Proceedings of National Symposium for Post Graduate Students (NSPGS 2010), 24 25 April, 2010: Vol 4 Civil, Materials &
p; Metallurgy
STUDY OF MECHANICAL PROPERTIES
&MICROSTRUCTURE OF B4Cp REINFORCED ALUMINUM
METAL MATRIX COMPOSITE
TRINATH.K, J.JAYA KUMAR, M.A.JOSEPH, M.JOSE MATHEW
ABSTRACT
Aluminium metal matrix composites
(Al MMCs) are being considered as a group
of new advanced materials . Particulate
reinforced Al composites can be processed
more easily by the liquid state i.e. melt-
stirring process. Melt stir casting is an
attractive processing method since it is
relatively inexpensive and offers wide
selection of materials and processing
conditions. Boron Carbide is one of the
hardest materials known, ranking third
behind diamond.
The main aims of the present work is
fabrication of Al alloy reinforced with the
B4C particles and this particulate composite
by varying particle size 50 micron and 150
micron and volume fraction of particles (0,
5,10 vol %) and study of its microstructure
using optical microscope is envisaged in this
investigation..
Trinath.K, Student,
(trinath.748@gmail.com)
M.A.Joseph, Associate Professor,
(joseph@nitc.ac.in)
M.Josemathew Professor,
J.Jaya kumar, project assistant,
(jk.nitc@gmail.com).
Department of Mechanical Engineering,
National Institute of Technology, Calicut,
India. (josemathew@nitc.ac.in)
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Hardness of specimens are to be determined
using Vickers test. Ultimate tensile strength
is to be obtained by using UTM. Impact
strength is to be determined using Charpy
Impact Testing Machine The effect of
reinforcement on the properties is to be
studing.To see the feasibility to produce Al
B4C composites by using conventional
liquid melt-stirring process open to
atmosphere or in atmosphere condition.
1. INTRODUCTION
There has been a constant need for
materials with high specific strength and
stiffness for various applications in
aerospace, automotive, civil construction
and industrial machinery sectors. This has
led the way for development of metal matrix
composites (MMCs). MMCs are gaining
increasing importance because of their
attractive properties such as high specific
strength, stiffness, better wear resistance and
improved elevated temperature properties
compared to the conventional metals and
alloys. Amongst metal matrix composites,
aluminium matrix composites (AMCs) have
gained wide acceptance in past three
decades. The aluminum matrix can be
reinforced by various types of
reinforcements in the form of particles,
whiskers or fibers. The nature of these
reinforcements is essentially B4C, SIC,
Al2O3 Other reinforcements have also been
used including mainly TiO, MgO or SiO2
,TiC, WC and C.
Among the group of hard ceramic
particles considered for inclusion in
aluminum based MMCs (the material of
interest in this present work), B4C particles
 Proceedings of National Symposium for Post Graduate Students (NSPGS 2010), 24 25 April, 2010: Vol 4 Civil, Materials & Metallurgy
have been found to have an excellent
compatibility with the aluminum matrix .
B4C has hardness just below that of
diamond, excellent thermal stability and
remarkable chemical inertness, is an
attractive strengthening agent for aluminum-
based composites. The motivation in using
B4C is twofold: boron carbide is as hard as
SiC (~2800 KH) and harder than Al2O3
(~2100 KH), and lighter (2.52 g/cm3) than
both reinforcements (3.20 and 3.96 g/cm3
respectively) and even aluminum alloy (2.70
g/cm3). A number of processing routes have
been developed for fabrication of Al based
MMCs. Widespread use of many of these
methods is limited by the high cost
associated with them. Melt stirring or stir
casting technique is a simple and cost
effective fabrication route for the
manufacture of particulate composites.
However, a large number of process
variables must be controlled in melt stirring
technique to get a quality product.
MMCs with discontinuous
reinforcements are usually less expensive to
produce than continuous fibre reinforced
MMCs, although this benefit is normally
offset by their inferior mechanical
properties. Consequently, continuous fibre
reinforced MMCs are generally accepted as
offering the ultimate in terms of mechanical
properties and commercial potential.
In general, the major advantages of
Aluminum Matrix Composites
(AMCs) compared to unreinforced
materials, such as steel and other
common metals, are Increased
specific strength
Increased specific stiffness,
Increased elevated temperature
strength, Improved wear resistance,
Lower density, Improved damping
447
capabilities, Good corrosion
resistance.
In preparing metal matrix composites
by the stir casting method, there are
several factors that need considerable
attention, including
1. The difficulty of achieving a
uniform distribution of the
reinforcement material
2. Wettability between the two main
substances;
3. Porosity in the cast metal matrix
composites; and
4. Chemical reactions between the
reinforcement material and the matrix alloy.
Strong bonds at the interface are required for
good wetting. These bonds may be formed
by mutual dissolution or reaction of the
particulates and matrix metal. The reaction
phenomena are very detrimental to the
composite as they bring about a decrease of
the mechanical properties.
Some studies on the reactivity B4C in
aluminum processed by infiltration and
powder metallurgy techniques reported the
formation of different compounds at
different processing temperature. Good
wettability of B4C in aluminum has been
found in air due to the formation of boron
oxide film around the particles . Literature
related on the microstructure and interface
of AlB4C composites processed by a stir
cast method in air is very scarce. The main
aims of the present work is to see the
feasibility to produce AlB4C composites by
using conventional liquid melt-stirring
process in air.
These composite Al-B4C reinforced
MMC used now in different fields like
automobiles, military weapons and in aero
space fields etc. In automobile field
manufacturing of Engine piston ,Cylinder
liner, Brake drum/disc due to their light
weight, high strength, high specific
 Proceedings of National Symposium for Post Graduate Students (NSPGS 2010), 24 25 April, 2010: Vol 4 Civil, Materials & Metallurgy

modulus, low co-efficient of thermal transmission beams and, stiffeners and

expansion and good wear resistance sporting equipment), because of the high
properties..In aerospace and high stiffness, strength.
performance sectors (production

Table:1 A comparative evaluation of the different techniques used for discontinuous

reinforced MMC fabrication
Method Range of Metal yield Range of Damage to cost
shape size volume reinforcement
fraction

Liquid wide range of very high, Upto 0.3 No damage Least

metallurgy(stir shapes; >90% expensive
casting) larger size;
up to 500 kg
Squeeze limited by low Upto 0.45 Severe damage Moderately
casting preform expensive
shape;
up to 2 cm
height
Powder wide range; high Reinforcement expensive
metallurgy restricted size fracture

2. MATERIALS AND EXPERIMENTAL

PROCEDURE
LM-25 grade aluminum alloy chemical
composition furnace with a stirring assembly (a graphite
Si 6.5-7.5 Max impeller) was used for the dispersion of the
Cu 0.25 Max ceramic particles into liquid aluminum. The
Fe 0.9 Max reinforcement particles preheated at 1700c
Mn 0.2-0.5 Max for 2hrs.
Mg 0.2-0.5 Max The heat-treated particles were then added
Zn 0.2 Max into the melt through the vortex at
Ti 0.1 Max 8200c.Finally the melt was poured into a
Sn 0.1 Max 52mm internal diameter cylindrical graphite
Ni 0.3 Max mould. Various compositions ranging from
Pb 0.1 Max 0-10% of B4C .

By varying the particle size of B4C with

different volume fractions used as
reinforcement in LM-25 aluminum alloy.
The B4C particle size 50 m and 150 m
used in this study. An electrical resistance
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 Proceedings of National Symposium for Post Graduate Students (NSPGS 2010), 24 25 April, 2010: Vol 4 Civil, Materials & Metallurgy

Total stirring time (stirring during and after 3. RESULTS AND DISCUSSION
particle addition) for some composites are
presented in table-2. Fig. 2 displays optical micrographs of LM-
Table-2: 25 aluminum alloy and Al-5% B4C
(150m) and Al-5% B4C(50 m) reinforced
aluminum metal matrix composite.
Composite Volume Stirring Stirring according to literature B4C is very reactive
fraction time during time after to air at elevated temperature, the air trapped
(%) of particle particle with B4C particles reacts with B4C inside
B4C addition addition the melt. This results a lower amount of
(min) (min)
pores and particle distribution and wetting in
Al-B4C is good.actually wetting of ceramic
LM- 0 20 10
25aluminum particles in aluminum controls the quality of
alloy Al MMC castings. The wettability of B4C
Al-B4C(50 5 30 15 with aluminum was found to increase in air.
m) This was attributed to the formation of a
Al-B4C(50 10 40 17 layer of liquid B2O3 on the B4C particulates.
m) Due to its low melting point, B2O3 exists
above 450 C as a liquid on the surface of
Al- 5 30 15
B4C(150m)
B4C and enhances wettability through a
liquidliquid reaction when contacted with
Al-B4C(150 10 41 17 aluminium liquid by forming B2O3Al2O3
m) oxide compound.
The morphology study was conducted under
optical microscope.the study of 0%
B4C,5%&10%of B4C reinforced LM-25
aluminum alloy.

Fig 1: stir casting furnace setup

The microstructure was investigated

by optical microscope and Hardness of
specimens are to be determined using a) 50m B4c in 5% volume fraction
Vickers and Brinell hardness tests. Ultimate
tensile strength is to be obtained by using
UTM. Impact strength is to be determined
using Charpy Impact Testing Machine.

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 Proceedings of National Symposium for Post Graduate Students (NSPGS 2010), 24 25 April, 2010: Vol 4 Civil, Materials & Metallurgy

was increased according to the volume

fraction of B4C.the particle size also varying
according to the volume fraction. The tensile
test was conducted under Universal Testing
Machine.the hardness and toughness
properties also varying as a function of
particle size and volume fraction.
Fig:3 EDX analysis also conducted
for determining the elements present in the
composite.
b) 150m B4c in 5% volume fraction

(c) 50m B4c in 10% volume fraction a

(d) 150m B4c in 10% volume fraction

b
Fig 2:scanning electron microscope showing a)Al reinforced with 50m B4C (5%)
the partical distribution of(a) 50m B4c in b) Al reinforced 150m B4C (5%)
5% volume fraction,(b) 150m B4c in 5%
volume fraction,(c) 50m B4c in 10%
volume fraction d) 150m B4c in 10%
volume fraction.

The tensile strength increased with the

reinforcement of B4Cp .the tensile strength
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 Proceedings of National Symposium for Post Graduate Students (NSPGS 2010), 24 25 April, 2010: Vol 4 Civil, Materials & Metallurgy
c 46 min), (b) Al5 vol.% B4C 150 m
d time is particle mixing time+ stirring time.
c) Al reinforced with 50m B4C (10%)
d) Al reinforced 150m B4C (10% )
The microstructure of the particulate
reinforced composite was examined by
using SEM.The EDX spectra showed the
elements present in the interaction layer at
the interface of Al-B4C composites.Tensile
test was conducted by using
UTM.Toughness was determined by using
charpy impact testing machine.The hardness
measured from rockwell and brinell
hardness testing machines.The distribution
of particles are observed from the casting
top, bottom and middle parts respectively.
Fig-2 shows the microstructure of
Al5 B4C 50m, Al10 B4C 50m and Al
5 B4C 150m ,Al- 10 B4C 150m cast
451
composites taken from a transverse section
cut at about 10mm from the bottom of the
cast. particle distribution in Al5B4C 150
m composites is found to be better. This is
due to the fact that the wetting of ceramics
particles in aluminium controls the quality
of Al MMC castings. The wettability of B4C
with aluminum was found to increase in air.
This was attributed to the formation of a
layer of liquid B2O3 on the B4C particulates.
Due to its low melting point, B2O3 Fig. 2.
SEM micrographs showing the interfaces of
(a) Al5 vol.% B4C 50 m (interaction time
(interaction time 46 min) and (c) Al10
vol.% B4C 50m (interaction time 46 min)d)
Al10 vol.% B4C 150m (interaction time
46 min). exists above 450 C as a liquid on
the surface of B4C and enhances wettability
through a liquidliquid reaction when
contacted with aluminum liquid by forming
B2O3Al2O3 oxide compound .As the
composites were processed in air, the
distribution of particles are better in Al.-B4C
composites only other composites like other
reinforcements SiC & Al2O3 .the interaction
From the EDX analysis results and
the peak ratio of Al-B4C. it suggested that
the phase formed at the interface of Al- B4Cp
composites with various particle size.the
temperature here maintained 8500c so B2O3
will leads to dehydroxylation as well as
increase of surface energy.
For AlB4C composite, no clear interaction
layer was detected at the interface at this
resolution level (Fig. 3b). The B4C particles
seemed to adhere well to the Al matrix..
From EDX analysis it is thought that these
phases are Al2O3 and aluminum boron
carbide. The presence of alumina particle in
AlB4C composites has also been reported
elsewhere [7]. The alumina may come from
B2O3Al2O3 in AlB4C composites during
processing mentioned earlier. The alumina
 Proceedings of National Symposium for Post Graduate Students (NSPGS 2010), 24 25 April, 2010: Vol 4 Civil, Materials & Metallurgy
particles are small and spread throughout the
Al matrix while the second phase forms
relatively larger particles but less in number.
B4C decomposes by chemical interaction
with solid or liquid aluminum at temperature
ranging from 627 to 1000 C. The reaction
products are ternary carbide Al3BC and
diboride AlB2 up to 868 C. At temperature
higher than 868 C, Al3BC is still formed
while Al3B48C2 replaces AlB2 [7]. As the
processing temperature is below 8500C in
the present work, the phases present are
expected in the AlB4C composites to be
452
Al3BC and AlB2. But no aluminum boron
containing phase was found. Hence, it is
thought that the aluminum boron carbon
containing phase is Al3BC. No Al4C3 is
present in AlB4C composites as it was
processed below 10000C. Moreover, the
secondary phases that are produced in Al
B4C system are
not detrimental for the composites like
Al4C3 this compound well appears in the
interface of Al-SiC composites. These rather
improve the properties of the composites.
 Proceedings of National Symposium for Post Graduate Students (NSPGS 2010), 24 25 April, 2010: Vol 4 Civil, Materials & Metallurgy

increases when the particle size of

The mechanical properties has been reinforcement reduces in the same manner
compared among various particle size of compression strength alsothis to two
B4C in different volume fractions.The properties internally enhancing the
wettability criteria comes for enhancing this tribological properties
mechanical properties.wettability increased
when B2O3 layer formation an the surface is 4. CONCLUSIONS
more respectively.among these composites Comparatively Particle distribution
only this mechanical properties was better in Al-5% B4C of 150m
considered.the voids and pores which are compared to Al-5% B4C of 50m ,Al-10%
present inthese composites are showed in B4C of 50m ,Al-10% B4C of 150m
micrographs.The hardness normally particle size.the mechanical properties also
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 Proceedings of National Symposium for Post Graduate Students (NSPGS 2010), 24 25 April, 2010: Vol 4 Civil, Materials & Metallurgy

shows better in 150m B4Cp reinforced in away from the interface in AlB4C
Al MMCs except hardness ,This property composites are thought to be Al2O3 and
comparatively more in the Al-5% B4C of Al3BC. B4C reinforced Al composite
50m MMC. B4C reinforced Al metal seemed to exhibit a better interfacial
matrix composites having good wettability bonding as compared to the other two
compared to other reinforcements. Two composites .
secondary phases in the aluminium matrix

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The reactive wetting and
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