EFFECT OF WEIGHT OF REINFORCEMENT AND COATING THICKNESS ON THE HARDNESS OF STIR CAST AL7075-NICKEL COATED DURALUMIN POWDER MMC

  • Karthik B M Department of Mechanical and Manufacturing Engineering, Manipal Institute of Technology, Manipal Academy of Higher Education, Manipal-576104, Karnataka, India
  • Sathyashankara Sharma Department of Mechanical and Manufacturing Engineering, Manipal Institute of Technology, Manipal Academy of Higher Education, Manipal-576104, Karnataka, India
  • Gowrishankar M C Department of Mechanical and Manufacturing Engineering, Manipal Institute of Technology, Manipal Academy of Higher Education, Manipal-576104, Karnataka, India
  • Ananda Hegde Department of Mechanical and Manufacturing Engineering, Manipal Institute of Technology, Manipal Academy of Higher Education, Manipal-576104, Karnataka, India
  • Doddapaneni Srinivas Department of Mechanical and Manufacturing Engineering, Manipal Institute of Technology, Manipal Academy of Higher Education, Manipal-576104, Karnataka, India
DOI: https://doi.org/10.5937/jaes0-34780
Keywords: stir cast, coating, composites

Abstract


In the present work, it is experimented to reinforce duralumin powder (3 to 7 wt %.) into Al7075 matrix by stir casting technique. Since matrix and reinforcement both have almost similar melting temperatures, the least expensive additive manufacturing metallurgical route seems to be the best fit. In this study, an effort was made to produce the Al7075 matrix composite reinforced with duralumin by a novel stir casting method by coating duralumin powders with nickel which has high temperature melting point compared to reinforcement material.. Nickel has good wettability and avoids undesirable chemical reactions between the reinforcement and matrix at higher temperatures, acting as a protector for both the duralumin and matrix. Since, aging kinetics of duralumin (Al2024) and Al7075 are different, both positively respond to heat treatment in a single stretch for property alteration. During stir casting, even though duralumin melts along with the matrix, it will be under the solid protection barrier (coat) of nickel, avoiding dissolution with the Al7075 matrix. To verify the presence of reinforcement duralumin in the matrix and to decide the soundness of the casting produced by stir casting, confirmation tests are made like microstructures with EDS and microhardness distribution. The microstructure analysis of the composite showed an even distribution of nickel coated duralumin in the matrix when the coating thickness of a nickel is greater than 8 µm. The hardness test analysis has shown an improvement in the hardness with the increase in the weight % of the reinforcement. Improvement in the hardness of composites is due to an increase in dislocation number, which shows higher resistance to plastic deformation [2]. Statistical analysis has shown that the coating of reinforcement does not have any significant effect on the mechanical properties. The regression equation is fit to determine the hardness of the composite involving the factors within the range of values considered for this study.

References

Kumar, G. B. V., Rao, C. S. P., Selvaraj, N., Bhagyashekar, M. S. (2010). Studies on Al6061-SiC and Al7075-Al2O3 metal matrix composites. Journal of Minerals and Materials Characterization and Engineering, vol. 09, no. 01, 43–55, DOI: 10.4236/jmmce.2010.91004

Ramesh, C. S., Safiulla, M. (2007). Wear behavior of hot extruded Al6061 based composites. Wear, vol. 263, no. 1-6, 629–635, DOI: 10.1016/j.wear.2007.01.088

Babajanzade Roshan, S., Behboodi Jooibari, M., Teimouri, R., Asgharzadeh-Ahmadi, G., Falahati-Naghibi, M., Sohrabpoor, H. (2013). Optimization of friction stir welding process of AA7075 aluminum alloy to achieve desirable mechanical properties using ANFIS models and simulated annealing algorithm. Journal of Minerals and Materials Characterization and Engineering, vol. 69, no. 5–8, 1803–1818, DOI:10.1007/s00170-013-5131-6

Khedekar, D., Gogte, C. L. (2018). Development of the cryogenic processing cycle for age hardenable AA7075 aluminium alloy and optimization of the process for surface quality using gray relational analysis. Materials Today: Proceedings, vol. 5, no. 2, 4995–5003, DOI: 10.1016/j.matpr.2017.12.077

Sameezadeh, M., Emamy, M., Farhangi, H. (2011). Effects of particulate reinforcement and heat treatment on the hardness and wear properties of AA 2024-MoSi2 Materials and Design, vol. 32, no. 4, 2157–2164, DOI: 10.1016/j.matdes.2010.11.037

Afzal, N., Shah, T., Ahmad, R. (2013). Microstructural features and mechanical properties of artificially aged AA2024. Strength of Materials, vol. 45, no. 6, pp. 684–692, DOI: 10.1007/s11223-013-9504-8

Emamy, M., Oliayee, M., Tavighi, K. (2015). Microstructures and tensile properties of Al/2024-Al4Sr composite after hot extrusion and T6 heat treatment. Materials Science and Engineering A, vol. 625, 303–310, DOI: 10.1016/j.msea.2014.12.023

Al-Salihi, H. A., Mahmood, A. A., Alalkawi, H. J. (2019). Mechanical and wear behavior of AA7075 aluminum matrix composites reinforced by Al2O3  Nanocomposites, vol. 5, no. 3, pp. 67–73, DOI:10.1080/20550324.2019.1637576

Sambathkumar, M., Navaneethakrishnan, P., Ponappa, K., Sasikumar, S. K. S. (2016). Mechanical and corrosion behavior of Al7075 ( hybrid ) metal matrix composites by two step stir casting process. Latin American Journal of Solids and Structures, vol. 7075, 243–255, DOI:10.1590/1679-78253132

Suryakumari, T. S. A., Ranganathan, S., Shankar, P. (2015). Study on mechanical properties of Al 7075 hybrid metal matrix composites. Applied Mechanics and Materials, vol. 813–814, no. 17, 230–234, DOI:10.4028/www.scientific.net/AMM.813-814.230

Gunasekaran, T., Vijayan, S. N., Prakash, P., Satishkumar, P., (2020). Mechanical properties and characterization of Al7075 aluminum alloy based ZrO2 particle reinforced metal-matrix composites. Materials Today: Proceedings, DOI: 10.1016/j.matpr.2020.11.114

Rebba, B., Ramanaiah, N. (2014). Evaluation of mechanical properties of aluminium alloy (Al-2024) reinforced with molybdenum disulphide (MOS2) metal matrix composites. Procedia Materials Science, vol. 6, 1161–1169, DOI: 10.1016/j.mspro.2014.07.189

Albiter, A., Contreras, A., Bedolla, E., Perez, R. (2003). Structural and chemical characterization of precipitates in Al-2024/TiC composites. Composites Part A: Applied Science and Manufacturing, vol. 34, no. 1, 17–24, DOI: 10.1016/S1359-835X(02)00259-2

Sanchez, M., Rams, J., Urena, A. (2010). Fabrication of aluminium composites reinforced with carbon fibres by a centrifugal infiltration process. Composites Part A: Applied Science and Manufacturing, vol. 41, no. 11, 1605–1611, DOI: 10.1016/j.compositesa.2010.07.014

Sudagar, J., Venkateswarlu, K., Lian, J. (2010). Dry sliding wear properties of a 7075-T6 aluminum alloy coated with Ni-P (h) in different pretreatment conditions. Journal of Materials Engineering and Performance, vol. 19, no. 6, 810–818, DOI: 10.1007/s11665-009-9545-0

Mohandas, A., Radhika, N. (2017). Studies on mechanical behaviour of aluminium/nickel coated silicon carbide reinforced functionally graded composite. Tribology in Industry, vol. 39, no. 2, 145–151, DOI:10.24874/ti.2017.39.02.01

Deepa, J. P., Abhilash, S., Rajan, T. P. D., Pavithran, C., Pai, B. C. (2015). Structure and properties of electroless Cu and Ni-B coated B4C particle dispersed aluminum composites by powder metallurgy technique. Material Science Forum, vol. 830–831, 480–484, DOI: 4028/www.scientific.net/MSF.830-831.480

Pancrecious, J. K., Deepa, J. P., Ramya, R., Rajan, T., Bhoje Gowd, E., Pai, B. C. (2015) Ultrasonic-assisted electroless coating of Ni-B alloy and composites on aluminum alloy substrates. Material Science Forum, vol. 830–831, 687–690, DOI: 10.4028/www.scientific.net/MSF.830-831.687

Pourhosseini, S., Beygi, H., Sajjadi, S. A. (2018). Effect of metal coating of reinforcements on the microstructure and mechanical properties of Al-Al2O3 Materials Science and Technology (United Kingdom), vol. 34, no. 2, 145–152, DOI: 10.1080/02670836.2017.1366708

Boopathi, M., Arulshri, K. P., Iyandurai, N. (2013). Evaluation of mechanical properties of Aluminium alloy 2024 reinforced with silicon carbide and fly ash hybrid metal matrix composites. American Journal of Applied Sciences, vol. 10, no. 3, 219–229, DOI:10.3844/ajassp.2013.219.229

Prasad, N. (2006). Development and characterization of metal matrix composite using red mud an industrial waste for wear resistant applications. Doctoral dissertation.

Lawson, J. (2014). Design and analysis of experiments with R: 115. Chapman and Hall/CRC, United Kingdom.

Rajasekaran, S., Udayashankar, N. K., Nayak, J. (2012). T4 and T6 treatment of 6061 Al-15 vol. % SiCP  International Scholarly Research Notices, vol. 2012, 1–5, DOI: doi.org/10.5402/2012/374719

Kalaiselvan, K., Murugan, N., Parameswaran, S. (2011). Production and characterization of AA6061-B4C stir cast composite. Materials & Design, vol. 32, no. 7, 4004–4009, DOI: 1016/j.matdes.2011.03.018

Auradi, V., Rajesh, G. L., Kori, S. A., (2014). Processing of B4C particulate reinforced 6061aluminum matrix composites by melt stirring involving two-step addition. Procedia Materials Science, vol. 6, 1068–1076, DOI: 10.1016/j.mspro.2014.07.177

Published
2022/05/27
Issue
Vol. 20 No. 3 (2022)
Section
Original Scientific Paper