Kandpal, et al.

, International Journal of Advanced Engineering Technology

E-ISSN 0976-3945

Research Paper

MANUFACTURING OF AMMCS USING STIR CASTING

PROCESS AND TESTING ITS MECHANICAL PROPERTIES
Ajay Singh, Love Kumar, Mohit Chaudhary, Om Narayan, PallavSharma, Piyush
Singh, *Bhaskar Chandra Kandpal, Som Ashutosh

Address for Correspondence

Department of Mechanical Engineering, Inderprastha Engineering College, Ghaziabad, Uttar Pradesh
ABSTRACT
Aluminum alloys are widely used in aerospace and automobile industries due to their low density and good mechanical
properties, better corrosion resistance and wear, low thermal coefficient of expansion as compared to conventional metals
and alloys. The excellent mechanical properties of these materials and relatively low production cost make them a very
attractive candidate for a variety of applications both from scientific and technological viewpoints. The aim involved in
designing aluminum based metal matrix composite materials is to combine the desirable attributes of metals and Ceramics.
Present work is focused on the study of behavior of Aluminum Cast Alloy (6063) with alumina (Al2O3) composite produced
by the stir casting technique. Different % age of alumina powder is used as reinforcement phase in this AMMC. Various
mechanical tests like tensile test, Hardness Test, Impact test are performed on the samples of AMMC to evaluate the
mechanical properties of this aluminum based metal matrix composite.
KEYWORDS- composite, alumina (Al2O3), metal matrix composite (MMC), aluminum metal matrix composite (AMMC)

1. INTRODUCTION
The aim involved in designing metal matrix
composite materials is to combine the desirable
attributes of metals and ceramics. The addition of
high strength, high modulus refractory particles to a
ductile metal matrix produce a material whose
mechanical properties are intermediate between the
matrix alloy and the ceramic reinforcement.
Aluminium metal matrix composite (AMMCs) refer
to the class of light weight high performance
aluminium
centric
material
systems.
The
reinforcement in AMMCs could be in the form of
continuous/discontinuous
fibres,
whisker
or
particulates, in volume fractions ranging from a few
percent to 70%. Properties of AMMCs can be tailored
to the demands of different industrial applications by
suitable combination of matrix, reinforcement and
processing routes. There are various types of AMMCs
like Al/SiC, Al/ Al2O3, Al. TiC, etc. which are
commonly used in automotive and defense. These
AMMCs have greater demand because of their
advanced properties like greater strength, improved
stiffness, reduced density, improved high temperature
properties, controlled thermal expansion coefficient,
enhanced and tailored electrical properties, improved
abrasion and wear resistance, control of mass
,improved damping capabilities.
1.1. Processing of MMCS
Accordingly to the temperature of the metallic matrix
during processing the fabrication of MMCs can be
classified into three categories: (a)Liquid phase
processes, (b) solid state processes, and (c) Two
phase (solid-liquid) processes
Stir Casting Process -Stir Casting is a liquid state
method of composite materials fabrication, in which a
dispersed phase (ceramic particles, short fibers) is
mixed with a molten matrix metal by means of
mechanical stirring. The liquid composite material is
then cast by conventional casting methods and may
also be processed by conventional Metal forming
technologies. The Stir Casting set up is shown in
Figure 1.
1.2 Literature review related to MMC and AMMC
The main concept of composite is that it contains
matrix materials. In composite material the
reinforcements can be fibers, particulates or whiskers,
and the matrix materials can be metals, plastics, or
ceramics. The reinforcements can be made from
polymers, ceramics and metals. [1].
Int J Adv Engg Tech/IV/III/July-Sept.,2013/26-29

Fig.1- Stir casting (1)

Some automotive companies using MMC for disc

brakes also. Honda Company used AMMC for
cylinder liners in some of their engines like F20C,
F22C and H22A. In recent years considerable
development has occurred in nonferrous composites
and attention is now being given to make iron based
composites. The paper [2] reviews the ongoing
research and interaction between iron based materials
and reinforcements including wetting and spreading
of iron melts on ceramic materials. The paper
provides insight into the evolution of the processes
that are used to manufacture iron based composites,
and the applications that benefit from their unique
characteristics. In order for ferrous based composite
materials to find applications in production
environments, consistent and controlled mechanical
and physical characteristics are required. Ultimately,
industry standards need to be written defining the
material design parameters. Over the past thirty years
Metal Matrix Composites (MMCs) have [3] emerged
as an important class of material within the
engineering industry. At present, MMCs offer
attractive performance or weight-saving alternatives
for a wide range of applications within the sport
industry, from Formula 1 racing components to golf
club shafts. This paper briefly reviews the advantages
of MMCs, and presents a study of the effects of
additional treatments (heat and surface) which
produce beneficial characteristics in monolithic and
alloy materials, but whose effects become more
complex when applied to composites. The material
used for this study was 2124 Al alloy matrix,
reinforced with particulate silicon carbide having a
mean particle size of around 3 m treatment. The
influence of machining parameters [4] such as cutting
forces and surface roughness on the machinability of
LM6/ SiCp metal matrix composites at different
weight fraction of SiCp discussed in this paper. It is
observed that the depth of cut and the cutting speed at

Kandpal, et al., International Journal of Advanced Engineering Technology

constant feed rate affects the surface roughness and

the cutting forces during dry turning operation of cast
MMCs. It is also observed that higher weight
percentage of SiCp reinforcement imparts a higher
surface roughness and needs high cutting forces. This
experimental analysis and test results on the
machinability of Al/SiC-MMC will provide essential
guidelines to the manufacturers. A detailed study [5]
on the processing of Al-metal matrix composites cites
with the reinforcement of different particulates such
as SiC, TiN and TiO2 was carried out. The results of
the present studies show that the Al based composites
prepared through various techniques exhibits
excellent mechanical, physical and tribological
properties and could emerge as promising materials
for defense, aerospace and other engineering
applications. With concern [6] increasing over
environmental issues, reduction in automobile weight
has become more important and has been proved to
be effective for improving fuel efficiency. Metal
Matrix Composites (MMC) are expected to be useful
to cope with these problems. The authors have
developed a new aluminium engine block which has
the cylinder bore surface structure reinforced with
short hybrid fibres of alumina and carbon. The
development of aluminum metal matrix composites
(Al-MMC) brake rotor and pad was discussed [7].The
improvement in fuel consumption rate requires a
reduction in vehicle weight. In this study, we
developed aluminum metal matrix composites brake
rotor and pads, which have equivalent braking effects
and wear resistance to those of the conventional cast
iron rotor, by optimization of the quantities and the
particle diameter ratio of hard particles used for the
rotor and the pad. Metal matrix composites [8] offer
considerable potential for widespread application in
most aerospace fields. The potential for the use of
these materials in civil aircraft is largely dependent on
costs and currently these are too high. However, by
the use of appropriate design and manufacturing
technology this intrinsic high cost can be overcome to
unlock their potential
1.3 Alumina as reinforcement
Aluminum oxide, commonly referred to as alumina,
possesses strong ionic inter atomic bonding giving
rise to its desirable material characteristics. It can
exist in several crystalline phases which all revert to
the most stable hexagonal alpha phase at elevated
temperatures. Its high hardness, excellent dielectric
properties, refractoriness and good thermal
properties make it the material of choice for a wide
range of applications.
1.4 Effect of particle size
The deformation and fracture behavior of the
composite revealed the importance of particle size. A
reduction in particle size is observed to increase the
proportional limit, yield stress and the ultimate tensile
stress. It is well established that large particles are
detrimental to fracture toughness due to their
tendency towards fracture. It would be highly
desirable to have a composite system where the
reinforcing particles are relatively fine (4m or less)
so as to get the stiffness benefits of a composite
without significantly lowering fracture toughness.
1.5 Effect of reinforcement distribution
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E-ISSN 0976-3945

Apart from the reinforcement level, the

reinforcement distribution also influences the
ductility and fracture toughness of the MMC and
hence indirectly the strength. A uniform
reinforcement distribution is essential for effective
utilization of the load carrying capacity of the
reinforcement.
Non-uniform
distributions
of
reinforcement in the early stages of processing was
observed to persist to the final product in the forms of
streaks or clusters of uninfiltrated reinforcement with
their attendant porosity, all of which lowered
ductility, strength and toughness of the material.
2. EXPERIENTIAL PROCEDURE
2.1 Preparation of aluminum based metal matrix
composite (AMMC)
The most important aspects of the microstructure is
the distribution of the reinforcing particles, and this
depends on the processing and fabrication routes
involved. The oxides of reinforcing particles used in
the composites have a varying density. Density of
the particles is one of the important factors
determining the distribution of the particles in
molten metal. Particles having higher density than
molten metal can settle at the bottom of the bath
slowly and particles of lower density can segregate
at the top. During subsequent pouring of the
composite melt, the particle content may vary from
one casting to another or even it can vary in the same
casting from one region to another. Therefore
uniform distribution of the particles in the melt is a
necessary condition for uniform distribution of
particles in the castings. The properties of
composites are finally dependent on the distribution
of the particles. Hence the study of the distribution
of the particles in the composite is of great
significance. Aluminum Alloy 6061 was melted in a
crucible by heating it in a muffle furnace at 800C
for three to four hours. The Alumina particles were
preheated at 1000 C and 900oC respectively for one
to three hours to make their surfaces oxidized. The
furnace temperature was first raised above the
liquidus temperature of Aluminum near about 750 C
to melt the Al alloy completely and was then cooled
down just below the liquidus to keep the slurry in
Semi solid state. Automatic stirring was carried out
with the help of radial drilling machine for about 10
minutes at stirring rate of 290 RPM. At this stage,
the preheated Alumina particles were added
manually to the vortex. In the final mixing processes
the furnace temperature was controlled within 700
10C. After stirring process the mixture was pour in
the other mould to get desired shape of specimen as
shown in Figure. The presence of reinforcement
throughout the specimen was inspected by cutting
the casting at different locations and under
microscopic examination. Same process was used for
specimens with different compositions of Alumina.
Compositions of samples are shown in Table 1:
Table 1- Compositions of samples
S.
N
o
1
2
3
4

Sample composition
(%of alumina in
ammc)
2.5
5
7.5
10

Aluminium
alloy 6063
( grams)
1950
1900
1850
1800

Aluminium
oxide
( grams)
50
100
150
200

Kandpal, et al., International Journal of Advanced Engineering Technology

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E-ISSN 0976-3945

2.2 Preparation of Patterns design and pattern

In this step we have prepared patters of wood for
various mechanical tests.

Fig 7- Casting

2.5 Casted samples of aluminum based metal

matrix composite

Fig8 - Sample of impact test

Fig9 - Sample of fatigue test

Fig.2 -Pattern Drawing of various test specimens

Fig 3- Torsion
pattern

Fig 4 -Fatigue
Fatigue
pattern

2.6 Mechanical testing of casted AMMC

After casting samples of various mechanical test of
AMMC material, following mechanical tests are
carried out to check the check the mechanical
properties of composite material. These tests are
done on various mechanical testing machines like
universal testing machine, Vickers hardness testing
machine, impact testing machine as discussed in this
section.
2.6.1 Impact Test
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 absorbed by
a material during fracture. This absorbed energy is a
measure of a given material's toughness.

Fig 5- Tensile pattern

2.3 Mould Making Process

In this step we have prepared mould for casting
specimen of various mechanical tests like tensile
test, hardness test, torsion test, etc.

Fig.10 Impact testing machine ((10)

With the increase in Al2O3 constituent Impact

strength is increases w.r.t. base metal. This is due to
proper dispersion of Al2O3 into the matrix or strong
interfacial bonding in between the Al alloy 6063&
Alumina interfaces.
2.6.2 Hardness test
A Vicker hardness tester machine used for the
hardness measurement of composite material.

Fig 6- Mould Making

2.4 Casting Process

In this step we have first prepared aluminum based
composite material in the open hearth furnace as
discussed in above section to cast specimens of
various mechanical tests.
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26-29

Fig 11. Vickers testing ((10)

Kandpal, et al., International Journal of Advanced Engineering Technology

The results predict that uniform increase in hardness

is also seen. This is due to increase in resistance to
deformation by adding Alumina as reinforcement in
6063 alloy.
2.6.3 Tensile test
Tensile tests were used to assess the mechanical
behavior of the composites and matrix alloy.
The composite and matrix alloy rods were machined
to tensile specimens with a diameter of 6mm and
gauge length of 30 mm. As the reinforcement wt. %
increases, UTS is also increases. This happens may
be due to dispersion of Alumina which creates
hindrance to dislocation motion. This may results
increase in tensile strength of reinforced Al 6063
alloy.
All these mechanical tests are done properly as per
the standards given in various material testing books.
For these tests we observed improved in mechanical
properties of newly manufactured AMMC material
using stir casting as compared to aluminum alloy
6063 and aluminum oxide.

Figure12 Universal testing machine (10)

CONCLUSION
The conclusions drawn from the present
investigation are as follows:
The results confirmed that stir formed Al alloy
6063 with Al2O3 reinforced composites is
clearly superior to base Al alloy 6063 in the
comparison of tensile strength, Impact strength
as well as Hardness.
Dispersion of Al2O3 particles in aluminum
matrix improves the hardness of the matrix
material.
It is found that elongation tends to decrease
with increasing particles wt. percentage, which
confirms that alumina addition increases
brittleness.
Aluminum matrix composites have been
successfully fabricated by stir casting
technique with fairly uniform distribution of
Al2O3 particles.
It appears from this study that UTS and Yield
strength trend starts increases with increase in
weight percentage of Al2O3 in the matrix.
ACKNOWLEDGEMENTS
The authors would like to acknowledge the support
of, in particularly Department of Mechanical
Engineering, Inderprastha Engineering College,
Ghaziabad, U.P funding the current research in this
area.
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