International Journal of Mechanical Engineering and Technology (IJMET)

Volume 8, Issue 7, July 2017, pp. 703716, Article ID: IJMET_08_07_079

Available online at http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=7
ISSN Print: 0976-6340 and ISSN Online: 0976-6359

IAEME Publication Scopus Indexed

SYNTHESIS OF BERYL REINFORCED

ALUMINIUM METAL MATRIX COMPOSITES
THROUGH VACUUM SINTERING
S.K. Rajendra
Research Scholar, Mechanical Engineering,
Jain University, Bengaluru and
Associate Professor, Department of Industrial Engineering and Management,
Dr. Ambedkar Institute of Technology, Bengaluru, Karnataka, India

C.M. Ramesha
Department of Mechanical Engineering, Ramaiah Institute of Technology,
Bengaluru, Karnataka, India

ABSTRACT
Al- beryl metal matrix composites (MMC) containing beryl (5%, 10%, 15%, 20%
and 30 wt. %) were fabricated using vacuum sintering. Al- beryl powders were selected
as starting materials The beryl as a mineral phase was initially crushed, and
mechanically sieved to various sizes. The final particle sizes in the range of 3010 m
were made. Beryl content in Al was varied from 5 to 30-wt%. The green pellets were
made to 25 mm diameter with a load of 1.02 MPa and sintered in a vacuum furnace
maintained at 600C. The hardness results clearly demonstrated that increasing beryl
from 5 to 15-wt% in vacuum sintering was responsible for increased hardness values.
The microstructural examination clearly demonstrated that vacuum sintering at 600C
has led not only to improved density level but also to improved sliding wear properties.
Key words: Aluminium, Beryl, Metal Matrix Composites, Sintering.
Cite this Article: S.K. Rajendra and C.M. Ramesha, Synthesis of Beryl Reinforced
Aluminium Metal Matrix Composites Through Vacuum Sintering. International
Journal of Mechanical Engineering and Technology, 8(7), 2017, pp. 703716.
http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=7

1. INTRODUCTION
Composite materials are well known for their tailor made properties by combining two or more
properties. The tailorable properties of MMCs suit the needs of extremely good thermal
stability, associated with high strength; ductility and toughness at a higher temperature are
desirable for design application in aero gas turbine engines. Al based MMCs having hard
ceramic materials has improved specific strength, specific modulus, and wear resistance. Many
of these properties help in defence, automobile, marine, and aerospace application. Al based

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 Synthesis of Beryl Reinforced Aluminium Metal Matrix Composites Through Vacuum Sintering

MMCs have been extensively studied. The incorporation of second phase particles [18, 19]
such as Al2O3, SiC, TiN, and TiO2, in Al alloy improves physical, mechanical, and tribological
properties. These ceramic particles have high density and high hardness. In liquid metallurgy
vertex route technique settling of ceramic particles was the limitation especially for hard
ceramic particle. In preparation of Al based MMCs with light ceramic particles, the ceramic
particles are comes out as a slag. Among various ceramic additions to Al, SiC has given much
greater attention by many researchers but the Al-SiC still has limitations such as the formulation
of Al4C3 during high temperatures which impairs the mechanical properties of the Al MMCs.
Thus, efforts are made to overcome the problems by incorporating other reinforcing materials
such as beryl and also synthesis through vacuum sintering [1, 4, 5, 6].
The present investigation is aimed with three specific points. The first one is selection of
ceramic particles such as beryl with a density of ~2.65 g/cc, which is lighter than other ceramic
particles such as SiC, Al2O3, TiN, and has similar density of Al. The beryl has a hardness of ~
1800 Hv. The second aim is to fabricate Al based MMCs using beryl as reinforcing particles
using vacuum sintering of powder metallurgy route. The third aim is to study the hardness, wear
rate, and wear resistance.

2. EXPERIMENTAL PROCEDURE
Commercially available aluminium powder with of 99.7% purity with average particle size of
40 5 m size of Leo Chemicals, Bangalore was selected as starting material. In addition, beryl
that is abundantly available in Karnataka region in the form of rocks was selected. Finally, the
powder was sieve to fine (38 53 m) and coarse (106 150 m). Aluminium is a metallic
element of atomic number 13. Its atomic weight is 26.98 atomic mass unit; its specific gravity
is 2.7 (the ratio between the density of the aluminium and water); the crystal structure of
aluminium is face-centered cubic (FCC); and the atomic radius is 0.1431 nm.
Aluminium is one of the easiest metal to form and has a good combination of high strength
and light weight. Beryl is naturally occurring and chemically having beryllium-alumina-silicate
[Be3Al2(SiO3)6] was used as the reinforcement material, and found following main advantages
in using it as reinforcement: It has high melting point of around 1400C, has low refractive
index of 1.57-1.59, has density almost same as aluminium of around 2.65g/cc, high strength
and high hardness of 1800 Hv.
The composition of beryl does not contain any carbon content which helps in avoiding the
formation of Al4C3 during high temperature synthesis of composites; It is not radio active in
nature. The particle size of the obtained beryl was in the range of 150-200 m, in order to reduce
these particles to the size of 38-53 m, a separate set up was made using a lathe machine, where
a bowl with lid was made and rotated using a lathe machine. The beryl particles which were in
the range of 150-200 m was poured along with the high carbon high chrome steel balls (50Nos)
of diameter 10mm in the portable ball mill with both the sides of the coated steel cylinder with
steel enclosures. A threaded long rod of length 200mm was passed through the center of both
enclosures and tightened it with the help of washers and nuts. This entire setup was fixed in
between the lathe canters and rotated at a speed ranging between 150-400rpm for duration of
2-5 hours. The powders that were obtained after the successful completion of process was
removed and sieved.
Figure 1 shows the photographs of beryl in mineral phase, and fine powder. In figure 2,
SEM images of Commercial Pure Aluminium (CPAl) and beryl are shown.

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 S.K. Rajendra and C.M. Ramesha

Figure 1 Photographs of beryl in (a) mineral phase (b) fine powder form

Figure 2: SEM images of CPAl and beryl

Starting material CPAl and beryl in required quantities were taken and blended together
properly using a pestle and mortar for 30 minutes and again in a ball mill for 30mins using PVA
as binder to ensure uniform distribution of the beryl particles throughout the Aluminium matrix.
The blended samples were then compacted in Universal testing machine at load of 5 ton applied
pressure.
The compacted pellets were taken and heated in a tubular furnace in an inert atmosphere
(99.99% pure argon gas) at temperatures of 600C for a holding time of 2 h to ensure the
densification of the compacted powder samples. The heating rate used was 5C/min and the
holding time for each sample was 1 hour after the heating period. The samples are pushed into
the cooling zone where the drop in part temperature is controlled precisely and cooled to room
temperature. Vickers Micro hardness tester (Model: MVH-I, METATECH Industries, Pune,
India). The tests were carried out on the polished specimens by applying a 50g (0.49N) load for
10s using a diamond indenter. The measurements were carried on the matrix of the alloys. Each
micro hardness value reported in the present work is an average value of five readings to get an
average values. The samples were etched with slandered Kellers reagent and examined under
both optical microscope and SEM (JEOL 840A). A pin-on-disc apparatus, Model: TR 20 LE,
DUCOM, Bangalore, India, was used to perform the wear experiment. The sintered pellet has
a height of 4 mm, has been raised to 40 mm by adhering the samples to steel pin of 6mm
diameter, and 36 mm height. The specimens were allowed to slide against a rotating EN 32
steel disc of hardness 65 Rc, wear rate, and wear resistance were monitored as a function of
sliding distance up to 1200 m at 0.5 and 0.75 kg loads.
Table 1 gives the chemical composition of commercial pure Al. A wet chemical analysis
method is used to analyze the presence of minor alloying elements such as Fe, And Si are 0.17,
and 0.11 respectively.

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 Synthesis of Beryl Reinforced Aluminium Metal Matrix Composites Through Vacuum Sintering

Table 1 Chemical composition (wt. %) of CPAl

Fe Si Al
0.17 0.11 Balance
Table 2 shows the chemical analysis of beryl powder. Chemical analysis of beryl powder
was carried by a inductively coupled plasma emission spectrometer (ICP-OES: Make - Thermo
fisher scientific, Model 6300 Duo).

Table 2 Chemical composition of beryl powder

Test
Test Parameter Unit Test Method
Result
Silica as SiO2 % 57.44
Alumina as Al2O3 % 21.01
Beryl oxide as BeO % 16.82
Iron oxide as Fe2O3 % 1.31
Calcium Oxide as CaO % 1.09 ICP-OES
Magnesium Oxide as MgO % 0.56
Sodium Oxide as Na2O % 0.017
Potassium Oxide as K2O % 1.56
Manganese Oxide as MnO % 0.017
In table 3, the composition of aluminium and wt. % of beryl for three samples A, B and C
for our experimental investigation is shown. the composition gives the various composition
of beryl powder in Al.

Table 3 Compositions of aluminium and wt. % of beryl

Sample Composition of Al Wt. % of Beryl

A 90 10
B 80 20
C 70 30
Figure 3 shows the photograph of a five ton vacuum sintering furnace for pressureless and
pressure sintering.

Figure 3 Photograph of a five ton sintering furnace

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 S.K. Rajendra and C.M. Ramesha

Figure 4 Photographs of (a) sintered green compacts (b) showing diameter and (c) showing height

Figure 5 Photograph of wear test specimen

2.1. XRD ANALYSIS

Figure 6 (a-c) shows the XRD pattern for the experimental alloys A, B, and C. Samples A, B,
and C denote Al-10 wt. % beryl, Al-20 wt. % beryl, Al-30 wt. % beryl, All the samples showed
the presence of beryl peaks along with Al peaks. To understand the influence of beryl content
and its direct influence on peak intensity, all three graphs are merged and shown in figure 6 (d).
The XRD pattern clearly demonstrates that the intensity Al decreased and beryl intensity
increased as the beryl content in Al-beryl is increased from 10 to 30 wt. % beryl.

Figure 6: XRD of vacuum sintered Al- beryl MMCs of (a) Al- 10 wt. % beryl (b) Al- 20 wt. % beryl
(c) Al- 30 wt. % beryl and (d) at varying beryl percentages

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 Synthesis of Beryl Reinforced Aluminium Metal Matrix Composites Through Vacuum Sintering

2.2. MICROSTRUCTURAL STUDIES

Figure 7 (a-c) shows the SEM images of Al-beryl MMCs having a particle size of 50 m, and
with 10- 30 wt. % beryl, vacuum sintered at 600oC. The optical images show that there is a
uniform distribution of beryl particles, and all the beryl particles are of regular size. Figure 8
shows optical images of Al- beryl composites with different magnification. The distribution of
beryl particles are uniform in aluminium matrix, and high magnified optical image taken at
X500 shown in figure 8 (b) shows a clear interface between the beryl particle and Al matrix.

Figure 7: SEM images of (a) Al 10 wt. % beryl (b) Al-20 wt. % beryl and (c) Al-30 wt. % beryl
composites containing average beryl particle size of 50 m, vacuum sintered at 600oC

Figure 8 Optical images of Al beryl composite at different magnifications

2.3. HARDNESS STUDIES

Load used on Vickers hardness tester was around 0.5kgs for micro hardness with a dwell time
of 30 seconds for each sample. The hardness is tested at 3 different locations on the specimen
and the average of 3 readings was taken for single specimen. The result of Vickers hardness
test for pure aluminium without reinforcement and the wt. % variation of beryl reinforcement
are as shown in the Table 4.

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 S.K. Rajendra and C.M. Ramesha

Table 4 Vickers hardness results

Sample Sample Particle Vickers Hardness(10 kgf) Mean
No Name Size Hv 1 Hv 2 Hv 3 Hardness
1 Pure 53-75m 28.32 24.56 27.84 26.90
Aluminium
2 5% Coarse 106-150m 28.26 30.47 32.20 30.37
3 10% Coarse 106-150m 30.47 35.77 41.30 35.80
4 15% Coarse 106-150m 33.86 40.10 43.89 39.28
5 5% Fine 38-53m 35.77 40.10 41.30 39.05
6 10% Fine 38-53m 45.27 49.83 48.24 47.77
7 15% Fine 38-53m 54.25 56.87 59.32 56.81

Figure 9 Comparison of hardness for pure aluminium at different wt. % of coarse Al-beryl MMCs

Figure10 Comparison of hardness for pure aluminium at different wt. % of fine Al-beryl MMCs

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 Synthesis of Beryl Reinforced Aluminium Metal Matrix Composites Through Vacuum Sintering

Figure 11 Effect of compaction pressure on Hardness

Table 4 shows the hardness values of pure Al, Al- 5 wt. % coarse beryl, Al- 10 wt. % coarse
beryl and Al- 15 wt. % coarse beryl MMCs, which are 26.90 Hv, 30.37, 35.80, and 39.28 Hv
respectively. It also shows the hardness value of Al- 5 wt. % fine beryl, Al- 10 wt. % fine beryl
and Al- 15 wt. % fine beryl MMCs, which are respectively 39.05 Hv, 47.77 Hv and 56.81 Hv.
It can be observed from figure 9 and figure 10 that hardness of the composite material
increases with increase in weight percentage of beryl compared to pure aluminium. This
increase is maybe due to beryl being ceramic which is harder compared to matrix material and
hence beryl acts as load barrier and resists the deformation caused by indentation. Figure 11
shows that the compaction pressure also plays a major role in increasing the hardness.

2.4. WEAR RESULTS

Wear test was carried out using a pin on disc tribometer according to ASTM G99 standard. The
wear track and specimens were cleaned thoroughly with acetone prior to test. The disc used
was a hardened EN 31steel disc. The hardness range was 60 HRc. The pin dimension used was
8 mm diameter and 24 mm height. Each specimen was then weighed using a digital balance
having an accuracy of ~ 0.0001 g. After the specimen was mounted on the pin holder, the
tribometer was readied for wear test. For all the experiments, the rpm was kept constant to 500
and velocity at 2.22 m/s with track diameter of 84mm. The loads used were 0.5 kg and 0.75 kg.
The sliding distances used were 400 m, 800 m and 1200 m.
Experimental results for the wear rate and wear resistance for two load categories 0.5 kg
and 0.75 kg are specified in table 5 and table 6 respectively.

Table 5 Wear rate and wear resistance for 0.5 kg load

Wear Rate in Wear resistance in m
Load (103 m/g)
R.P.M Sample (g/m)
(Kg)
400 m 800 m 1200 m 400 m 800m 1200 m
0.5 500 Pure Al 11.5 8.75 5.583 86.95 93.14 179.115
Al -5%
0.5 500 4.25 1.5 0.583 235.29 666.667 1715.265
beryl
Al-10%
0.5 500 3.75 0.87 0.75 266.66 1149.42 2403.846
beryl
Al-15%
0.5 500 3.5 0.75 0.166 285.71 1333.33 6024.096
beryl

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 S.K. Rajendra and C.M. Ramesha

Table 6 Wear rate and wear resistance for 0.75 kg load

Wear Rate in Wear resistance in m (103
Load (g/m) m/g)
R.P.M Sample
(Kg)
400 m 800 m 1200 m 400 m 800m 1200 m
0.75 500 Pure Al 11.25 4.5 1.75 88.88 222.22 571.42
Al -5%
0.75 500 4.5 2 1.083 222.22 500 923.36
beryl
Al-10%
0.75 500 3.5 1.625 .75 285.71 615.38 1333.33
beryl
Al-15%
0.75 500 2.75 1.375 .33 363.63 727.2 3030.30
beryl

Figure 12 Wear rate vs sliding distance for 0.5 kg load

Beryl addition decreases the sensitivity towards the sliding distance during wear. It has been
observed (figure 12) that with increasing sliding distance the wear rate decreases linearly for
pure aluminium. However, for Al-beryl composites, the wear rate follows an exponentially
decreasing nature and the sensitivity or rate of decrease has been found to change when the
sliding distance has been changed from 800m to 1200m. The maximum decrease has been seen
for Al-10 wt. % beryl, while increasing the amount of beryl does not effect this sliding distance
dependency on wear rate here.

Figure 13 Wear resistance vs sliding distance for 0.75 kg load

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 Synthesis of Beryl Reinforced Aluminium Metal Matrix Composites Through Vacuum Sintering

The wear resistance has also been calculated and it has been seen to be a function of sliding
distance too. The sensitivity is very low for the pure Al but for the Al-15 wt. % beryl the direct
evidence is that the wear resistance increases drastically. The optimum spatial distribution of
the reinforcement within the matrix actually plays the role to increase the resistance towards
wear. However, this also gives an indication that the machinability of those composites also
have been investigated for further applications.

Figure 12 Wear rate vs sliding distance for 0.75 kg load

Figure 13 Wear resistance vs sliding distance for 0.75 kg load

For a higher load of 0.75 kg and sliding distance 400m, it can be observed that the beryl
volume fraction effect gets prominent with increasing load, the critical volume fraction and the
exponentially decreasing nature of worn weight loss disappeared and a distinct and sharp drop
is there from pure Al to Al-5 wt. % beryl addition and then the loss becomes more or less
gradual with increasing beryl content.
For 800m sliding distance for the same load, the beryl volume fraction effect gets prominent
with increasing load like 400m case but the wear loss value decreases from 0.0011 to 0.0004

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 S.K. Rajendra and C.M. Ramesha

when it comes to the wear resistance testing of Al-15 wt. % beryl, the critical volume fraction
and the exponentially decreasing nature of worn weight loss disappears, but, for Al-beryl
composites not much of wear loss difference in intermediate compositions i.e. 5 wt. % and 10
wt. % can be seen and a distinct and sharp drop is there from pure Al to Al-5 wt. % beryl
addition and then the loss becomes more or less gradual with increasing beryl content.
For 1200m sliding distance and 0.75 kg load, it can be observed that the drop from pure Al
to Al-5 wt. % beryl becomes more gradual, the exponential nature of decrease becomes more
linear and the weight loss exhibits linearly decreasing nature with increasing beryl content.
The wear rate and wear resistance curves shown in figure 12 and figure 13 respectively
show a sharp drop for pure Al with sliding distance whereas beryl addition limits the decreasing
trend. Further, beryl addition enhances the ability to resist wear with sliding distance for Al-
beryl composites. For highest beryl addition up to 15 wt. %, shows a continuously increasing
trend of wear resistance with increasing sliding distance.

2.5. WORN OUT SURFACES

Figure 14 SEM images of pure aluminium (a) before wear (b) after wear
Figure 14 shows the SEM images of pure aluminium before wear, and after wear. SEM
images of the worn out surfaces gives an indication of the ductility imperfection with cracking
while the material removal was taking place. The scar marks on the wear ridges gives an idea
of sticking and elasto-plastic contact more than the elastic contact here.
With the addition of beryl particle the wear resistance increases and it naturally depends
upon the adherence of Matrix and particulate matter in order to develop the resistance. The
scouring marks during wear has been studied extensively, it has been seen when there is a low
beryl content i.e. 5%, the wear behavior is more or less like Pure Aluminium, little ductility
involvement is there during the wearing process. The irregular shaped scouring marks present
the evidence of sticking. Wear tracks have shown meandering and discontinuities due to plastic
contact but in most of the cases they maintained the linearity in the orientations (figure 15).

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 Synthesis of Beryl Reinforced Aluminium Metal Matrix Composites Through Vacuum Sintering

Figure 15 SEM images of Al-5% beryl (a) Before wear (b) After wear
The SEM Images of Al-10 wt. % beryl in figure 16 shows that it has a little bit more ductility
than the Al-5 wt. % beryl composites. But the linear wear tracks are apparently prevalent in the
worn out surfaces. The non-linearity in the wear tracks is not evident in the length scale that is
employed to study it. The length scale, if magnified, shows that the edges of the wear tracks got
roughened and some sticking evidence can also be seen in the worn out surface.

Figure 16 SEM Images of Al-10% beryl (a) before wear (b) after wear

Figure 17 SEM images of Al-15% beryl (a) before wear (b) after wear
Figure 17 shows the SEM images of Al-15 wt. % beryl. Al-15 wt. % orientation dependent
roughening has been observed in the worn out surfaces. As it can be seen that there exists two
inclined domains with angularly inclined wear marks, it is not that wear direction got changed
in the midst of the experiment but it is very much possible that there exists a roughening

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 S.K. Rajendra and C.M. Ramesha

phenomenon that cause differential wear in two different crystallographically inclined domains
for Al-15 wt. % beryl which is expected to show the maximum wear resistance depending upon
the beryl percentage.

3. CONCLUSION
In this work, powder metallurgy route is used to successfully fabricate aluminium beryl metal
matrix composites using pressure less sintering method. Al-beryl MMCs sintered at 600C
exhibited good mechanical and tribological properties. Good interfacial bonding between
aluminium matrix and beryl particle can be seen in microstructural studies which clearly
suggests this sintering temperature was optimum. Significant improvement is seen in hardness
and sliding wear properties. Al-beryl MMCs fabricated with fine beryl particles showed
superior hardness values as compared to coarse beryl particles.

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