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EXPERIMENTAL AND INVESTIGATION OF

AL-SI- GRAPHITE WITH RICE HUSK ASH


COMPOSITE MATERIAL AND EVALUATE
THE MECHANICAL PROPERTIES
ABSTRACT

• Within the last few years there has been a rapid increase in the
utilisation of aluminium Composite, particularly in the automobile
industries, due to their high strength to weight ratio, high wear
resistance, low density and low coefficient of thermal expansion.
• The advancements in the field of application make the study of their
wear and impact behaviour of utmost importance. In this present
investigation, Aluminium composite with Silicon and graphite were
using Stir casting method.
• Compositional analysis and studies of different alloys composition
have shown near uniform distribution of Si and graphite in the
prepared alloys.
• This paper discussed composite of Al-Si- graphite with rice husk ash
material and to evaluate the Mechanical properties of the model
composite plate.
INTRODUCTION
COMPOSITE MATERIAL

A composite material can be defined as a combination of two or


more materials that results in better properties than those of the
individual components used alone. In contrast to metallic alloys,
each material retains its separate chemical, physical, and mechanical
properties. The two constituents are reinforcement and a matrix. The
main advantages of composite materials are their high strength and
stiffness, combined with low density, when compared with bulk
materials, allowing for a weight reduction in the finished part.
LITERATURE REVIEW

It has been found that the addition of graphite improves the wetting
characteristics of aluminium-based composites because of its lower surface
tension. In accordance, Sukumaran et al. found the optimum percentage
(of graphite ) for obtaining the best distribution and mechanical properties
to be around 1 and Mahendra Boopathi et al. added 1.5 per cent of
graphite to increase the wettability of the Al-Si composite. graphite also
acts as a scavenger of oxygen, there by increasing the surface energy of the
particles. However, care must be taken not to add excess graphite , as this
will form low melting compounds, which will degrade the mechanical
properties of the composite
• In year 2011 MMC Materials began as “Mississippi concrete and Material
Company” in Jackson, Mississippi, formed by the company now known as “Dunn
Investment Company in Birmingham. Saravanan explained, “The possibilities of
reinforcing aluminum alloy (AlSi10Mg) with locally available inexpensive rice
husk ash for developing a new composite material.” They developed metal matrix
composite using a liquid metallurgy route. In this process they prepared MMC with
different weight fraction of reinforcement material of (RHA). Finally they observed
the percentage reinforcement of RHA will increase ultimate tensile strength,
compressive strength and hardness of the composite. Anlit Mittal concludes that
Rice husk ash is the only agricultural waste containing largest amount of silica in it.
PROCESS FLOW
• Selection Of Composite Material (Al-sic-
graphite With Rice Husk Ash )
• Make The Testing Composite Plate By Using
Stir Casting Process
• Evaluate The Mechanical Properties Of The
Plate
• Analysis The Report
Mixing ratio

• The composite sample of different


composition are prepared. The composite of
mixing ratio
aluminium 6061 -80%
silicon carbide -13%
 graphite -5%
 RHA -2%
ALUMINIUM

• Aluminium and aluminium alloy are gaining huge industrial significance


because of their outstanding combination of mechanical, physical and
tribological properties over the base alloys.

• These properties include high specific strength.

• High wear and seizure resistance, high stiffness,

• Better high temperature strength, controlled thermal expansion coefficient


and improved damping capacity.
ALUMINIUM
MATERIAL PROPERITIES OF
ALUMINIUM ALLOY 6061
Properties Value

Elastic Modulus 69000 N/mm2

Poisson's Ratio 0.33

Thermal Expansions Co-efficient 2.4x10-5 /K

Thermal Conductivity 170 w/mk

Specific Heat 1300 J/kg k


EFFECT OF ALUMINIUM

• Aluminium and aluminium alloy are gaining huge industrial


significance because of their outstanding combination of
mechanical, physical and tribological properties over the base
alloys.
• These properties include high specific strength.
• High wear and seizure resistance, high stiffness,
• Better high temperature strength, controlled thermal expansion
coefficient and improved damping capacity.
SILICON CARBIDE

• Silicon carbide is the most important single alloying element used in


majority of aluminium casting alloys.
• It is primarily responsible for so called good cast ability (high fluidity, low
shrinkage),low density(2.34g/cm3)which may be advantage in reducing
total weight of cast component and has very low solubility in Aluminium
therefore precipitates as virtually pure Si which is hard and improve the
abrasion resistance.
• Si reduces thermal expansion coefficient of Al-SiC alloys. Machinability is
poor with addition of silicon in Aluminium.
• Depending on the SiC concentration in weight percentage
SiC POWDER
PROPERTIES OF SiC
Properties value

Poisson’s Ratio 0.14

Coefficient of Thermal Expansion 4.0

Thermal Conductivity 120 W/m•°K

Specific Heat 750 J/Kg•°K


EFFECT OF SILICON
• Silicon is the most important single alloying element used in majority of
aluminium casting alloys.

• It is primarily responsible for so called good cast ability (high fluidity, low
shrinkage),low density(2.34g/cm3)which may be advantage in reducing
total weight of cast component and has very low solubility in Aluminium
therefore precipitates as virtually pure Si which is hard and improve the
abrasion resistance.

• Si reduces thermal expansion coefficient of Al-Si alloys. Machinability is


poor with addition of silicon in Aluminium.

• Depending on the Si concentration in weight percentage


EFFECT OF GRAPHITE

• Effect of graphite on hot hardness of aluminum alloys it is shown that


graphite can be utilized to improve the hot hardness.
• Effect of graphite Addition on Microstructure and Mechanical Properties of
Aluminum-Based Alloys.
• It give more corrosion resistance
• Improve Strength.
PHYSICAL PROPERTIES OF GRAPHITE

Theoretical Density 2.25 g/cm3

Atomic volume 5.315 cm3/mol

Boiling point (estimated) 4560 K

Heat of fusion 46.84 kJ/mol

Color Black
RHA (RICE HUSK ASH)
STIR CASTING
STIR CASTING

• The composites were prepared by stir casting process. Shows


schematic diagram the original setup of the stir casting process.
Resistance furnace with a temperature range of 3000 C was used to
melt the matrix material. The furnace has a temperature controller
with k type thermocouple to control and measure the temperature.
An electric motor is fixed at the top of the furnace to provide stirring
motion to the stirrer. The speed of the stirrer can be varied as the
setup has a speed controller attached to it.
TESTING

• Wear test
• Hardness test
• Toughness test
APPLICATIONS

• AUTOMOBILE COMPONENTS-(covers, pans, casings, pulleys,


manifolds, valve Covers, brake rotors)
• CORROSION RESISTING AREAS
• TIDAL POWER PLANT COMPONENTS.
• MARINE LOGISTICS COMPONENTS.
CONCLUSION

• Though problem of agglomeration is a major problem in stir casting method, in


this research work it has been found that agricultural wastes such as rice husk ash
can be used as particulate in Al alloys, silicon and graphite to form metal matrix
composites, thus resulting in improved mechanical and physical properties like
hardness and strength. Aluminium-si-graphite with rice husk ash composites have
potential applications as covers, pans, casings, pulleys, manifolds, valve Covers,
brake rotors, and the electromechanical industry sectors. Hence which is used for
various applications where moderate impact strength is required can be replaced
by RHA/Fly Ash based MMCs therefore reducing the cost and weight.

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