SYNTHESIS AND CHARACTERISATION OF Al-SiC COMPOSITES
A PROJECT REPORT
Submitted by
1. V.ESAKKI (96907114017)2. N.PRABU
(96907114040)3. S.VASANTHA KUMAR(96907114057)4. P.VISHNU
SANKAR
(96907114060)in partial fulfillment for the award of the
degree
of
BACHELOR OF ENGINEERING
INMECHANICAL ENGINEERING
SCAD COLLEGE OF ENGINEERING & TECHNOLOGY
CHERANMAHADEVI-627414
ANNA UNIVERSITY OF TECHNOLOGY
TIRUNELVELI 627007MARCH-2011
ANNAUNIVERSITY: TIRUNELVELI-627007
BONAFIDE CERTIFICATE
Certified that this project report SYNTHESIS AND
CHARACTERISATION OF Al-SiC COMPOSITES is the bonafide work of
S.VASANTHA KUMAR (96907114057), N.PRABU (96907114040), V.ESAKKI
(96907114017), P.VISHNU SANKAR (96907114060) who carried out the
project work under my supervision.SIGNATURE SIGNATURE
Prof. T. LOURDU XAVIER CLAUVER Mr.S.VENKATA SUBRAMANIAN
HEAD OF THE DEPARTMENT,SUPERVISOR,Mechanical Engineering,
Lecturer,
Mechanical Engineering,SCAD College of Engineering SCAD College
of Engineering
& Technology, & Technology,
Cheranmahadevi-627414. Cheranmahadevi-627414.
Submitted for PROJECT WORK - ME 1452 Examination held at SCAD
College of Engineering & Technology, Cheranmahadevi for ANNA
UNIVERSITY OF TECHNOLGY TIRUNELVELI held on 29.03.2011
Internal Examiner
External Examiner ACKNOWLEDGEMENT We do feel highly dated in
manifesting a sense of gratitude to our beloved principal
Dr.N.MOHAMMED SHERIFF, Ph.D., We express our gratitude to our Head
of the department Prof.T.LOURDU XAVIER CLAUVER, M.E., for his
encouragement and Valuable supports to bring out our project in
spectacular way. We are grateful to our project guide
Mr.S.VENKATASUBRAMANIAN, M.E., for his encouragement guidance,
suggestions and proper directions which enable us to pursue our
project work with great enthusiasm.
We also extend our sincere thanks to our beloved parents for
provided us all the facilities through the department of Mechanical
Engineering.
We express our special word of thanks to all faculty members of
Mechanical Engineering and our Department lab technicians who have
given the support to us and encouragement in bringing out project
work in a fine way.
ABSTRACTComposites are emerging as realistic alternatives to the
metal alloys in many applications like automobiles, marine,
aerospace applications, sports goods etc,. In this project work we
are mainly concentrating on the metal matrix composites which are
widely used in the field of engineering. The aluminum metal is
taken as a metal matrix and the silicon carbide in taken as
reinforcement in this project. These composites exhibit high
hardness and stiffness and superior resistance to wear resistance
properties. In this project, metal matrix composite (MMC) was
produced by using the stir casting technique. By this process a
more uniform distribution of silicon carbide particulates can be
achieved. Hardness, wear and the density of composites were
measured to study the characteristic behavior of the composite. The
hardness test is conducted by using the Brinell hardness testing
machine, the wear of the component is measured by using the pin on
disk apparatus and the density of composite is measured by using
the Archimedess principle and the scanning electron microscopic
study is made to know the distribution of the reinforcement
material.Keywords: Al-based MMC, SiC particulates, SEM scanning
electron microscope, microstructure, Abrasive Wear, Hardness.TABLE
OF CONTENTSCHAPTER NO.
TITLE
PAGE NO.
ABSTRACT
ivTABLE OF CONTENTS
vLIST OF FIGURES
viiLIST OF TABLES
ix1.
INTRODUCTION
11.1. Composite material
11.2. Comparison of the Composite
Materials with other materials.
21.3. Phases of composites
21.3.1. Matrix phase
21.3.2. Reinforcement phase
21.4. Classification of composite
21.4.1. Based on matrix material
31.4.2. Based on reinforcement Material
71.5. Aluminum matrix composite
81.6. Silicon carbide
112.
LITERATURE REVIEW
2.1 Introduction
15
2.2 Summary
173. FABRICATIONS OF AMCS
3.1 Fabrications of AMCs
18
3.1.1 Solid state fabrication
18
3.1.2 Deposition method
20TABLE OF CONTENTSCHAPTER NO.
TITLE
PAGE NO.
3.1.3 Liquid state fabrication method
223.1.3.1 Infiltration method
22
3.1.3.2 Stir casting method
264.
TESTING AND RESULT ANALYSIS
35
4.1 Introduction
35
4.2 Hardness test
35
4.2.1 Theory
36
4.2.2 Calculation
38
4.2.3 Result
38
4.3 Density measurement
39
4.3.1 Principle
39
4.3.2 Calculation
39
4.3.3 Result
40
4.4 Wear test
40
4.4.1 Technical specification data
40
4.4.2 Testing procedure
42
4.4.3 Calculation of sliding time
43
4.4.4 Observations
434.5.5 Result
44
4.5 Scanning electron microscope study
46
4.6 Discussion on results
495.
RESULTS & CONCLUSION
50
5.1 Conclusion
50
5.2 References
51LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.1.1.
Composite material representation 11.2.
Comparison of the composites with
Other materials
21.3.
Elements of Aluminum 6061 alloy
101.4.
Aluminum 6061 alloy 121.5.
Silicon carbide particles 13
1.6.
Relationship between the density and strength
143.1.
Diffusion bonding process 203.2.
Sintering process 203.3.
Gas pressure Infiltration process 243.4.
Squeeze casting Infiltration 253.5.
Pressure Die Infiltration 263.6.
Stir casting apparatus 273.7.
Cross section of electrical resistance furnace. 293.8.
Muffle furnace 293.9.
Arranging with stirrer 30
3.10.
Pyrometer Assembly
31
3.11.
Arrangement of apparatus
32
3.12.
Serving the silicon carbide to the Aluminum 343.13.
Melted Aluminum
34
3.14.
Finished components 35LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.4.1.
Pin-on-disc Apparatus
41
4.2.
Load Vs Frictional Force
444.3.
Load Vs Co-Efficient of Friction
44 4.4. Load Vs Wear
45
4.5.
Load Vs Wear (Comparision of Coefficient of
Friction between aluminum and Al &SiC Composites)45LIST OF
TABLETABLE NO.
TITLE
PAGE NO.1.1 Composition of aluminum 6061 alloy
10
1.2 Properties of silicon carbide particles
124.1 Reference table for hardness measurement
36
4.2 Tabulation of hardness measurement
37
4.3 Result comparison of hardness
38
4.4 Result comparison of density measurement
40
4.5 Tabulation for the wear test
43
4.6 Comparison of the properties
49viii
