SYNTHESIS AND CHARACTERISATION

OF Al-SiC COMPOSITES
A PROJECT REPORT
Submitted by

1.
2.
3.
4.

V.ESAKKI
N.PRABU
S.VASANTHA KUMAR
P.VISHNU SANKAR

(96907114017)
(96907114040)
(96907114057)
(96907114060)

in partial fulfillment for the award of the degree

of

BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING

SCAD COLLEGE OF ENGINEERING & TECHNOLOGY

CHERANMAHADEVI-627414

ANNA UNIVERSITY OF TECHNOLOGY

TIRUNELVELI 627007
MARCH-2011

ANNAUNIVERSITY: TIRUNELVELI-627007
i

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,

Mechanical Engineering,

SUPERVISOR,
Lecturer,
Mechanical Engineering,
SCAD College of Engineering
& Technology,
Cheranmahadevi-627414.

SCAD College of Engineering

& Technology,
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

ii

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.

ABSTRACT
iii

Composites 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 CONTENTS
iv

CHAPTER NO.

1.

TITLE

PAGE NO.

ABSTRACT

iv

TABLE OF CONTENTS

LIST OF FIGURES

vii

LIST OF TABLES

ix

INTRODUCTION

1.1. Composite material

1.2. Comparison of the Composite

Materials with other materials.

1.3. Phases of composites

1.3.1. Matrix phase

1.3.2. Reinforcement phase

1.4. Classification of composite

1.4.1. Based on matrix material

2
3

1.4.2. Based on reinforcement

2.

3.

Material

1.5. Aluminum matrix composite

1.6. Silicon carbide

11

LITERATURE REVIEW
2.1 Introduction

15

2.2 Summary

17

FABRICATIONS OF AMCS
3.1 Fabrications of AMCs

18

3.1.1 Solid state fabrication

18

3.1.2 Deposition method

20

TABLE OF CONTENTS
v

CHAPTER NO.

TITLE
3.1.3 Liquid state fabrication method

4.

22

3.1.3.1 Infiltration method

22

3.1.3.2 Stir casting method

26

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

5.

PAGE NO.

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

43

4.5.5 Result

44

4.5 Scanning electron microscope study

46

4.6 Discussion on results

49

RESULTS & CONCLUSION

50

5.1 Conclusion

50

5.2 References

51

vi

LIST OF FIGURES
FIGURE NO.
1.1.
1.2.

TITLE

PAGE NO.

Composite material representation

Comparison of the composites with

Other materials

1.3.
1.4.
1.5.
1.6.
3.1.
3.2.
3.3.
3.4.

Elements of Aluminum 6061 alloy

Aluminum 6061 alloy
Silicon carbide particles
Relationship between the density and strength
Diffusion bonding process
Sintering process
Gas pressure Infiltration process
Squeeze casting Infiltration

10
12
13
14
20
20
24
25

3.5.

Pressure Die Infiltration

26

3.6.

Stir casting apparatus

27

3.7.

Cross section of electrical resistance furnace.

29

3.8.

Muffle furnace

29

3.9.

Arranging with stirrer

30

3.10.

Pyrometer Assembly

31

3.11.

Arrangement of apparatus

32

3.12.

Serving the silicon carbide to the Aluminum

34

3.13.

Melted Aluminum

34

3.14.

Finished components

35

LIST OF FIGURES
vii

FIGURE NO.

TITLE

PAGE NO.

4.1.

Pin-on-disc Apparatus

41

4.2.

Load Vs Frictional Force

44

4.3.

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)

LIST OF TABLE
viii

45

TABLE NO.

TITLE

PAGE NO.

1.1
1.2

Composition of aluminum 6061 alloy

Properties of silicon carbide particles

10
12

4.1

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

49

ix