ABSTRACT

Nowadays composite materials have become more popular for its wi

de range of applications and design flexibility. Since the fuel costs are increa
sing day to day, most of the automobile industries are conducting various experi
ments to develop composites having less densities and superior mechanical and tr
ibological properties which are equally cost effective. In view of these types o
f composites most of the research is focused on improving mechanical and tribolo
gical properties aluminium alloys by adding with ceramic reinforcements.
Silicon carbide is a compound of silicon and carbon with chemical formul
a SiC. Grains of silicon carbide can be bonded together by sintering to form ver
y hard ceramics that are widely used in applications requiring high endurance, s
uch as car brakes, car clutches and ceramic plates in bulletproof vests.
Graphite is well known for its self-lubricating properties, which is a semi meta
l and an allotrope of carbon.
Research was done to improve the properties of aluminium using both grap
hite and SiC as reinforcements on various alloys. This work mainly focuses on th
e Preparation and Analysis of Silicon Carbide & Graphite Particulate Reinforcemen
ts in Aluminium Matrix .
1.
INTRODUCTION
1.1.
Composite Material
A composite is when two or more different materials are combined together to cre
ate a superior and unique material.
A composite material is made by combining two or more materials
often ones that
have very different properties. The two materials work together to give the com
posite unique properties. However, within the composite you can easily tell the
different materials apart as they do not dissolve or blend into each other.
1.1.1. Natural Composites
Many of us may not be noticed that several, naturally formed materials around us
are composites.
Wood is a composite made from cellulose and lignin. The advanced forms of wood c
omposites can be ply-woods. An excellent example of natural composite is muscles
of human body. The muscles are present in a layered system consisting of fibers
at different orientations and in different concentrations. These result in a ve
ry strong, efficient, versatile and adaptable structure. The muscles impart stre
ngth to bones and vice a versa. These two together form a structure that is uniq
ue. The bone itself is a composite structure. The bone contains mineral matrix m
aterial which binds the collagen fibres together.
The other examples include: wings of a bird, fins of a fish, trees and grass. A
leaf of a tree is also an excellent example of composite structure. The veins in
the leaf not only transport the food and water but also impart the strength to
the leaf so that the leaf remains stretched with maximum surface area. This help
s the plant to extract more energy from sun during photo-synthesis (1).
1.1.2. Man-Made Composites
These composites are made by artificial mixing of two or more materials in defin
ite proportions under controlled conditions. Mud mixed straw to produce stronger
mud mortar and bricks, Plywood, Chipboards, Decorative laminates, Fibre Reinfor
ced Plastic (FRP), Carbon Composites, Concrete and RCC, Reinforced Glass etc. Th
e composites exist in day to day life applications as well. The most common exis
tence is in the form of concrete. The concrete is a composite made from gravel,
sand and cement. Further, when it is used along with steel to form structural co
mponents in construction, it forms one further form of composite.
1.2.
Why use composites?
The biggest advantage of modern composite materials is that they are light as we
ll as strong. By choosing an appropriate combination of matrix and reinforcemen
t material, a new material can be made that exactly meets the requirements of a
particular application. Composites also provide design flexibility because many

of them can be moulded into complex shapes.

1.3.
History of Composites
The first uses of composites date back to the 1500s B.C. when early Egyp
tians and Mesopotamian settlers used a mixture of mud and straw to create strong
and durable buildings. Straw continued to provide reinforcement to ancient comp
osite products including pottery and boats.
Later, in 1200 BC, the Mongols invented the first composite bow. Using a
combination of wood, bone, and animal glue, bows were pressed and wrapped with
birch bark. These bows were extremely powerful and extremely accurate. Composite
Mongolian bows provided Genghis Khan with military dominance, and because of th
e composite technology, this weapon was the most powerful weapon on earth until
the invention of gunpowder (2).
As said, Need is the mother of all inventions , the modern composites, that is, pol
ymer composites came into existence during the Second World War. During this per
iod the fighter planes were the most advanced fighting means. The light weight y
et strong materials were in high demand. Further, for application like housing o
f electronic radar equipment require non-metallic materials. Hence, the Glass Fi
bre Reinforced Plastics (GFRP s) were first used in these applications (3).
In 1935, Owens Corning introduced the first glass fiber, fiberglass. Fib
erglass, when combined with a plastic polymer creates an incredibly strong struc
ture that is also lightweight. This is the beginning of the Fiber Reinforced Pol
ymers (FRP) industry as we know it today (2).
1.4.
Constituents of a Composite Material
In a composite, typically, there are two constituents. One of the consti
tuent acts as a reinforcement and other acts as a matrix. Sometimes, the constit
uents are also referred as phases.
1.4.1. Matrix Phase
The primary phase, the monolithic material into which the reinforcement
is embedded, and having a continuous character, is called matrix. Matrix is usua
lly more ductile and less hard phase.
Classification of Matrix
The matrix in a composite material can be grouped based on the type of material
as given below
Figure 1.1 Classification of Matrix
1.4.2. Reinforcement (Dispersed) Phase
The second phase (or phases) is embedded in the matrix in a discontinuou
s form. This secondary phase is called dispersed phase. Dispersed phase is usual
ly stronger than the matrix, therefore it is sometimes called reinforcing phase.
Classification of reinforcements
The reinforcements in a composite material come in various forms.
Figure 1.2 Classification of Reinforcements
Fibre: Fibre is an individual filament of the material. A filament with length t
o diameter ratio above 1000 is called as a fibre. The fibrous form of the reinfo
rcement is widely used. The fibres can be in the following two forms:
Continuous fibres: If the fibres used in a composite are very long and unbroken
or cut then it forms a continuous fibre composite. The fibrous composite is the
widely used form of composite.
Short/chopped fibres: The fibres are chopped into small pieces when used in fabr
icating a composite. A composite with short fibres as reinforcements is called a
s short fibre composite.
Particulate: The reinforcement is in the form of particles which are of the orde
r of a few microns in the diameter. The particles are generally added to increas
e the modulus and decrease the ductility of the matrix materials. The composite
with reinforcement in particle form is called as particulate composite.
Flake: Flake is a small, flat, thin piece or layer (or a chip) that is broken fr
om a larger piece. Since these are two dimensional in geometry, they impart almo
st equal strength in all directions of their planes. Thus, these are very effect

ive reinforcement components. The flakes can be packed more densely when they ar
e laid parallel, even denser than unidirectional fibres and spheres.
Whiskers: These are nearly perfect single crystal fibres. These are short, disco
ntinuous and polygonal in cross-section.
1.5.
Types of Composite Materials
There are two classification systems of composite materials. One of them
is based on the matrix material and the second is based on the reinforcing mate
rial structure:
1.5.1. Classification of Composites Based on Matrix Material
Since composite materials does not limit to any specific materials or me
tals, matrix can be any of the materials like plastics, glass, metals etc. all t
hese materials were grouped based on the type of material. Figure 1.3 shows the
classification of composites based on the matrix materials.
Figure 1.3 Classification of Composites Based on Matrix Material
Metal Matrix Composites (MMC)
Metal Matrix Composites are composed of a metallic matrix (aluminium, ma
gnesium, iron, cobalt, copper) and a dispersed ceramic (oxides, carbides) or met
allic (lead, tungsten, molybdenum) phase.
Ceramic Matrix Composites (CMC)
Ceramic Matrix Composites are composed of a ceramic matrix and embedded
fibers of other ceramic material (dispersed phase).
Polymer Matrix Composites (PMC)
Polymer Matrix Composites are composed of a matrix from thermoset (Unsat
urated Polyester, Epoxy) or thermoplastic (Polycarbonate, Polyvinylchloride, Nyl
on, Polystyrene) and embedded glass, carbon, steel or Kevlar fibers (dispersed p
hase).
Carbon and Graphite
carbon/carbon composites used under extre
Carbon fibres in carbon matrix
me mechanical and thermal loads in space applications.
1.5.2. Classification of Composites Based on Reinforcing Material
Reinforcing material in composites can be of different materials or the
combination of two or more materials (Hybrid Composites). One simple schema for
the classification of composites bases on reinforcing material is shown in Figur
e 1.4.
Figure 1.4 Classification of Composites Based on Reinforcements
Particulate Composites
Particulate Composites consist of a matrix reinforced by a dispersed pha
se in form of particles.
i.
Composites with random orientation of particles.
ii.
Composites with preferred orientation of particles. Dispersed phase of t
hese materials consists of two-dimensional flat platelets (flakes), laid paralle
l to each other.
Fibrous Composites
Short-fiber reinforced composites. Short-fiber reinforced composites consist of
a matrix reinforced by a dispersed phase in form of discontinuous fibers.
i.
Composites with random orientation of fibers.
ii.
Composites with preferred orientation of fibers.
Long-fiber reinforced composites. Long-fiber reinforced composites consist of a
matrix reinforced by a dispersed phase in form of continuous fibers.
i.
Unidirectional orientation of fibers.
ii.
Bidirectional orientation of fibers (woven).
Structural Composites
Structural composites are combinations of composites and homogeneous mat
erials. When a fiber reinforced composite consists of several layers with differ
ent fiber orientations, it is called multilayer (angle-ply) composite.
Composite Materials with Metal Matrix
Particulate composites consist of particles immersed in matrices
such as alloys and ceramics. They are usually isotropic since the particles

are added randomly. Particulate composites have advantages such as improved

strength, increased operating temperature and oxidation resistance etc.
Typical examples include use of aluminium particles in rubber, silicon carbide p
articles in aluminium, and gravel sand, cement to make concrete.
Flake composites consist of flat reinforcements of matrices. Typical fla
ke materials are glass, mica, aluminium, and silver. Flake composites provide ad
vantages such as high out-of plane flexural modulus, higher strength, and low co
st.
Figure 1.5Composite Materials with Metal Matrices
1.6.
Manufacturing and forming methods of MMC
MMC manufacturing can be broken into three types solid, liquid, and vapour
.
1.6.1. Liquid state methods
Stir casting: Discontinuous reinforcement is stirred into molten metal, which is
allowed to solidify.
Electroplating and electroforming: A solution containing metal ions loaded with
reinforcing particles is co-deposited forming a composite material.
Squeeze casting: Molten metal is injected into a form with fibers pre-placed ins
ide it.
Spray deposition: Molten metal is sprayed onto a continuous fiber substrate.
Reactive processing: A chemical reaction occurs, with one of the reactants formi
ng the matrix and the other the reinforcement.
1.6.2. Solid state methods
Powder blending and consolidation (powder metallurgy): Powdered metal and discon
tinuous reinforcement are mixed and then bonded through a process of compaction,
degassing, and thermo-mechanical treatment (possibly via hot isostatic pressing
(HIP) or extrusion).
Foil diffusion bonding: Layers of metal foil are sandwiched with long fibers, an
d then pressed through to form a matrix.
1.6.3. Semi-solid state methods
Semi-solid powder processing: Powder mixture is heated up to semi-solid state an
d pressure is applied to form the composites.
1.6.4. Vapour deposition
Physical vapour deposition: The fiber is passed through a thick cloud of vaporiz
ed metal, coating it.
1.6.5. In situ fabrication technique
Controlled unidirectional solidification of a eutectic alloy can result
in a two-phase microstructure with one of the phases, present in lamellar or fib
er form, distributed in the matrix.
1.7.
Stir Casting
Stir Casting is a liquid state method of composite materials fabrication
, in which a discontinuous reinforcement is mixed with a molten matrix metal by
means of mechanical stirring. The layout of conventional Stir Casting set up is
shown in Figure 1.6.
Figure 1.6 Stir Casting Process
At first, the matrix metal is melted in the crucible and then metal trea
tment (like degassing, fluxing, etc.) is carried out without stirring. Later, st
irrer is inserted into the crucible and allowed to rotate the molten metal. Vort
ex is formed in the crucible due to the rotation of stirrer. Required quantity o
f reinforcement is preheated in a separate chamber and is gradually added to the
vortex for uniform mixing of reinforcement in to the matrix.
After the addition of reinforcement stirrer is removed from the crucible
and the liquid composite material is then cast by conventional casting methods
and may also be processed by conventional Metal forming technologies.
2.

LITERATURE REVIEW
In the last two decades, research has shifted from monolithic materials

to composite materials to meet the global demand for light weight, high performa
nce, environmental friendly, wear and corrosion resistant materials. Metal Matri
x Composites (MMCs) are suitable for applications requiring combined strength, t
hermal conductivity, damping properties and low coefficient of thermal expansion
with lower density. These properties of MMCs enhance their usage in automotive
and tribological applications (4). In the field of automobile, MMCs are used for
pistons, brake drum and cylinder block because of better corrosion resistance a
nd wear resistance (5).
There is a growing interest worldwide in manufacturing hybrid metal matr
ix composites [HMMCs] which possesses combined properties of its reinforcements
and exhibit improved physical, mechanical and tribological properties (6).
DiASil (Die Cast Aluminium Silicon) Cylinder, its application can be fou
nd on Yamaha R series bikes. A conventional cylinder has a steel sleeve, but the
DiASil cylinder doesn t need a steel sleeve because it is made of abrasion-resist
ant aluminium alloy. The all-aluminium combustion chamber has a heat dissipation
rate that is three times better than steel, which means great cooling performan
ce. DiASil Cylinder adds a silicon content of 20% to the aluminium alloy to achi
eve the required hardness to resist abrasion (7). Honda Company used AMMC for cy
linder liners in some of their engines like F20C, F22C and H22A (8).
According to Rohit Kumar, Ravi Rajan, & R K Tyagi, 2013 (9), the yield strength
and tensile strength of the composites decrease with increasing the volume fract
ion of the SiC particles, while the hardness of the composites increases with in
creasing the volume fraction of the SiC particles so that impact strength increa
ses with increase in volume fraction of reinforcement at a certain limit (upto10
%) after starts decreasing.
G.G. Sozhamannan, S. Balasivanandha Prabu and V. S. K. Venkatagalapathy 2012 (10
) observed that production of Aluminium composite reinforced with discontinuous
ceramic particulates by Stir casting route will have homogeneous mix and is cost
effective process. The major problem in this technology is to obtain sufficient
wetting of particle by the liquid metal and to get a homogeneous dispersion of
the ceramic particles.
Neelima, Mahesh, & Selvaraj, 2011 (11) has conducted experiments on Al-SiC and s
howed that the weight tostrength ratio for Aluminium silicon carbide is about th
ree times that of mild steel duringtensile test. Aluminium silicon carbide alloy
composite material is two times less in weightthan the aluminium of the same di
mensions. The maximum tensile strength has been obtainedat 15% SiC ratio. This i
ndicates that the Aluminium silicon carbide composite material ishaving less wei
ght and more strength.
Dunia Abdul Saheb 2011 (12) compared the micro and macro structural behavioural
of Al-SiC and Al-Gr particulate composites by varing the weight fractions of SiC
and Graphite. This study reveals that increasing trend of hardness with the inc
rease in graphite up to 4 wt% weight fraction. Beyond this the hardness of compo
site decreases as graphite particles interact with each other leading to cluster
ing of particles.
S. Naher, D. Brabazon and L. Looney 2003 (13) has simulated stir casting process
using different blade designs and studied the effects of stirring speed, blade
angles and number of blades on the uniform dispersion of SiC particles into diff
erent liquid medium and time required for uniform dispersion of particles. They
noticed the excessive vortex height is responsible for air entrapment into the l
iquid and is more in more viscous liquid. It was observed that settling times of
particles only depends on the viscosity of the liquid metal and does not depend
on the stirring speed and blade design.
Elango, B.K.Raghunath, & K.Thamizhmaran (14) have conducted mechanical tests on
a hybrid metal matrix composite with SiC and TiO2 on which the addition of SiC a
nd TiO2 particulate significantly improves the yield strength and the ultimate t
ensile strength of LM25 alloy, when compared with that of unreinforced matrix. T
he ultimate tensile strength of Al LM25+SiC+TiO2 metal matrix composite when rei
nforced 15 vol. % is increased by 45.38%
A.R Riahi and A.T Alpas 2001 (14) have focused on systemic tests of the role of
tribo-layers which are formed on contact surfaces of hybrid composites with A356

aluminium base. Tests were done on Al/SiC/Gr hybrid composite with A356 base, 1
0% SiC with particle size of 16 m and 3% of graphite with particle size of 80 m an
d 138 m. Performed tribological tests determined dependence between wear and slid
ing speed and load. The tests were performed on block on ring tribometer for loa
ds of 5 420 N and for sliding speeds of 0.2 3.0 m/s.
M.L. Ted Guo and C.Y.A. Tsao 2000 (15) have studied tribological behaviour of Al
-SiC and graphite hybrid composites with different graphite composition and foun
d that friction coefficient decreases with the addition of graphite up to 5% and
no considerable change noticed with further increase in graphite and also obser
ved that hardness of the composite decreases with addition of graphite.
B.MALLICK, P.C. MAITY and V.K. SINHA 1998 (16) explained that addition of magnes
ium to the liquid aluminium will reduce the surface tension of the melt facilita
ting the depression of ceramic particles in to the melt and also increases the w
etting properties of metal-ceramic systems through reduction in solid-liquid int
erfacial energy.
Basavaraju.S, November 2012 et al (18), studied the behaviour of graphite and fl
y ash by varying the percentage of Silicon Carbide and aluminum LM25 as base met
al Prepared MMC s provide excellent wear characteristics up to a limit load. The t
ensile strength improves for 2% addition of SiC and 4% of SiC in Al+Graphite. Th
is proportion is ideal for many results to outcome easily. Similarly, 2% and 4%
addition of SiC in Fly ash combination makes an efficient material. The hardness
of the material increases with the combination of 2% addition of SiC and Graphi
te. The compressive strength is ideal at 2% and 4% addition of SiC graphite and
Flyash.
Till now, significant work has been done on production of MMC s especially
on producing light and durable composites using aluminium. Various works has be
en done for strengthening aluminium with reinforcements. In this regard, number
of researchers conducted experiments on aluminium composite with graphite and Si
C reinforcements on various alloys. The present work will focus on fabrication m
echanical properties of aluminium composite having LM16 as a matrix, SiC and gra
phite as reinforcements.
3.
3.1.

PROBLEMFORMULATION
Identification of Need
Usage of automobiles was increasing day to day. But at the same time, se
arch for alternate fuels increased as the conventional non-renewable sources of
petroleum getting depleted. Simultaneously, automotive industries promoting the
development of lighter and fuel efficient vehicles considering the manufacturing
costs and the life of the vehicle.
Composite materials have more advantages over steel in automobile manufa
cturing. Composites are being considered to make lighter, safer and more fuel-ef
ficient vehicles. Affordability is an important issue in vehicle manufacturing,
which includes factoring in the costs associated with a car s complete life-cycle in
cluding manufacturing, operating and disposal costs.
In view of developing less dense, low cost, highly durable materials for
the automobile components, composites were the best choice for obtaining materi
als with such type of properties. Even though aluminium has replaced most of the
ferrous based engine components like cylinder head, piston, cylinder block etc.
, its usage was restricted to very few applications due to very less wear resist
ance of aluminium alloys. This can be improved by pairing aluminium alloy with t
he materials having good tribological properties.
3.2.
Selection of Matrix
Aluminium is a relatively soft, durable, lightweight, ductile and mallea
ble metal. Aluminium is remarkable for the metal's ability to resist corrosion d
ue to the phenomenon of passivation. Aluminium has a lower density of 2.7 g/cc c
ompared to 7.8 g/cc of steel. Aluminium alloys are lightweight with good corrosi
on resistance, ductility and strength. The greater use of aluminium can decrease
vehicle weight, improve its performance and reduce fuel costs.
Pure aluminium possesses relatively poor casting features, for this reas

on castings are prepared from aluminium alloys. The main alloying elements are s
ilicon, copper, magnesium, zinc, etc. Aluminium silicon alloys have good casting
and corrosion resistance properties. The fluidity increases with silicon additi
on. The addition of copper to aluminium increases its strength and hardness. The
aluminium copper alloys are heat treatable and possess good machinability. Nowa
days, aluminium alloys are replacing the ferrous alloys in manufacturing of auto
mobile components.
Even though aluminium alloys have such remarkable properties, usage of a
luminium is limited to some components because, compared to ferrous alloys alumi
nium alloys possess less hardness and wear resistance which can be improved by m
ixing suitable reinforcement.
Among various aluminium alloys LM16(Al Si5CulMg0.5) is one of the most po
pular aluminium alloy used for water-cooled cylinder heads, valve bodies, water
jackets, cylinder blocks, fire hose couplings, air compressor pistons, fuel pump
bodies, aircraft supercharger covers and similar applications where leak-proof
castings having the high strength produced by heat-treatment are required.
3.2.1. Chemical Composition of LM16 Alloy
According to BS 1490; 1988 the chemical composition of LM16 alloy by weight is g
iven below
Copper 1.0 - 1.5
Magnesium
0.4 - 0.6
Silicon 4.5 - 5.5
Iron
0.6 max
Manganese
0.5 max
Nickel 0.25 max
Zinc
0.1 max
Lead
0.1 max
Tin
0.05 max
Titanium
0.2 max
Aluminium
remainder
3.2.2. Mechanical Properties of LM16 Alloy
According to BS 1490; 1988 the mechanical properties of LM16 alloy is as
below
Tensile Stress (N/mm2) 270 - 280
Impact Resistance Izod (Nm)
1.4
Brinell Hardness
100 - 110
Modulus of Elasticity (x103 N/mm2)
71
3.3.
Selection of Reinforcements
Aluminium has very poor wear resistance compared to ferrous alloys. To i
mprove the hardness and wear properties of aluminium alloy, reinforcement must p
ossess relatively high hardness and wear resistance. Ceramics are the materials
which stood in the top and well ahead of ferrous alloys. If a sound composite ca
n be produced with ceramic reinforcement, then the composite may possess superio
r qualities equivalent or even better than some ferrous alloys.
In this regard, the reinforcement should also possess the chemical stabi
lity while mixing with aluminium. Materials having corrosion resistance, self-lu
bricating properties etc. will be an added advantage in this process.
Research has already been started to improve the tribological properties
of aluminium alloy. Different experiments showed that the materials like SiC, g
raphite, granite, garnet etc. improved the hardness and wear properties of alumi
nium alloys (5) (17) (18) (15).
This work is mainly concentrated to develop a hybrid composite reinforce
d with both Silicon Carbide and graphite particulates.
3.3.1. Silicon Carbide (SiC)
Silicon carbide is a compound of silicon and carbon with chemical formul
a SiC. Grains of silicon carbide can be bonded together by sintering to form ver
y hard ceramics that are widely used in applications requiring high endurance, s
uch as car brakes, car clutches and ceramic plates in bulletproof vests. The fir
st use of SiC was as an abrasive. This was followed by electronic applications.
SiC also has a very low coefficient of thermal expansion 4.0 10-6/K.

SiC is used for its hardness in abrasive machining processes such as gri
nding, honing, water-jet cutting and sandblasting. Particles of silicon carbide
are laminated to paper to create sandpapers and the grip tape on skateboards.
3.3.2. Graphite
The mineral graphite is an allotrope of carbon. Unlike diamond (another
carbon allotrope), graphite is an electrical conductor, a semimetal. It is, cons
equently, useful in such applications as arc lamp electrodes. Graphite is the mo
st stable form of carbon under standard conditions. Therefore, it is used in the
rmochemistry as the standard state for defining the heat of formation of carbon
compounds. Graphite may be considered the highest grade of coal, just above anth
racite and alternatively called meta-anthracite, although it is not normally use
d as fuel because it is difficult to ignite.
Graphite and graphite powder are valued in industrial applications for t
heir self-lubricating and dry lubricating properties. And hence, graphite may su
pport SiC hardness by providing a layer self-lubrication between contact surface
s resulting in increase of wear resistance.
3.4.
Selection of Process
There are many advanced processes for producing metal matrix composites
with discontinuous particulate reinforcement. Among all the processes, stir cast
ing route by producing vortex in the crucible by means of mechanical stirring is
the most suitable and cost effective method for producing larger components wit
h homogeneous mixture of metal-ceramic particulates (10), (16).
Most of the automobile components were produced by means of liquid metal
lurgy technique. This type of process is simple and cost effective technique of
producing components. Stir casting is also one of the liquid metallurgy techniqu
es for producing metal matrix composite.
3.5.
Selection of Optimal Composition
It is obvious that the properties of the final composite depend on the o
ptimal composition of the SiC and Graphite. According to various studies conduct
ed on Al-Gr MMC s, better properties were obtained up to 4% of Graphite in the Al
matrix and the grain size of Graphite particulates varies from 40 to 150 microns
based on process parameters.
It was observed that the conducted studies yields better properties of c
omposite were obtained on 15% w/w Sic in Al matrix. In this regard, SiC ranging
from 10% to 15% w/w will be sufficient for the present work. By comparing with s
imilar ceramic particulates like SiC, Granite and alumina in various research wo
rks, the grain size of SiC particulates ranging from 50m to 150m may give better r
esults.
Since a hybrid composite is going to be prepared, composition of reinfor
cements for obtaining better composite may differ from the results obtained from
studies done with a single reinforcement. The resulting composite may show comb
ined results of SiC and graphite. By studying Al-Graphite composites, it was obs
erved that the graphite can be limited to 4% w/w and the SiC can be varied from
10% to 15% w/w with a step of 5%.
4.
EXPERIMENTALWORK
Construction of Stir Casting Furnace
For the present work, it requires a stir casting furnace with 4 blade stainless
steel stirrer. Since stir casting is not a conventional casting method, a suitab
le furnace has to be designed. Even though some stir casting furnaces are readil
y available in the market, a custom made conventional stir casting furnace is mu
ch cheaper and is best suited for the present work to vary process parameters ac
cording to the requirements.
A conventional stir casting furnace consists of the following basic components.
a.
Furnace
b.
Crucible
c.
Stirring Equipment
4.1.1. Preparation of Furnace
A furnace is prepared by using a cylindrical thick sheet metal drum. The

inner wall of furnace is lined with refractory ceramic material to prevent heat
losses and is sealed with glass wool material which is prepared form glass.
Fig. 4.5. Furnace
Total furnace was made with kanthaal wire. It is applicable to produce heat up t
o 13500C. It is protected by 15mm thickness of ceramic material integrated with
10% of iron.
Preparation of furnace body
A furnace body is prepared by using different types of mat
erials and sizes depend up on the requirement. Actual furnaces bodies are heavy
weight and thick. In all types of furnaces body is the main thing, it hold s the t
otal set up except temperature controller. So it is very expensive and cost also
. In this process preparation of body is low weight and low cost and expensive.
It can withstands the high temperature depends on giving temperature. This type
of furnaces are easily to maintain, controllable and moving one place to another
place is very easily, because it is low weight and convenient to moving. the sp
ecifications of the furnace body is discussed below.
Figure 4.1 Preparation of furnace body
Temperature controller
A temperature controller is used to control the temperature of the furnace by th
e help of heat sensor.
Figure 4.2 Temperature controller
Temperature controllers are needed in any situation requiring a given temperatur
e be kept stable. This can be in a situation where an object is required to be h
eated, cooled or both and to remain at the target temperature , regardless of th
e changing environment around it. There are two fundamental types of temperature
control; open loop and closed loop control. Open loop is the most basic form an
d applies continuous heating/cooling with no regard for the actual temperature o
utput. Closed loop control is far more sophisticated than open loop. In a closed
loop application, the output temperature is constantly measured and adjusted to
maintain a constant output at the desired temperature. Closed loop control is a
lways conscious of the output signal and will feed this back into the control pr
ocess.
4.1.2. Preparation of Stirrer
A 1200 rpm high torque reversible motor is taken and connected with a po
tentiometer for varying speeds as per the requirement. The motor shaft is couple
d to a stainless steel rod and the other end is connected to a graphite three-bl
ade impeller and is tested by stirring water in the crucible and grinded to the
desired angle for producing vortex.
Figure 4.3 Stirrer Setup
Assembly of stir casting
Stir Casting is a liquid state method of composite materials fabrication
, in which a discontinuous reinforcement is mixed with a molten matrix metal by
means of mechanical stirring. The layout of conventional Stir Casting.
Figure 4.4 Stir Casting Process
At first, the matrix metal is melted in the crucible and then metal trea
tment (like degassing, fluxing, etc.) is carried out without stirring. Later, st
irrer is inserted into the crucible and allowed to rotate the molten metal. Vort
ex is formed in the crucible due to the rotation of stirrer. Required quantity o
f reinforcement is preheated in a separate chamber and is gradually added to the
vortex for uniform mixing of reinforcement in to the matrix.
After the addition of reinforcement stirrer is removed from the crucible
and the liquid composite material is then cast by conventional casting methods
and may also be processed by conventional Metal forming technologies.
4.2.
Consumables and Miscellaneous Materials

A 15 litre silicon carbide crucible is bought for this purpose and is pr

eheated to red hot condition (6500C) to relieve from internal stress. A stand is
prepared for mounting of stirrer assembly above the furnace. To avoid vibration
s in the stirrer, motor is mounted on springs which damp the vibrations. A ceram
ic cap is used to prevent motor from exposing to direct heat from the furnace. T
he stand is made as such that some small adjustments can be made to centre the s
tirrer to the crucible.
4.3.
Procurement of Raw Materials
As the project is carried at SIBAR Auto Parts Limited, Aluminium alloy i
s provided from the company s inventory which was used for the production of engin
e cylinder heads. SiC and Graphite is purchased from a chemical shop in Chennai
and is also sieved for desired particle size.
4.4.
Sample Preparation
A standard test bar die (Permanent mould) is barrowed from Sibar Auto Pa
rts Ltd. which will produce 27 mm diameter cylindrical rod with large riser on i
t to avoid shrinkage. It was tested that the test bar casting consumes 1 kg of m
olten metal.
Metal is melted in a separate furnace and is transferred to the stir cas
ting furnace using a standard ladle which will carry 1.5 kg of molten aluminium.
The metal is maintained at 700oC temperature in the stir casting furnace. A sam
ple is taken with no reinforcements directly before transferring to the stir cas
ting furnace.
At first molten aluminium of weight 4 kg is taken in to the stir casting
furnace. Graphite and SiC of 4% and 10% by weight is measured separately and si
multaneously preheated in separate containers on the furnace itself. When the te
mperatures in the furnace were settled nearly above 700oC metal treatment is car
ried out by adding coverall to the molten metal which removes oxides and other i
mpurities in the metal. Later, stirrer is inserted and allowed to rotate and cre
ate vortex in the crucible. The speed of the stirrer is controlled using potenti
ometer to get desired vortex. After the desired speed is maintained in the cruci
ble reinforcements were added slowly to the vortex and after completely adding t
he reinforcements the stirrer is further allowed to rotate for ten more minutes
for uniform distribution of particulates.
After stirring, molten metal from the crucible is poured into the die ca
vity using ladle and allowed to cure for about two minutes and removed from the
die. The remaining metal in the crucible is also used for taking the test sample
s. Same procedure is followed for producing samples of 4 % graphite and 15% SiC.
All the samples were grouped and marked based on the composition of reinforceme
nts and is sent to heat treatment process.
Figure 4.5 Test Sample With Riser
All the samples were fully heat treated which includes solution heat tre
atment for 12 hours at 520-530oC and quenched in hot water followed by precipita
tion treatment of 8 hours at 170oC.
4.5.
Experimental Procedure
After heat treatment of samples the following operations were performed.
1.
Specimens were analysed for variation in density as per Archimedes princ
iple.
2.
Specimens were freed from risers and turned to required dimensions on a
lathe machine. Riser portions were shaped to rectangular sections and polished.
3.
Hardness test was conducted on the riser sections.
4.
Tensile test was conducted on turned samples with the help of Universal
testing machine. And average values of each composition were noted.
5.

RESULTS AND DISCUSSIONS

After heat treatment of all samples, each sample was separately tested f
or the density, hardness and tensile strength and the average values were analys
ed by comparing with the zero sample. The results in various tests were discusse
d below.
For convenience of presentation and plotting, from here onwards pure LM-

16 alloy samples were referred as Group 0, LM-16 with 4% Graphite and 10% SiC sa
mples were referred as Group 1and LM-16 with 4% Graphite and 15% SiC samples wer
e referred as Group 2.
5.1.
Density
Density of each sample was measured based on Archimedes principle in a c
alibrated glass jar. In Figure 5.1, it can be noticed that the density of compos
ite is increased because of the increase of SiC composition.
Figure 5.1 Comparison of Density
5.2.
Hardness
Since the SiC is superior to aluminium and graphite in case of hardness,
in general it can be expected that the dominance of SiC in increase of hardness
of the composite. The practical observations revealed that the hardness of the
composite increased considerably. It was noticed that the increase of hardness f
rom Group 0 to Group 1 is form 108 BHN to 142 BHN has a difference of 34 BHN and
the increase form Group 1 to Group 2 is from 142 BHN to 154 BHN has a differenc
e of only 12 BHN (see Figure 5.2). This can be considered that the incorporation
of SiC in the aluminium gives hardness to the composite but the further increas
e of SiC has given a little increase in hardness due to the domination of alumin
ium alloy over the composite since the composition of SiC is only 10% of weight.
Further addition of graphite may give a considerable increase in hardness at so
me point but may affect interfacial strength and uniform distribution of reinfor
cement and also the other mechanical properties like density, tensile strength.
Figure 5.2 Comparison of Hardness
5.3.
Tensile Strength
As it was the maximum stress that a material can withstand while being s
tretched, interfacial bonds may affect greatly on the tensile strength of the co
mposite. In Figure 5.3, we can see that the tensile strength was increased in th
e composites but doesn t have comparable variation. Weak interfacial bonds may res
ult in decrease in tensile strength of the composite, but here the increase of t
ensile strength shows that there was good interfacial strength. Since the reinfo
rcements were preheated before mixing with aluminium there might be uniform dist
ribution and smooth interface while mixing. From this result we can expect good
interfacial strength when we heat the reinforcements at higher temperatures whic
h will facilitate uniform distribution of more amount of composite without losin
g the strength.
Figure 5.3 Comparison of Tensile Strength
5.4.
Modulus of Elasticity
Modulus of elasticity shows linear relation with tensile strength as sam
e as conventional materials. In Figure 5.4 we can observe that the modulus of el
asticity was increased but not greatly as same as tensile strength. The elongati
on of material is similar to the base alloy, almost negligible amount of elongat
ion for all the groups. Since all the samples are fully heat treated, the sample
s will gain brittleness and hardness losing ductility which might be resulted in
tendency of brittle failure.
Figure 5.4 Comparison of Modulus of Elasticity
Even though no particular wear tests were performed on the samples, whil
e removing the risers on a band saw cutting machine some resistance was observed
on both the composite samples.
5.5.
Analysis of Composites using ANSYS 13.0
A pre modelled petrol engine cylinder is taken and is imported to ANSYS
WORKBENCH. The model is meshed using a tetrahedral element and is subjected to b
oundary conditions i.e. forces, contacts, supports etc. The obtained results are
imported to the material library and are applied to the model for obtaining the
results. Since the design of the cylinder is not changed, for the given gas pre
ssure the stress developed in the cylinder will be same for all the compositions
, only strain and deformation will change as per the material.

Figure 5.5 3-Dimensional Petrol Engine Cylinder Model

Figure 5.6 Boundary Conditions and Constraints Defined to Model

Figure 5.7 Cylinder Model After Mesh Generation
Figure 5.8 Variation of Total Deformation for Group 0 (Pure Alloy)
Figure 5.9 Variation of Strain for Group 0 (Pure Alloy)
Figure 5.10 Variation of Total Deformation for Group 1
Figure 5.11 Variation of Strain for Group 1
Figure 5.12 Variation of Total Deformation for Group 2
Figure 5.13 Variation of Strain for Group 2
5.5.1. Comparison of Total Deformation
It can be clearly observed in Figure 5.14 that for the given gas pressur
e the maximum total deformation of the cylinder model gets decreasing with incre
ase of SiC in the composite. But the decrease of total deformation is not varyin
g linearly. The slope of the curve from Group 0 to Group 1 is steeper than the c
urve from Group 1 to Group 2.
Figure 5.14 Comparison of Total Deformation
5.5.2. Comparison of Strain
As the deformation is proportional to the strain, the maximum strain dev
eloped in the model seems similar to the comparison of total deformation.
Figure 5.15 Comparison of Strain
6.
6.1.

CLOSURE
Conclusion
From the experimental and analysis of present work the following conclus
ions are drawn.
1.
Addition of SiC will increase the mechanical properties of the composite
.
2.
By comparing with amount of SiC in the composite LM-16 with 4% graphite
and 15% SiC is most suitable for regular casting process.
3.
Hardness of the composite increased by 31.4% for 10% SiC and 42.5% for 1
5% SiC.
4.
It was noticed that the density of the composite is increasing with the
increase of silicon carbide.
5.
From the analysis the total deformation has been decreased by 6.9% for 1
0% SiC and 9.2% for 15% SiC. So, it can be concluded that this composite materia
l in engine cylinders can be used for higher capacities than that of which they
are now using.
6.2.
Scope of Future Work
1.
Wear analysis can be done on the same composition to find the wear prope
rties and lubrication effect of graphite in the composite.

2.
Since SiC has very low thermal expansion and an insulator, thermal prope
rties of the composite can be studied for using at higher temperatures.
3.
Microstructure analysis can be performed to study the interfacial streng
ths and uniform distribution of particulates.
4.
More composites with higher SiC and graphite percentage can be prepared
by employing some modifiers and changing process parameters which might result i
n better properties.
5.
Other self-lubricants like boron nitride can be used in place of graphit
e which will further increase wear resistance and hardness.