Material Engineering Department - Faculty of Mechanical

Universiti Teknologi Malaysia

EFFECT OF POURING TEMPERATURE AND STIRRING

SPEED ON MECHANICAL, MICROSTRUCTURE AND
MACHINING PROPERTIES OF AL6061-CU
REINFORCED SiCP METAL MATRIX COMPOSITES

Prepared by :
Haque , S. (2014).
International Journal of Research in Engineering and Technology, 03(22),
pp.104-109.

Summarized by :
Abdillah Sani Bin Mohd Najib
MKMM1903
 Contents

Introduction

Methodology

Result

Discussion

Conclusion

Sustainability and Entrepreneurship

2
 Introduction
Light weight material
AT = aluminum
CVT
MT
Hybrid

*http://www.mlit.go.jp/jidosha/nenpi
*http://www.mlit.go.jp/jidosha/nen Ford-Shelby-GR-1-Concept-Aluminum-RS.jpg
pi

Young modulus / Ultimate tensile

Material Density g/cm3
GPa strength, UTS / MPa
Carbon steels 7.9 190-210 276-1882

Alloy steels 7.9 190-210 758-1882

Aluminum and its
2.6-2.8 70-79 230-570
alloys

Aluminum 1/3 Steel Lack of strength

3
 Introduction
Metal matrix composite (MMC)
Stiffness

Strength
Al SiC
Corrosion Resistance
http://www.popularsteelengg.net/alumini
http://www.wheeloblast.com/abrasive- Wear Resistance
um-metal-products.html#aluminum-
media.html#black-silicon-carbides
grades-6061-2024-5052-7075

Young modulus / Ultimate tensile

Material Density g/cm3
GPa strength, UTS / MPa
Carbon steels 7.9 190-210 276-1882

Alloy steels 7.9 190-210 758-1882

Aluminum and its
2.6-2.8 70-79 230-570
alloys
Silicon Carbide 3.1 410 34-137

4
 Introduction
Condition for effective reinforcement

1) Reinforcement dispersion

2) Strong interfacial bonding Stir Casting

(2) Strong interfacial bonding

CNT
Reinforcement

Mg matrix
(1) Reinforcement dispersion
5
 Introduction
Stir casting

Motor

Adjustable
Screw

Stirrer

Furnace

Crucible
Thermocouple
Molten Metal

6
 Methodology
Pre-heat MIXING Casting
Al Final mixing process, the furnace
temperature was within 800 C and
the composite slurry was poured in
a sand mould designed to get
http://www.ecplaza.net/trade-
leads-seller/aluminium-billets-- standard specimens
7053757.html
http://portuguese.alibaba.com/prod
uct-gs/copper-billet-
232825804.html

450 C Heat above liquidus

40 minutes melt Al-Cu completely
http://www.fwaf.com/custom-
aluminum-sand-castings.html

cooled down just

below the liquidus
1100 C
2 hours preheated SiC particles were
added and mixed manually
composite slurry was reheated
to a fully liquid state and then
automatic mechanical mixing
was carried out for about 10
minutes
7
 Methodology
Manipulative Variables
Pouring
675 700 725 750 775
Temperature
Stir Speed
50 rpm
200 rpm
400 rpm
600 rpm
800 rpm
constant pouring speed 2.5 cm/s

Responsive Variables
1) Hardness Brinnel Hardness Test
2) Impact Strength Izod Impact Test
3) Removing Rate - EDM
8
 Result - Hardness

Highest Hardness 87 BHN

Optimum Stirring Speed 400 rpm
Optimum Pouring Temperature 725
9
 Result - Impact

Highest Impact 61 J
Optimum Stirring Speed 400 rpm
Optimum Pouring Temperature 725
10
 Result - REMOVING Rate

Highest Removing Rate 440 x 10-3 g/min

Optimum Stirring Speed 400 rpm
Optimum Pouring Temperature 725
11
 Al6061+4% Cu and 5%
Result - MICROSTRUCTURE
SiC Composite
Micrograph of
Stir Speed
rpm

200 400 800

Description

Insufficient mixing of
alloy metal and SiC Homogenous mixing Clouting of SiC
ceramic

12
 Discussion - Stirring Speed
OPTIMUM
Homogenous

Best Performance at intermediate

stirring speed because of
Homogenous Dispersion of SiC
throughout the matrix

13
 Discussion - Temperature
Optimum Pouring Temperature = 725
OPTIMUM Freezing Temperature of Al = 660

Grain Size Effect

- Higher pouring temperature
Slower cooling
Larger grain
Less Hard
- Lower pouring temperature
Faster cooling
Smaller grain
Harder

**Not Stated in Paper

MUST CONSIDER !!

DISPERSION EFFECT
INTERFACE BONDING
Lower temperature, less reaction to form good bonding
etc
14
 Conclusion

Reinforcement of SiCp increases the Impact strength ,

Hardness and also material removal rate.

Increase in stirring speed increases the impact strength and

hardness of material up to a certain limit after that these
properties decrease drastically.

The optimal value of hardness and impact strength for

MMC is obtained at stirring speed 400 rpm as better
homogeneity can be obtained

15
 Sustainability
Introduction of light metal MMC as replacement of steel need researches and
studies to improve the properties such as strength of light metal to satisfy the
application requirement of industries

Lighter material need less energy to

be operated, less gas emission
Light metal has better machinability,
less production cost for machining

Less energy to be operated, less

fossil fuel needed
Higher performance of material
could be fabricated to serve
more application 16
 Entrepreneurship
Introduction of light metal MMC as replacement of steel need researches and
studies to improve the properties such as strength of light metal to satisfy the
application requirement of industries

Key players profiled in the report include Materion Corporation, Sandvik AB, GKN PLC, 3M,
Plansee SE, Sumitomo Electric Industries, Ltd., Hitachi Metals, Ltd., CPS Technologies
Corporation, Deutsche Edelstahlwerke GmbH and 3A Composites
17
Marking / grading

18
Thank You
-Q&A

21