace consists of
automatic bottom pouring technique which provides instant pouring of the melt
mix (matrix and reinforcement). Automatic bottom pouring is mainly used in
investment casting industry. In this technique, a hole is created in the base of
melting crucible to provide bottom pouring and was shielded by a cylinder-
shaped shell of metals [15]. In stir casting process, the matrix material is melted
and maintained a certain temperature for 2–3 h in this furnace. Simultaneously,
reinforcements are preheated in a different furnace. After melting of the matrix
material, the stirring process has been started to form the vortex.

Fig.3.8 Graphite Crucible Cup

The above Fig.3.8 shows the Graphite Crucible Cup. A graphite crucible is
a container used for melting and casting non-ferrous, non-iron metals such as
36
gold, silver, aluminium, and brass. Their thermal conductivity, high temperature
resistance, small thermal expansion coefficient for high temperature applications,
and anti-strain properties to rapid heating and cooling make graphite crucibles an
ideal metal casting tool. They are resistant to the effects of acids and alkaline
solutions and have excellent chemical stability.
Graphite crucibles have slowly developed into an essential part of metal
forming. They can be as small as teacups or large enough to hold several tons of
molten metal and be permanent parts of furnaces.

Factors that influence casting are the temperature of the alloy being cast
and the temperature of the crucible. Graphite crucibles are exceptionally capable
of providing the proper vessel for casting due to their high resistance to the effects
of increases in temperature, regardless of the type of metal alloy.

The many hundreds of shapes of graphite crucibles are categorized by

letters, which begin with A. Each form is divided into subcategories that are
determined by the crucibles inside diameter (d or ID), outer diameter (D or OD),
and height (H) and its shape. The crucible pictured below is cylindrical with a flat
bottom and no spout or lid.

Fig.3.9 Stirrer

The Fig.3.9 shows the stirrer. The stirrer was preheated before immersing

37
into the melt, and is located approximately to a depth of 2/3 height of the molten
metal from the bottom and runs at a speed of 1000 rpm. The composite mixture
was poured into permanent cast iron molds having a length of 200mm and a
diameter of 20mm at a pouring temperature of 7500°C.
The impeller blade may be of, various geometry and various number of
blades. Flat blade with three number is the preferred as it leads to axial flow
pattern in the crucible with less power consumption. This stirrer is connected to
the variable speed motors, the rotation speed of the stirrer is controlled by the
regulator attached with the motor. Further, the feeder is attached with the furnace
and used to feed the reinforcement powder in the melt. A permanent mold, sand
mold or a lost-wax mold can be used for pouring the mixed slurry.

Fig.3.10 Melting of reinforcement

The Fig.3.10 shows the melting of reinforcement. The reinforcement is

placed in the Metal plate and burned and it’s melted with the help of the Butane
gas torch. And then the reinforcement is added to the molten metal.

Reinforcement is a constituent of composite material which increases the

composite's stiffness and tensile strength. Here we used the PET (Polyethylene

38
Terephthalate) bottle as reinforcement. It is the most
common thermoplastic polymer resin of the polyester family and is used
in fibers for clothing, containers for liquids and foods, thermoforming for
manufacturing, and in combination with glass fiber for engineering resins.

The stir casting setup. Stir casting offers better matrix particle bonding
due to the stirring action of particles into the melts. Reinforcement is a constituent of
composite material which increases the composite's stiffness and tensile
strength. Here we used the PET (Polyethylene Terephthalate) bottle as
reinforcement. It is the most common thermoplastic polymer resin of
the polyester family and is used in fibers for clothing, containers for liquids and
foods, thermoforming for manufacturing, and in combination with glass fiber for
engineering resins.
The above process is the most important of which liquid metallurgy
technique has been explored much these days. This involves the incorporation of
ceramic particulate into liquid aluminium melt and allowing the mixture to
solidify. Al6063 and recycled polymers are mixed and melted. The melt is stirred
slightly above the liquid us temperature (800-850 °c).

39
 Fig.3.11 Pouring of mixture in the mold

Fig.3.11,The molten mixture is then poured in preheated mold and kept

for natural cooling and solidification. After the solidification the surface
cleaning and finishing is done.

Fig.3.12 Casting material

40
 Fig.3.14,Finally, the casting material, the Aluminium polymer composite
material is obtained after the solidification process. The net weight and the total
density of the material is identified.

Fig.3.13 Material cutting process

All the three casting materials were cut into pieces for testing process and the
materials were cut according to the desired cutting standards. The testing material
were cut into no. of pieces with help of the wire EDM machine method.

Fig.3.15 CNC wire EDM machine

41
 Fig.3.15,The testing material were cut into no. of pieces with help of the wire
EDM machine method. Any conductive material such as steel, titanium, aluminium,
brass, alloys and superalloys can be cut using the EDM wire method. With its accuracy,
the EDM wire cut technique has become a convention cutting method in all industries.

Fig.3.16 Tensile testing machine

Tensile tests were performed on round specimens having 15mm gauge diameter and
30mm gauge length. An average of three observations has been considered in this
study. The equipment used for carrying out the tensile was universal testing machine.
Tensile test was carried out at room temperature.

The Fig 3.16 shows the tensile testing machine. The test set up requires that
equipment be properly matched to the test at hand. There are three requirements of
the testing machine force capacity sufficient to break the specimens to be tested;
control of test speed (strain rate or load rate, as required by the test specification; and
precision and accuracy sufficient to obtain and record properly the load and extension
information generated by the test.

The grips must properly fit the specimens and they must have sufficient force
capacity so that they are not slipped during testing. A tensile involves mounting the
specimen in a machine and subjecting it to tension.

The grips must properly fit the specimens and they must have sufficient force
42
capacity so that they are not slipped during testing. A tensile involves mounting the
specimen in a machine and subjecting it to tension.

The tensile force is recorded as a function of the increase in gauge length. As

a result we get a stress-strain curve. ASTM B557M is a standard test method for
tension testing of metallic materials. In general, the particle reinforced Al -MMCs are
found to have higher elastic modulus, tensile and fatigue strength over monolithic
alloys.

Increases in elastic modulus and strength of the composites are reasoned to the
strong interface that transfers and distributes the load from the matrix to the
reinforcement.

Fig.3.17 Compression testing machine

Fig.3.17,So,Compression test uses compression testing machines to determine

material behavior under constantly increasing compressive loading. Compression
tests examine the safety, durability, and integrity of materials and components.
Typical applications include compression tests on plastic tubes and plastic pipes,
43
compression test on flexible cellular foam material, compression/crush tests on paper and
cardboard, compression spring testing in the metals industry, compression tests in
the medical/pharmaceutical field including compression testing of medical implants,
stents, syringes or medical packaging, compression and notched compression tests on
composites.

A compression testing machine is a universal testing machine (UTM) equipped

with application-specific compression test tools or compression platens. The tools are
selected and installed in the machine based on criteria such as test type, specimen
material and dimensions, test temperature and maximum force values expected. A
Compression Testing Machine or Compression Tester is a machine or equipment used
to test the quality. Compression tests are performed to characterize the behavior
of a material under compressive loading. During the test, pressure is applied to a
specimen using compression platens or special tools mounted on a universal
testing machine to determine various properties of the material being tested.

This can also be defined as a machine that is used to test the compressive strength of
any material using a standard static force and a standard displacement rate.

Because of the variety of uses, there are several different types of compression
testing machines available. The type of CTM machine used depends on the material
being tested and the type of information needed from the result. For example, some
types are used for gas cylinders (compression only), oil barrels, and for cylinder
blocks. Others measure tensile forces, but not torsional forces.

Some are used for non-destructive evaluation (NDT) for inspection and
acceptance testing of pressure vessels and piping, welded joints, and castings. Some
machines can measure more than one feature at a time, such as different combinations
of force, pressure, and time; time-temperature curves; strain; torque; compression, or
tension. The type chosen should be based on what is most relevant to the users’ needs.

44
 Fig.3.18 Impact testing machine

Fig.3.18,The Charpy impact test, also known as the Charpy V-notch test, is a high
strain- rate test that involves striking a standard notched specimen with a controlled
weight pendulum swung from a set height. The impact test helps measure the
amount of energy absorbed by the specimen during fracture.

The Charpy impact test, also known as the Charpy V-notch test, is a
standardized high strain rate test which determines the amount of energy abs orbed bya
material during fracture. Absorbed energy is a measure of the material's notch
toughness. It is widely used in industry, since it is easy to prepare and conduct and
results can be obtained quickly and cheaply. A disadvantage is that some results are
only comparative.

The apparatus consists of a pendulum of known mass and length that is dropped
from a known height to impact a notched specimen of material. The energy transferred
to the material can be inferred by comparing the difference in the height of the hammer
before and after the fracture (energy absorbed by the fracture event).

45
 The notch in the sample affects the results of the impact test thus it is necessary
for the notch to be of regular dimensions and geometry. The size of the sample can
also affect results, since the dimensions determine whether or not the material is in
plane strain. This difference can greatly affect the conclusions made.

Fig.3.19 Microstructure Testing

Machine Name : Micro Vickers Hardness Tester

Testing load range : 10g to 1 Kg Load
Make : HDNS-Kelly Instruments, made in china.
Vernier caliper least count : 0.01 mm
Available Hardness testing Scale : HV, HRA, HRC, 15N, 30N etc.,

Fig, 3.19, The microstructure of aluminum consists primarily of two distinct

components: grainsand grain boundaries. Grains are regions where atoms have formed
a crystal lattice that imparts strength to the metal. Microstructure analysis is an
important process used to evaluate the properties of aluminum alloys. This type of
analysis examines the microscopic structure of the alloy, allowing for a better
understanding of its physical and mechanical properties

46
 CALCULATION

WEIGHT PERCENTAGE OF THE COMPOSITE MATERIALS:

Table 3.1 weight percentage of the composite materials

SPECIMEN Al6063 PET (Polyethylene Terephthalate)

NO.
1 97% (834g) 3% (6g)
2 94% (738g) 6% (8g)

47
 CHAPTER 4

RESULT AND DISCUSSION

4.1 TENSILE TEST

The tensile tests were carried out using computerized universal testing
machine as per ASTM standards. But we can find the Tensile strength by
conversion of Rockwell hardness to tensile strength. The approximate tensile
strength is taken according to hardness value of aluminum composite. Tensile
test is a fundamental material science test in which a sample is subjected control
tension until failure. Properties that are directly measured via tensile test are
ultimate tensile strength.

Table 4.1 Tensile test

SPECIMEN LOAD TENSILE

Fmax STRENGTH
(KN) (Mpa)
T1-1 3.07 95.09
T1-2 3.04 107.55
T1-3 3.02 100.24
T2-1 4.29 152.31
T2-2 4.13 146.75
T2-3 3.25 114.47

48
SAMPLE 1

T1-1 T1-1SS

T1-2 T1-2SS

T1-3 T1-3SS

49
SAMPLE 2

T2-1 T2-1SS

T2-2 T2-2SS

T2-3 T2-3SS

50
CONCLUSION

Table 4.2 Tensile test conclusion

SPECIMEN TENSILE CONCLUSION

STRENGTH
(Mpa)
T2-1 152 HIGH STRENGTH
T1-1 95 LOW STRENGTH

Sample 1

Fig 4.1 Final Result of Tensile specimen test

51
 Sample 2

Fig 4.2 Final Result of Tensile specimen test

4.2 IMPACT TEST

The Charpy impact test, also known as the Charpy V-notch test, is a high strain-
rate test that involves striking a standard notched specimen with a controlled weight
pendulum swung from a set height. The impact test helps measure the amount of
energy absorbed by the specimen during fracture. It is a standardized high strain rate
test which determines the amount of energy absorbed by a material during fracture.
Absorbed energy is a measure of the material's notch toughness. It is widely used in
industry, since it is easy to prepare and conduct and results can be obtained quickly
and cheaply. A disadvantage is that some results are only comparative.

The below result shows the impact test result of aluminum polymer composite which was
carried out in impact test machine. When compared to specimen 1(Al6063- 94%, PET-
6%) and specimen 2(Al6063-92%, PET-8%) and specimen 3(Al6063- 85%, PET-
15%).
52
RESULT

Table 4.3 Impact test

SAMPLE Zone-1, Joules Zone-2, Joules Zone-3, Joules

1 8.9 13.6 11.7
2 13.6 13.7 11.4

Sample 1

Fig 4.3 Final Result of Impact specimen test

Sample 2

Fig 4.4 Final Result of Impact specimen test

53
CONCLUSION

Table 4.4 Impact test result

SPECIMEN IMPACT CONCLUSION

(J)
1 13.7 HIGH IMPACT
2 8.9 LOW IMPACT

4.3 COMPRESSION TEST

A Compression test uses compression testing machines to determine material

behavior under constantly increasing compressive loading. Compression tests
examine the safety, durability, and integrity of materials and components. Typical
applications include compression tests on plastic tubes and plastic pipes, compression
test on flexible cellular foam material, compression/crush tests on paper and
cardboard, compression spring testing in the metals industry, compression tests in the
medical/pharmaceutical field including compression testing of medical implants,
stents, syringes or medical packaging, compression and notched compression tests on
composites.

The below result shows the compression test result of aluminium polymer
composite which was carried out in impact test machine. When compared to specimen
1(Al6063-94%, PET-6%) and specimen 2(Al6063-92%, PET-8%) and specimen
3(Al6063-85%, PET-15%).

54
 Sample 1

Fig 4.5 Final Result of Compression specimen test

Sample 2

Fig 4.6 Final Result of Compression specimen test

55
 Table 4.5 Compression test

SPECIMEN LOAD COMPRESSIVE

(KN) STRENGTH
(Mpa)
C1-1 31.6 643.42
C1-2 30.53 624.05
C1-3 31.66 644.04
C2-1 32.35 687.67
C2-2 28.38 603.02
C2-3 30.38 637.55

SAMPLE 1

C1-1 C1-1SS

C1-2 C1-2SS
56
 C1-3 C1-3SS

SAMPLE 2

C2-1 C2-1SS

C2-2 C2-2SS

57
 C2-3 C2-3SS

CONCLUSION

Table 4.6 Compressive test conclusion

SPECIMEN COMPRESIVE CONCLUSION

STRENGTH
(MPa)
C2-1 687.67 HIGH STRENGTH
C2-2 603.02 LOW STRENGTH

4.4 MICROSTRUCTURE TEST

Microstructure analysis is an important process used to evaluate the

properties of aluminum alloys. This type of analysis examines the microscopic structure
of the alloy, allowing for a better understanding of its physical and mechanical
properties. Microstructural examination is generally performed using optical or
scanning electron microscopes to magnify features of the material under analysis. The
amount or size of these features can be measured and quantified,and compared to
acceptance criteria

58
 Sample 1

Fig.4.7 Final Result of Microstructure specimen test

Sample 2

Fig.4.8 Final Result of Microstructure specimen test

59
Sample-1

Photo -1 Photo -2

Photo -3 Photo -4

Photo -5 Photo -6

Magnification: 100X, 200X Etchant: H.F Soln.

60
Sample-2

Photo -1 Photo -2

Photo -3 Photo -4

Photo -5 Photo -6

Magnification: 100X, 200X Etchant: H.F Soln.

61
62
 CHAPTER 5

SCOPE OF THE PROJECT

 Identifying new materials

 Replacement of current materials in automobile, aerospace, military and

sports components.
4.4.1 Break caliper

4.4.2 Vehicle Exhaust manifold casing

4.4.3 Upper and lower receiver of M16 Rifle parts

4.4.4 Net of Lacrosse sticks

4.4.5 Camping gadgets

63
 CHAPTER 6

CONCLUSION

The conclusions based on the present work on Al6063 – PET (Polyethylene

Terephthalate) metal matrix composites are as follows,

 The Selection of matrix base material.

 Mould making as per specimen.

 Composite preparation with Al6063 and PET (Polyethylene Terephthalate)

 Casting of metal matrix composites by stir casting process by using Al6063

/ PET (Polyethylene Terephthalate) as reinforcements.

 The casting material is obtained and weight percentage of the composite

materials is calculated.
 We have undergone Mechanical testing like Tensile, Impact,
Compression and Microstructure.

 In tensile testing there are totally six specimens (T1, T2, T3, T4, T5, T6)
out of the six T2-1 was found to high strength and T1-1 was found to be
low strength.
 In Impact testing there are totally three specimens in which the specimen
no.1 was found to be stronger than other two.
 Also in Compression test there are 3 specimens (C1-1, C1-2,C1-
3,C2-1,C2-2,C2-3) out of the two specimens the C2-1 is found to be
stronger. 

64
 CHAPTER 7

REFERENCES

1. Jawalkar, C. S., Verma, A. S., & Suri, N. M. (2017). Fabrication of aluminium

metal matrix composites with particulate reinforcement: a review. Materials
Today: Proceedings, 4(2), 2927-2936.
2. Kumar, G. V., & Pramod, R. (2017, July). Investigation of mechanical
properties of aluminium reinforced glass fibre polymer composites. In AIP
Conference Proceedings (Vol. 1859, No. 1, p. 020084). AIP Publishing LLC.

3. Prasad, B., & Singh, M. (2017). Fabrication of aluminium polymer nano

composite by in-situ technique. Journal of Graphic Era University, 3-9.
4. Dickson, A. N., Barry, J. N., McDonnell, K. A., & Dowling, D. P. (2017).
Fabrication of continuous carbon, glass and Kevlar fibre reinforced polymer
composites using additive manufacturing. Additive Manufacturing, 16, 146-
152.
5. Stöbener, K., & Rausch, G. (2009). Aluminium foam–polymer composites:
processing and characteristics. Journal of Materials Science, 44(6), 1506-
1511.
6. Surappa, M. K. (2003). Aluminium matrix composites: Challenges and
opportunities. Sadhana, 28(1), 319-334.
7. Babrekar, H. A., Kulkarni, N. V., Jog, J. P., Mathe, V. L., & Bhoraskar, S. V.
(2010). Influence of filler size and morphology in controlling the thermal
emissivity of aluminium/polymer composites for space
applications. Materials Science and Engineering: B, 168(1-3), 40-44.
8. Kumar, G. V., & Pramod, R.(2017, July). Investigation of mechanical
properties of aluminium reinforced glass fibre polymer composites. In AIP
Conference Proceedings (Vol. 1859, No. 1, p. 020084). AIP PublishingLLC.
65
9. Azghan, M. A., & Eslami-Farsani, R. (2018). The effects of stacking sequence
and thermal cycling on the flexural properties of laminate composites of
aluminium-epoxy/basalt-glass fibres. Materials Research Express,
5(2),025302.

66
67